APR 2022
PUT ALL THE PIECES TOGETHER, OKUMA JUST MAKES SENSE
AMW SYDNEY 2022: WHERE TECHNOLOGY MEETS INNOVATION AMW 2022 PREVIEW
Construction & Infrastructure State Spotlight: South Australia
PUT ALL THE PIECES TOGETHER, OKUMA JUST MAKES SENSE Innovative technology, quality manufacturing and comprehensive service and support define the Okuma experience.
Service Reliability Quality Model Range Support Technology Reputation
We offer the leading edge of ‘full service’ distribution and lifetime support for Okuma CNC machines. Solution focussed, our team work with our customers to provide machining realities, with exceptional results. Our team gives you immediate access to decades of industry experience and a network of local and global machine tool experts. We partner with you from the very first meeting, guide you through project planning and support you through implementation, training and after sales care.
CONTACT OKUMA FOR ALL YOUR CNC MACHINE REQUIREMENTS
APR 2022
AMW SYDNEY 2022: WHERE TECHNOLOGY MEETS INNOVATION AMW 2022 PREVIEW
Construction & Infrastructure State Spotlight: South Australia
WHERE TECHNOLOGY MEETS INNOVATION
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AUSTRALIA’S PREMIER MANUFACTURING SOLUTIONS EVENT
SHOWCASING THE LATEST IN MANUFACTURING TECHNOLOGIES AND PROCESSES ACROSS 6 PRODUCT ZONES
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. For more information visit WWW.AUSTRALIANMANUFACTURINGWEEK.COM.AU
MEET THE EXHIBITORS
SYDNEY 7-10 June, 2022 INTERNATIONAL CONVENTION CENTRE SYDNEY
1585AMW/AMTAPR22
European Hydraulic NC Guillotines SWINGING TOP BEAM WORKING ON HIGH PRECISION AND SELF ALIGNING ROLLER BEARINGS HGL. MGH. HNC Series • • • • • • • • • • •
Programmable NC 1000mm ballscrew backgauge Swing beam box type construction Welded steel frame for rigidity & cutting accuracy Adjustable stroke to reduce production time Rear safety light guarding Quick action blade gap adjustment Individual hydraulic hold down system Transfer balls on table with support arms Swing-up backgauge for shearing longer material Equipped with shadow line lighting-alignment device Optional pneumatic sheet supports available
S859A
MODEL
HGL-3106
HGL-3106
HGL-3108
Order Code Shearing Capacity - Mild Steel mm Shearing Capacity - Stainless Steel mm Shearing Length mm Strokes / min SPM Blade Angle deg Motor Power kW / hp Voltage / Amperage V / amp
S859A 6 4 3060 20 1.6º 11 / 15 415
S860B 6 4 3060 20 1.6º 11 / 15 415
S862 8 5 3060 13 1.8º 15 / 20 415
HNC Variable Rake Series • • • • • • • •
Programmable NC 1000mm ballscrew backgauge Digital control unit for rake adjustment & blade gap setting Variable rake design with deep 350mm throat Welded all steel frame providing maximum rigidity and cutting accuracy Ballscrew backgauge system with retract function Adjustable stroke length to reduce cutting time and increase production Individual hydraulic hold down system Optional pneumatic sheet supports available
CAPACITY RANGE 3070 x 6mm 3070 x 10mm 3070 x 13mm 3070 x 16mm
3070 x 20mm 3070 x 25mm 4070 x 6mm 4070 x 10mm
4070 x 13mm 4070 x 16mm 4070 x 20mm 6070 x 6mm
6070 x 10mm 6070 x 13mm 6070 x 16mm 6070 x 20mm
EX-STOCK Hydraulic NC Guillotine IMMEDIATE DELIVERY freight charges may apply HGL-3106 3060 x 6mm ORDER CODE: S859A
PRICED FROM
$47,950 EX GST
Available at www.machineryhouse.com.au Specifications are subject to change without notice. All prices exclude GST and are valid until 30-04-22
HEADING
European CNC Hydraulic Pressbrakes
Made in in Turkey Made Turkey
ECONOMICAL, EFFICENT AND COMPACT With a foundation history going back to early 1950s, Baykal today is placed as a leading manufacturer and global supplier of sheet metal working machinery specialising in the production of Syncro CNC press brakes, some of the main features are:
APHS Series • • • • •
• • •
• • •
Rigid welded monoblock steel frame for minimum deflection under load One piece forged cylinders precision machined and honed for accuracy Full electronic synchronization Y1-Y2 with european proportional valve technology Universal wedge type punch clamping system for european tool styles Precision CNC controlled X axis back gauge with AC servo driven ballscrew motor providing high speed & accuracy Large stroke and open heights to provide maximum bending flexibility T slotted sheet support arms on linear guides for easy positioning Stroke-depth measurement through high precision Heidenhein linear scales which are bed referenced European hydraulics with Cartridge valves mounted in a single steel manifold to reduce heat and wear European tooling consisting of an upper segmented precision ground punch and a lower 4 way multi-vee die German FISSLER AKAS laser guarding systems are standard on all Baykal pressbrakes
MACHINES KEPT IN STOCK PLEASE CALL WITH REQUIREMENTS MODEL
APHS-31120
APHS-31120
APHS-3106
APHS-31160
APHS-31160
APHS-4106
APHS-31160 APHS 41200
Order Code Control Unit Type Nominal Pressure - Tonnage Tonne Nominal Pressure - Kilonewtons kN Machine Axis No. Length of Work Table mm Distance Between Columns mm Maximum Open Height mm Ballscrew Backgauge Travel mm Motor Power kW / hp Voltage / Amperage V / amp
S884D DELEM DA66T CNC 120 1200 5 3100 2550 540 750 11 / 15 415
S884F DELEM DA69T CNC 120 1200 5 3100 2550 540 750 11 / 15 415
S884S DELEM DA69T CNC 120 1200 7 3100 2550 530 750 11 / 15 415
S885D DELEM DA66T CNC 160 1600 5 3100 2550 540 750 15 / 20 415
S885G DELEM DA69T CNC 160 1600 5 3100 2550 530 750 15 / 20 415
S889D DELEM DA66T CNC 160 1600 5 4100 3550 530 750 15 / 20 415
S885F DELEM DA69T CNC 160 1600 7 3100 2550 530 750 15 / 20 415
S896A DELEM DA66T CNC 200 2000 5 4100 3550 530 750 18.5 / 24.6 415
Delem Pressbrake CNC Systems • The new generation DELEM DA-Touch controls offer an even higher grade of efficiency in programming, operation and control of today’s pressbrakes. Ease of use combined with state-of-the-art technology go hand in hand, improving productivity. • The touch screen gives access to the proven Delem user-interface and enables direct navigation between programming and production. Functions are directly located where you need them, offering optimised ergonomics throughout the application.
Profile•T
NSW
(02) 9890 9111
1/2 Windsor Rd, Northmead
DA-69T 3D Graphical CNC Control
QLD
(07) 3715 2200
625 Boundary Rd, Coopers Plains
VIC
(03) 9212 4422
4 Abbotts Rd, Dandenong
WA
(08) 9373 9999
11 Valentine Street, Kewdale
02_AMTIL_010422
DA-66T 2D Graphical CNC Control
• DA-Offline bend sequencing and simulation software • DA-Offline software maximises machine efficiency and productivity of your press brakes. The Profile-T software facilitates offline programming and simulation of the bending process. • Production preparation, feasibility studies and tooling verification, operator training, adding notes for production and many other functions can be carried out offline.
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CONTENTS
Volume 22 Number 02 APRIL 2022 ISSN 1832-6080
FEATURES AUSTRALIAN MANUFACTURING WEEK 2022 PREVIEW AMW 2022 – Where technology meets innovation
42
ROBOTICS & AUTOMATION Automating cricket ball production Bringing Australian-made agility to automation worldwide Rockwell Automation expands technology suites
66 68 70
FORMING & FABRICATION Wazer Desktop waterjet: An innovation success story Applied’s expanded Yawei range and new Fanuci welder Automation according to Salvagnini
72 74 76
MATERIAL REMOVAL Effective material removal using lasers Real-time productivity for APT with Okuma Connect
82 84
QUALITY & INSPECTION Production measurement: Meeting the key requirements
85
CUTTING TOOLS Specifying a tool like never before Multi-axis roughing extends tool life Have you considered the benefits of bar peeling? Iscar – To hold effectively
86 88 89 90
CONSTRUCTION & INFRASTRUCTURE Recycled beverage carton walls for Aussie buildings How Monitum future-proofed its business with Ind.4.0 Innovative building materials help moderate temperature Rocking the foundations of the building industry
92 93 94 95
STATE SPOTLIGHT SA Assistive tech company’s growth opportunities at Tonsley Fleet Space Technologies’ factory launches SA: A powerhouse in plant protein manufacturing
98 99 100
SOFTWARE How manufacturing CFOs can achieve ROI from ERP Scheduling & supplier management in a changing world Managing pricing complexity in uncertain times The intelligent edge to win in industrial AI Harnessing the value of data: calculating KPIs
102 103 104 105 106
WORKHOLDING Lang Modular Plates: Improved ergonomics
42 Australian Manufacturing Week 2022 – Where technology meets innovation Sydney will be the stage for a showcase of the latest manufacturing technology and cutting-edge innovation in June, as the inaugural Australian Manufacturing Week exhibition takes place at Darling Harbour.
66 Automating cricket ball production Global cricket ball manufacturer Kookaburra, with the help of TM Robotics and MAP Services, designed its innovative machine-tending robotic system to produce the perfect ball.
78 One-on-One: Dr Mark Dean
107
REGULARS From the Editor From the CEO From the Industry From the Union
8 10 12 14
INDUSTRY NEWS Current news from the Industry
18
Dr Mark Dean is the Laurie Carmichael Distinguished Research Fellow at the Carmichael Centre, in the Centre for Future Work at The Australia Institute. He spoke to AMT.
96
VOICEBOX Opinions from across the manufacturing industry 28 PRODUCT NEWS New and interesting products
34
ONE-ON-ONE Dr Mark Dean
78
COMPANY FOCUS K-TIG - Innovative welding technology
96
AMTIL FORUMS
108
AMTIL INSIDE The latest news from AMTIL
112
MANUFACTURING HISTORY – A look back in time
118
AMT APR 2022
Company Focus: K-TIG – Taking on the world with its innovative welding World-wide distributors and ongoing global deals for K-TIG’s automated welding systems, plus a severe shortage of welders across the globe, is helping the Adelaide high tech welding manufacturer succeed on all fronts.
HEADING
PUT ALL THE PIECES TOGETHER, OKUMA JUST MAKES SENSE Innovative technology, quality manufacturing and comprehensive service and support define the Okuma experience. We offer the leading edge of ‘full service’ distribution and lifetime support for Okuma CNC machines. Solution focussed, our team work with our customers to provide machining realities, with exceptional results. Our team gives you immediate access to decades of industry experience and a network of local and global machine tool experts. We partner with you from the very first meeting, guide you through project planning and support you through implementation, training and after sales care.
CONTACT OKUMA FOR ALL YOUR CNC MACHINE REQUIREMENTS
Service Reliability Quality Model Range Support Technology Reputation
008
FROM THE EDITOR WILLIAM POOLE
Closing time This is my last column for AMT. After 10 years as editor, I’m moving on to pastures new. Working here has been a terrific period of my career, and I owe a huge debt of thanks to my colleagues on AMT, the wider team at AMTIL, and the incredible people I’ve met in the Australian manufacturing community for the opportunities this job has given me. So as I started writing this final From The Editor column, I found myself thinking about what’s changed in Australian manufacturing since I started at AMT. Ten years ago, the world was emerging from the GFC, a global crisis from which Australia had escaped comparatively unscathed. We were led by an exhausted government, riddled by internal divisions, and facing likely defeat at the next election. And a key Australian industry was reportedly nearing its demise. That industry was manufacturing. If I had a dollar for every time someone said to me “Australian manufacturing’s doomed”, I might be retired by now. The doom-mongering worsened over the next few years as Australia’s last carmakers shut down. I remember one meeting early on where I was told “Two years from now, that whole industry, and your magazine, will be gone.” And yet 10 years on, here we all are. Today the world is struggling to emerge from another crisis – this time COVID-19 – with Australia again spared the worst impacts (until recently, at least). In Canberra, another troubled government limps towards the polls, with defeat seeming a strong possibility. And while manufacturing is resurgent, another key Australian industry is facing harbingers of dooms. This time that industry is coal. In February, Origin announced plans to close its Eraring coal-fired power station in 2025, seven years earlier than projected. This came shortly after AGL revealed it was also fast-tracking closure of two of its coal generators. But the biggest news came soon after, as tech billionaire Mike Cannon-Brookes led a takeover bid for AGL, with the aim to get the company – Australia’s biggest greenhouse gas emitter – to net zero by 2035. AGL ultimately rejected the bid, but Cannon-Brookes’ move was widely seen as indicative of things to come. The Eraring announcement was widely attributed to it getting “hammered” by competition from renewables, and the reliability of Australia’s ageing coalfired generators has plunged in the last decade (as has AGL’s share price). The private sector is sensing the opportunities in clean energy transition, and acting accordingly.
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 FSC™ 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
Those predictions 10 years ago of manufacturing’s imminent demise today seem as exaggerated as the current prevailing wisdom regarding the importance to Australia of coal – or of oil & gas. They’re important no doubt, but not as important as we’re often led to believe – not in terms of their contribution to the economy, to jobs, or indeed to the manufacturing sector. And the fact is, their importance is only going to dwindle.
© 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)
Like many, I always thought the “gas-fired recovery” was a woeful idea – a plan that failed to recognise not just the scale of the crisis we faced with COVID-19, but also the scale of the opportunities emerging. It’s not gas that will drive our post-pandemic recovery. It’s manufacturing. It’s manufacturing that will drive the inevitable transition of our energy systems, our transport networks, our homes and our cities. It’s manufacturing that will drive Australia’s economy and prosperity for the future.
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.
I’ve had a great time covering this industry in these pages for the last 10 years, and I’ll be cheering on Australian manufacturing from the sidelines for years to come.
Disclaimer
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 $185.00 (ex GST) per annum. Contact AMTIL on 03 9800 3666 for further information.
1619AMTAPR2022
AMT APR 2022
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Technical Excellence, Innovative Products
010
FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL
A Budget with a half pike Rebuild the road and they will come. How does a government bring down a Federal Budget for a population numb from body blows over so many years? In the late March Federal Budget there was a one-off payment of $250 for pensioners and concession card holders, tax cuts and bonuses for others, in a measure heralded to cost $5.6m. Treasurer Frydenberg revealed he would be halving the fuel excise for a few months, but then what? A regional development package has been revealed as well, targeting a bunch of regional centres includes massive investment into infrastructure projects in the Northern Territory, Queensland, New South Wales and the Pilbara area of WA. These sectors cover telecommunications, road, rail and regional health. The commitments total more than $21bn over the medium term. Simon Birmingham, the Liberal government finance minister, described the government’s budget management was allowing for the delivery of a dividend back to taxpayers. But, he said, “it seeks to apply those dividends in a careful, cautious, responsible way to set Australia up for the future.” The deficit for 2021-22 is expected to be $79.8bn, with total deficits across the fouryear forward estimates totalling $224.7bn. For Science, nothing much. EV and other renewables research and incentives, not much at all. Manufacturing? The instant asset write off (or temporary full expensing to use the technical term) has already been extended to June 2023 so there was not a need for the budget to consider this unless they can see value in continuing this past June 2023. We have certainly seen an immense increase in investment in technology over the past few years as a result of this scheme which has led to business growth and jobs. Why not make it permanent? “They don’t have a plan that goes beyond the May election,” said Jim Chalmers, Labor’s Shadow Treasurer. “It is the most short-sighted budget in memory – it has a shelf life of about six or seven weeks.” But when the deficit is already plumbing the depths of the mine, the bright sparks in the wall are hard to find. Some of the investment has been in assisting SMEs and businesses. How do we get from here to there? Recent natural disasters have torn our nation’s roads and rail lines apart with damage from floods, storm surges and more floods. You don’t need to be on the ground to understand what this does to transport routes. This year’s budget saw the allocation of an extra $17.9bn to priority rail and road projects across Australia, which is
AMT APR 2022
a blessing which the Australian Flexible Pavement Association has welcomed. “We are pleased to see that the government shares our view that recent natural disasters and indeed the pandemic have highlighted how crucial the roadways that connect us are,” said Carlos Rial, CEO of AfPA. He added that industry needs to reinforce the challenge of the nation’s declining road conditions. “The Federal Government supporting increased maintenance funding in partnership with States and Local Government will also support sustainability and the circular economy.” Speaking of getting there from here, there was some healthy new rail funding and an increased focus on level crossing safety. This was amongst some of the more positive notes included in the late March Federal Budget by the Treasurer Josh Frydenberg. Shipping and freight security is so important, especially in these pandemicriddled, economically trying times. If you don’t get the goods to their destination, nobody gets anything.
One of the more positive notes to take from the budget was a renewed commitment to education and training, particularly skills development through new apprenticeships assistance. •
$954m over five years from 202122 to introduce a new Australian Apprenticeships Incentive Scheme from 1 July 2022, providing support to employers and apprentices in priority occupations
•
$365.3m to extend the Boosting Apprenticeship Commencements and Completing Apprenticeship wage subsidies by 3 months to 30 June 2022, to further support employers taking on and retaining new apprentices
•
$2.8m in 2022-23 to increase apprenticeships In-Training Support by an additional 2,500 places for young Australians aged 15-20 years.
With so many industry sectors having skill shortages and crying out for assistance, hopefully these initiatives will help address some of these issues.
Best choice. Cutting. Bending. Automation.
Next evolution: Xpert 80 automated Take the next step in the field of bending. Bystronic is enhancing the Xpert 80 to create the Mobile Bending Cell. The result is a compact solution for the rapid switching between manual and automated bending.
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012
FROM THE MINISTRY THE HON ANGUS TAYLOR MP – Minister for Industry, Energy and Emissions Reduction
We are working hard to ensure a reliable and affordable natural gas supply Energy security and keeping prices low for Australians has never been so important. The global fragility and security of gas and oil is at the forefront of international discussions. Russia’s unwarranted and unjustifiable invasion of Ukraine has raised the stakes even further. Australian manufacturers are aware of how important reliable and affordable gas supply is to their successful operations, with gas making up 42% of total energy use in the manufacturing sector. Natural gas is an essential input in the production of many goods we use every day such as plastics for personal protective equipment and of course fertiliser which is critical to putting food on the tables of all Australians and people around the world. Gas delivers crucial dispatchable electricity during periods of peak demand and plays a vital role in backing up intermittent renewable energy. Gas complements renewable energy, it does not compete with it. European gas prices were high before the Russian invasion of Ukraine but the fallout from that attack sent prices even higher. Russian gas accounted for around 32% of total European and UK gas consumption in 2021. Europe’s high dependence on imports – around 85% of total supply between 2019 and 2021 – has in part been caused by a lack of investment in local supply and storage infrastructure. At the recent International Energy Agency (IEA) Ministerial Meeting, I stressed the importance of global gas security and reiterated that secure, reliable and affordable energy must remain central to any low emissions pathway. As a result of industry and government working together, our local gas supplies have helped to keep prices internationally competitive. In the middle of March this year domestic Australian East coast spot prices were around 78% lower than in Asia and Europe. These lower prices have been maintained while Australia has been meeting surging export demand. This has meant Australian manufacturers have been able to benefit from these highly internationally competitive prices. By taking a common-sense approach, we can develop and use our gas reserves at the same time as we meet Australia’s emissions reduction commitments. However, we cannot drop the ball.
Darwin is positioned to become one of the world’s leading low-cost clean energy hubs, with access to excellent onshore and offshore natural gas and greenhouse gas storage resources, including the Beetaloo and Petrel basins and the Barossa and Bayu-Undan fields. Gas will also play an increasingly important role as a flexible, reliable source of generation, an ideal complement to growing renewables, and increasingly needed to fill the gap in dispatchable energy as aging reliable generators close. Our relentless focus on bringing electricity prices down has seen electricity costs fall to their lowest levels in eight years. Ensuring we have enough flexible, on-demand power is critical to keeping prices low and the lights on. This is why we have stepped in to fill dispatchable capacity gaps not met by the market. This includes our investment in Snowy Hydro’s Hunter Power Project at Kurri Kurri, which will provide 660MW of dispatchable capacity to the National Electricity Market, and together with our support of Energy Australia’s Tallawarra B gas project, will help replace the Liddell Power Station, which will close in 2023. These gas-fired power stations complement our landmark $1.38bn investment in the 2000 megawatt Snowy 2.0 – a pumped hydro project – which is on track to deliver the largest electricity storage facility in Australia.
The Australian Competition and Consumer Commission (ACCC) is forecasting southern supply gas shortfalls from 2024 to 2030, and an east-coast wide shortfall from 2027. It is therefore critical that local gas production increase or we will risk higher prices for businesses and households. As part of our commitment to gas in the 2022-23 Budget, the Morrison Government is investing an extra $50.3m, in seven priority projects – across the Northern Territory, Queensland and along the east coast to Victoria – as well as support for key carbon capture and storage infrastructure.These projects will help ensure Australia has adequate supply and storage capacity to avoid the forecast supply shortfalls.
We are also helping the Port Kembla gas generator reach final investment decision and investing more than $800m to support major priority transmission projects such as Project Energy Connect, VNI West and Marinus Link.
The Budget also includes $1.3bn of new investment to maintain energy security, keep downward pressure on energy prices while reducing emissions. These measures will further support affordable, reliable and secure energy and help Australia reach its target for net zero emissions by 2050, without imposing new taxes or financial burdens on households, businesses or industry.
We expect the private sector to step up to fill the gap and where it doesn’t the Government is prepared to step in. We are also continuing to strongly support the rollout of renewable energy and the development of new energy technologies.But we are determined that this will be done in a way that does not compromise a reliable, secure and affordable supply of electricity for Australian businesses and households.
This investment includes $300m to support low emissions LNG and clean hydrogen production at Darwin, together with associated carbon capture and storage infrastructure.
AMT APR 2022
Of course, the announcement in February by Origin Energy that it would close its Eraring Power Station in mid-2025 – 21 per cent of NSW generation capacity – has presented a big challenge. The closure is seven years earlier than its original 2032 closure date and will leave a considerable gap in reliable generation in the NEM. Plans to replace Eraring’s 2880MW capacity with a 700MW battery will not come anywhere close to filling the gap that will be left.
We need manufacturers to join us in publicly affirming the importance of gas to their businesses and our future national development.
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LightWELD enables dramatically faster welding, is easier to learn and operate, and provides higher-quality, consistent results across a wider range of materials and thicknesses than MIG or TIG with minimal distortion, undercut or burn-through. The heat affected zone is dramatically minimized, as is the need for traditional post-processing grinding or polishing for increased productivity, less scrap and lower cost-per-part. Minimal Fixturing and Rework required for INCREASED PRODUCTIVITY OPTIMISED BUILT-IN MODES for High-Quality Results including pre and post weld cleaning mode on XC models. SINGLE SIDED WELD THICKNESS Stainless Steel, Galvanized Steel, Mild Steel and Aluminium: Up to 4mm, Copper: Up to 1mm BUILT TO LAST WITH LEGENDARY IPG Photonics RELIABILITY Every LightWELD handheld laser welder is designed and built with the most reliable fiber laser components and technologies in the world. More uptime for more throughput and more possibilities. APPLICATIONS • Metal fabrication shops • Construction and piping
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014
FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group
Hydrogen and industry Hydrogen has long been seen by many as a solution in search of a problem. Hydrogen from fossil fuels was of interest in refining and fertilisers and rocketry. But in a world with cheap and secure fossil fuels, and no apparent consequences from burning them, why would you bother with hydrogen for any other purpose? And why would you go to the expense and trouble of making it cleanly? That sentiment is recent. But subjectively it now feels quite distant. Today the climate, price and security problems of traditional energy are urgent and glaring. Hydrogen is clearly one of the most scalable and broadly relevant solutions, even if it will not solve everything. The Ukraine situation is an earthquake for energy, as for so many other topics. Existing disruption to Russia’s immense coal, gas and oil exports, and the fear of more to come, has seen fossil energy prices soar. Among the many consequences is that hydrogen will receive two big boosts: the first is to its immediate cost competitiveness; the second to the speed of long-term hydrogen cost decline. Every doubling of global installed electrolysis capacity slashes the cost of the next doubling as manufacturers and supply chains learn and scale up. So as Europe and others deploy more hydrogen in response to high fossil energy costs, we should expect cost reduction goals to be hit earlier than past forecasts. There may be growing pains in the immediate term as supply chains adjust, however. So what can Australia do to realise the opportunities and manage the risks in hydrogen development? Ahead of the upcoming Federal Election, Ai Group recently launched policy statements setting out industry priorities for Australia’s next Government, whoever forms it. In our Energy paper, we suggested national policy needs a sharper focus on gas transition and the demand side. The states are taking the lead here at the moment, including through Victoria’s Gas Substitution Roadmap. But gas has national implications for the economy, emissions and security. Managing these risks only on the supply side, and without an eye to the net zero destination, is like trying to fly a plane with a missing wing – blindfolded. A big push on all the options for gas transition – hydrogen, biogas, electrification and efficiency – is essential. Different tools and different solutions will be appropriate for different users. For large industry, changes to the existing Safeguard Mechanism to gradually lower emissions baselines would help make hydrogen and other solutions more investable. Care will be needed to ensure uneven policies don’t compromise competitiveness. But with investors and customers expecting deep emissions cuts, and major economies developing carbon border adjustments, there are also competitive risks in being left behind. The Safeguard Mechanism also presents a possible solution to the social license and credibility questions around blue hydrogen, made from fossil fuels with the carbon emissions captured and stored underground. High carbon capture rates are physically possible, but what will motivate their achievement? In addition to baselines for existing facilities, the Safeguard contains a latent system of best practice benchmarks for new facilities. Nothing has yet been done with it. But a technology-neutral benchmark for hydrogen production – most logically, zero tonnes of emissions per tonne of hydrogen produced – would provide a strong regulatory motive to capture as much carbon from blue hydrogen projects as possible, and to offset any residual emissions. Other tools will be relevant too. The NSW Government has opened a new Australian policy frontier by legislating a green hydrogen
AMT APR 2022
target that ramps up to eight petajoules by 2030. Similar to previous renewable energy targets, the scheme requires gas retailers and large gas customers to buy certificates from accredited green hydrogen producers (made using renewables-powered electrolysis). The cost of buying those certificates will depend both on the evolving cost of producing hydrogen, and the price that physical customers for that hydrogen are willing to pay given the alternatives in each context for its use. Scheme costs will be passed through to gas users, with some exemptions still to be finalised. This kind of scheme could be extremely promising for underpinning hydrogen expansion. Eight petajoules is not much in a net zero world, but it is a hell of a lot more guaranteed demand than existed beforehand. Ai Group has tried to calculate the cost of the NSW scheme. Every time we run the numbers it looks cheaper. Pre-Ukraine, assuming a long-term natural gas price of $12 per gigajoule, the target looked like it might add 23 cents per gigajoule to the cost of using gas in NSW for unexempted users. Post-Ukraine it will be cheaper, as hydrogen costs fall faster and methane prices rise higher. How much cheaper? Who knows? If natural gas is $25 a gigajoule in 2030, the scheme costs nothing. And that eye-watering gas price would be cheap in Berlin or Tokyo right now. Cheaper schemes could potentially be pushed harder and faster. And the technology-specific NSW scheme is not the only option. The broader energy savings schemes in NSW, Victoria and SA can boost gas transition in a more technology-neutral way. But the costs of any of these schemes need to be better understood and fairly distributed. Trade-exposed industry needs a pathway to net zero – but they need to stay alive on the way there. And vulnerable households will also need help with the cost of living and transition, whether that is delivered through energy-specific arrangements or the broader social safety net. The key message is urgency. The invasion of Ukraine has unleashed immense upheaval in energy, trade and global security. Geopolitical, economic and climate factors are now lined up to require an accelerated transition from oil and gas starting in earnest this decade. Hydrogen is well placed to provide big chunks of that transition. But both the supply and demand sides need to get on with it – and government needs to play its part. Ai Group’s Federal Election Policy Statement on Energy and Climate is available here: www.aigroup.com.au/news/ election-2022
Visit us at AMW on stand MT 46, Sydney, 7-10th June 2022.
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FROM THE UNION STEVE MURPHY – National Secretary Australian Manufacturing Workers Union
Skills are our pathway to a brighter future I think most of us would agree that learning a trade is a good way to improve your lot in life. It gives you important skills, gives you a career path and improves the range of opportunities that are open to you. We encourage young people to go into apprenticeships to start their careers, and our skills-based Award system rewards workers who improve or expand their skills with higher wages. Or at least it is meant to – more on that later. We’ve long known that skills are a key part of unlocking improved productivity, which is as vital to the success of our key industries as it is for the profitability of an individual business. Our standard of living will only improve if we’re able to continually improve our productivity and we can’t do that without a skilled workforce. So, if we all know how important skills are for individuals, businesses and our nation, why are we so bad at delivering them? In my view, there is a lack of certainty amongst employers, workers, students and the community about what the Vocational Education and Training (VET) system is for. Are we aiming to develop a highly skilled, agile and mobile workforce based on recognition of portable and transferable skills? When it comes to higher education, the answer seems to be “yes”. However, when it comes to vocational training, the system seems to be designed to specifically to meet the narrow interests of individual employers rather than that of industry or the nation. This disconnect between what we need and what the VET system is delivering has many causes. Too often governments have thrown their hands in the air and said it was all just too hard, and left it all to the bureaucrats. Too often changes have simply tinkered at the edges of a system that needs a complete overhaul. Worst of all, when it’s training providers telling industry what they are going to have, we are really in trouble. I don’t have the space here to cover all of them, so I’ll highlight some of the most urgent changes that I think the winner of the next federal election will need to address right away.
Invest in workers It is clear that more needs to be done to invest in the skills that workers need in the 21st century. These skills are best taught at TAFE and perfected in the workplace. We need better funding for TAFE because they have shown time and again that they are the best provider to deliver quality outcomes that benefit workers, the industry and employers in the long run. These things can’t be done on a shoestring budget, with casualised educators and without proper resources. We need a properly funded, professionally developed and supported workforce at TAFEs around the country who can deliver the skills that we need. Time and again we’ve seen that private providers do not meet the same standards or deliver the same outcomes. We need to get back to what works, and invest in TAFE.
Pay more for skills I recently saw a statistic that amazed me in a Productivity Commission report. The report highlighted that while 85% of the workers in the VET system are there because they want to improve their skills in the workplace, only 18% are employed at a higher level after they’re finished. Australia’s has a world-leading Award system that for decades has linked skills with wages so that workers were encouraged to improve their flexibility and productivity with the promises of higher pay. As the Award has moved from the primary wage setting device for most workers to a safety net, the nexus between skills and wages has been forgotten.
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We need to reagitate the classification structures in Australian workplaces to ensure that workers can be trained and assessed in their workplace and be paid according to the skills that they’ve got. This not only encourages workers to seek out additional training, it also helps workers to get formal, national accreditation of the skills that they already possess. As a union secretary I am always going to argue for higher wages for my members. I can already hear the employers out there complaining that they don’t want to pay for skills that they don’t use, but it is this sort of small thinking that has landed us in our current skills crisis. We need to think about skills at an industry level, which helps everyone in the long run as the pool of skilled and available workers gets larger and are able to move between jobs with greater flexibility.
Investment is the key In our industry, you can’t talk about skills and productivity without talking about investment in capital. While our skilled workers can work miracles, they can only do it for so long as the machinery that they’re working with isn’t ageing and out of date. Labour productivity has improved much faster than multifactor productivity in Australia for the last 30 years. Workers are doing their bit to produce more for each hour that they work – it is a lack of investment in capital and intermediate systems, and a failure to fully realise the potential of that investment, that is holding Australia back. The future of Australian manufacturing is bright. But to realise that future, we need government and employers to be willing to invest in skills, to pay skilled workers what they’re worth and to deliver modern capital equipment that we'd can work with. We need each of these three elements in lockstep if we want to deliver a future that is Made in Australia.
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INDUSTRY NEWS
Visitor registrations open for AMW 2022 Online registrations are open now for visitors to the inaugural Australian Manufacturing Week exhibition, taking place in Sydney in June 2022. Owned and operated by AMTIL, AMW is Australia’s premier manufacturing solutions event. Under the theme ‘Where technology meets innovation’, AMW 2022 will take place at the International Convention Centre Sydney (ICC Sydney) in Darling Harbour from 7-10 June 2022. The opening of registrations marks a major milestone in the build-up to the exhibition. Preparations for AMW 2022 have been marked by high levels of early interest, with the floor space almost entirely booked out well before the end of last year. “It’s great to finally have opened up registrations for visitors to AMW,” says Kim Banks, Head of Events at AMTIL. “We’ve had an incredible response from exhibitors, with stands getting booked faster than any of us had anticipated. There’s clearly a really strong appetite across the industry for an exhibition like AMW. Now we’re just concentrating on welcoming as many visitors to the show as we can.” AMW will occupy more than 9,000 sqm of floor space at the ICC Sydney, with more than 155 organisations taking stands to exhibit some of the very latest manufacturing technologies, processes and support services. AMTIL will be making regular announcements between now and the start of the event about its plans for the show, so it’s worth keeping an eye on the AMW website as well as its social media channels for the latest updates. The AMW exhibition will consist of six dedicated zones offering a comprehensive view of the modern manufacturing landscape. The Austech Machine Tools & Ancillary Equipment Zone will host an extensive range of metalworking and machine tool technology, including the latest state-of-the-art cutting tools from Iscar Australia. Exhibitors such as Automated Solutions Australia and Epicor Software will be displaying their products in the Robotics
& Automation Zone, while the Weld Solutions Zone will feature the latest cutting-edge welding technology. The Additive Manufacturing Zone will feature the latest innovations from the fast-evolving world of 3D printing, from companies such as RAM3D, while the Australian Manufacturers Pavillion will showcase some of the most innovative manufacturing businesses operating today, including Marand Precision Engineering and Marsh Alliance. Finally, the Manufacturing Solutions Zone will offer optimised solutions to the most common challenges experienced by manufacturers. “We’re thrilled to be open for online registrations for AMW 2022,” said Shane Infanti, CEO of AMTIL. “AMW is a brand new exhibion from AMTIL and it’s been a long road getting to this point. Now we’re really into the final stages of making sure we put on the best show possible for the Australian manufacturing industry.” Australian Manufacturing Week 2022 will take place at the International Convention Centre Sydney (ICC Sydney) in Darling Harbour from 7-10 June 2022. For more information and to register your intention to attend, visit the AMW website at: www.australianmanufacturingweek.com.au
Australia to become EV-manufacturing powerhouse A unique combination of advantages has handed Australia an historic chance to become a sustainable global manufacturer of electric vehicles (EVs) – provided the Federal Government acts swiftly and decisively, according to new research by the Australia Institute’s Carmichael Centre. The new report, Rebuilding Vehicle Manufacturing in Australia: Industrial Opportunities in an Electrified Future, has found Australia is uniquely blessed with advantages to attract and retain EV manufacturing and rebuild the nation’s car-making capacity. This potential, however, will not be met without major government action. “When it comes to creating an EV manufacturing sector, Australia enjoys advantages other nations would die for: rich reserves of lithium and rare earths, strong industrial infrastructure, a highly skilled workforce, powerful training capacity, abundant renewable energy options, and untapped consumer potential,” said Dr Mark Dean, the report’s lead author. “And contrary to popular belief, we wouldn’t be starting from scratch. Thanks to the resilience of our remaining automotive manufacturing supply chain, a surprising amount of auto manufacturing work – including components, specialty vehicles, and engineering – still exists here.” However, Dr Dean said his research found Australia’s advantages would count for little without significant government support. The report makes a range of recommendations including: •
Using tax incentives to encourage firms involved in the extraction of key minerals – primarily lithium and rare earths – with local manufacturing capabilities, especially emerging Australian EV battery industries.
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Introducing a long-term strategy for vocational training, ensuring the establishment of skills to service major EV manufacturers looking to set up operations Australia.
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Offering major global manufacturers incentives (tax incentives, access to infrastructure, potential public capital participation, etc) to global manufacturers to set up – especially in Australian regions undergoing transition from carbon-intensive industries.
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Introducing local procurement laws for the rapid electrification of government vehicle fleets.
“No nation builds a major industry without its government taking a proactive role. Our new research shows there’s no excuse for inaction, because there are a huge range of powerful levers our government could be pulling,” Dr Dean said. “If we capture the moment we’ll capture abundant benefits: creating tens of thousands of regional manufacturing jobs, reducing our dependence on raw resource extraction, reinforcing our accelerating transition toward non-polluting energy sources, and spurring innovation, research, and engineering activity in Australia. We just need our government to act.” www.carmichaelcentre.org.au/rebuilding_vehicle_ manufacture_in_australia
INDUSTRY NEWS
New defence centre brings manufacturing jobs to Geelong Avalon will soon be home to a major defence manufacturing facility, bringing more than 300 new jobs to the Geelong region, with support from the Victorian State Government. Minister for Industry Support and Recovery Martin Pakula on 22 February welcomed Hanwha Defense Australia’s announcement that its $170m Armoured Vehicle Centre of Excellence will be established at the Avalon Airport Industrial Precinct. “We’re backing Hanwha to make the Geelong region its home because we know it will grow the economy for years to come,” said Pakula. “Victoria continues to lead the way in advanced manufacturing and this state-of-the-art facility in Avalon will create hundreds of jobs and deliver major benefits for local businesses in the supply chain.” Hanwha will use the new Avalon facility to build self-propelled howitzers to deliver the Commonwealth’s approximately $1bn LAND 8116 program. The investment will strengthen the state’s defence capabilities and create hundreds of highly skilled local jobs in design, engineering and advanced manufacturing. Construction of the 32,000sqm state-of-the-art facility is expected to start later this year and take two years to complete – creating more than 100 jobs during construction. Richard Cho, Managing Director of Hanwha Defense Australia, commented: “The Hanwha Armoured Vehicle Centre of Excellence will become the home of Hanwha tracked vehicle operations in Australia and, if successful under the Land 400 phase 3 program, the home of our Redback family of vehicles for both the Australian Defence Force and global markets.” Victoria’s supply chain will directly benefit from Hanwha setting up in the Geelong region with businesses expected to generate $200m in flow-on investment, more local jobs and export opportunities. Hanwha Corporation is South Korea’s largest defence company and also operates in other sectors including aerospace, fintech, mining and clean energy. Hanwha Defense Australia was established in 2019 and is headquartered in Melbourne. In January 2021, the Victorian Government signed a Memorandum of Understanding with Hanwha to formalise a long-term partnership to support the establishment of Hanwha’s defence manufacturing operations in the state. Hanwha is also one of the final two bidders to deliver the Federal Government’s multibillion LAND 400 Phase 3 Infantry Fighting Vehicle program. If successful, Hanwha will create more than 1,000 jobs in the Geelong region over the next 12 years and an estimated $5.7bn for Victoria’s economy. www.hanwhadefense-intl.com
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INDUSTRY NEWS
Camfil Kaire Unit named AIRAH Product of the Year Camfil’s Kaire Unit has been named AIRAH 2021 Product of the Year Camfil’s Kaire Unit has been named AIRAH (Australian Institute of Refrigeration, Air Conditioning and Heating) 2021 Product of the Year - a prestigious, peer reviewed award recognising excellence in product manufacture within the Australian HVAC&R (Heating, Ventilation, Air Conditioning, and Refrigeration) industry.
The Kaire unit achieves this with staged particulate filters and activated carbon media. Designed to operate at 1.85m/s, the Kaire Unit delivers a minimum 0.3 micron particulate removal efficiency of 95%+ (EN 1822- 5:2009) and an initial contact efficiency of 98%+ with odours.
This Australian designed and manufactured multi-staged, combination filtration system was designed to control light to heavy kitchen exhaust emissions (smoke, grease and cooking odours) for all types of commercial cooking applications.
The Kaire Unit stands out from alternative HVAC industry offerings such as filter frames mounted in ductwork due to its build quality, customisability, range of sizes and purpose-built filters for kitchen effluent - grease, smoke and odour. This system is a relatively low CAPEX expense and reduces OPEX. Maintenance costs and time is reduced as the filters can be quickly changed rather than spending a significant amount on labour and time cleaning ESP cells. An optional range of integrated inline fan systems that match perfectly with the Kaire Unit also reduce installation time and eliminates the need for separate fan selections by clients.
Kaire Unit incorporates three stages of particulate filtration using custom designed mechanical filters to deliver effective filtration of kitchen exhaust emissions with increasing efficiency through each stage at a minimal cost. A final gaseous filtration stage uses activated carbon media to remove odours. With restricted space in buildings, it is preferred to horizontally discharge kitchen exhaust instead of vertically above the roof line. Horizontally discharged kitchen effluent requires an engineered solution to remove particulates and odour, as per Australian Standards (NCC, AS 1668.1:2012 and AS 1668.2:2012).
Since its product launch in 2016, the Kaire Unit has gone through several revisions and improvements to become the go-to, deemed as a solution for the economical filtration of commercial kitchen exhaust to Australian standards. www.camfil.com
ICS vulnerability disclosures grows 110% A biannual Industrial Control System Risk & Vulnerability Report from Claroty finds that Industrial Control System vulnerabilities are expanding beyond Operational Technology to the Extended Internet of Things. Industrial control system (ICS) vulnerability disclosures grew a staggering 110% over the last four years, with a 25% increase in the second half of 2021 compared to the previous six months, according to new research released by Claroty, the security company for cyber-physical systems across industrial, healthcare, and enterprise environments. The fourth Biannual ICS Risk & Vulnerability Report also found that ICS vulnerabilities are expanding beyond operational technology (OT) to the Extended Internet of Things (XIoT), with 34% affecting IoT, medical devices and IT assets in the second half of 2021. “As more cyber-physical systems become connected, accessibility to these networks from the internet and the cloud requires defenders to have timely, useful vulnerability information to inform risk decisions,” said Amir Preminger, Vice President of research at Claroty. “The increase in digital transformation, combined with converged ICS and IT infrastructure, enables researchers to expand their work beyond operational technology (OT), to the Extended IoT (XIoT). Highprofile cyber incidents in the second half of 2021 such as the Tardigrade malware, the Log4j vulnerability and the ransomware attack on NEW Cooperative show the fragility of these networks, stressing the need for security research community collaboration to discover and disclose new vulnerabilities.”
Key Findings •
•
ICS vulnerability disclosures grew 110% over the last four years, demonstrating heightened awareness of this issue and the growing involvement of security researchers shifting toward OT environments. 797 vulnerabilities were published in the second half of 2021, representing a 25% increase from 637 in the first half of 2021. 34% of vulnerabilities disclosed affect IoT, medical devices and IT assets, showing that organisations will merge OT, IT, and IoT under converged security management. Therefore, asset owners and operators must have a
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thorough snapshot of their environments in order to manage vulnerabilities and reduce their exposure. •
50% of the vulnerabilities were disclosed by third-party companies and a majority of these were discovered by researchers at cybersecurity companies, shifting their focus to include ICS alongside IT and IoT security research. In addition, 55 new researchers reported vulnerabilities during the second half of 2021.
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Vulnerabilities disclosed by internal vendor research grew 76% over the last four years. This demonstrates a maturing industry and discipline around vulnerability research, as vendors are allocating more resources to the security of their products.
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87% of vulnerabilities are low complexity, meaning they don’t require special conditions and an attacker can expect repeatable success every time. 70% don’t require special privileges before successfully exploiting a vulnerability, and 64% of vulnerabilities require no user interaction.
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63% of the vulnerabilities disclosed may be exploited remotely through a network attack vector, indicating that the need for secure remote access solutions, which accelerated due to the COVID-19 pandemic, is here to stay.
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Claroty’s Team82 continues to lead the way in ICS vulnerability research, having disclosed 110 vulnerabilities in the second half of 2021 and more than 260 vulnerabilities to date.
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The leading potential impact is remote code execution (prevalent in 53% of vulnerabilities), followed by denial-of-service conditions (42%), bypassing protection mechanisms (37%), and allowing the adversary to read application data (33%).
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The top mitigation step is network segmentation (recommended in 21% of vulnerability disclosures), followed by ransomware, phishing and spam protection (15%) and traffic restriction (13%). www.claroty.com
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INDUSTRY NEWS
Charging into the US market An Australian electric battery manufacturer has charged into the US market. US President Joe Biden announced in February that Brisbanebased EV charging company Tritium will build a manufacturing facility in Tennessee, while reiterating his commitment to electrify the US government's car fleet. The new plant will produce up to 30,000 EV chargers per year and create 500 local US jobs over the next five years. The facility is expected to house up to six production lines for Tritium’s DC fast chargers, including its award-winning RTM and PKM150 models. Production is scheduled to start in the third quarter of 2022. Tritium CEO Jane Hunter appeared alongside Mr Biden at the White House and said Pres. Biden's policies "have contributed to enormous demand" for Tritium products in the US. "This directly led us to pivot and change our global manufacturing strategy. Tritium’s investment in a US-based, cutting-edge facility for manufacturing is part of our strong push toward global growth in support of the e-mobility industry. We are thrilled to work with the US Federal government and the State of Tennessee on this initiative. With the help of the hard-working residents of Tennessee, we expect to double or even triple our charger production capacity to further our product distribution throughout the US” added Hunter. “I welcome Tritium to Tennessee and thank the company for its commitment to create more than 500 new jobs in Wilson County,” said Tennessee Governor Bill Lee. The news was also welcomed in Australia by Dr Jake Whitehead, Head of Policy at the Electric Vehicle Council in Australia. "It's such exciting news for Tritium, which is a Brisbane-based company, founded out of a backyard shed 20 years ago. I've known this team for a long time, they've been working super hard and now,
Jane Hunter, CEO of Tritium, inside the Tritium Electric Vehicle Charging Test Facility in Brisbane.
“Tritium could be the most important Australian company most Australians have never heard of — an example of a successful homegrown business that's exporting a high-tech clean-energy product, rather than shiploads of ore, sheep or gas” (ABC Science News). they've gone from strength to strength, recently being listed on the NASDAQ and today taking the stage with the President of the United States."
Planet Innovation and Lumos Diagnostics establish local RAT manufacturing facility A Victorian Rapid Diagnostics Manufacturing Facility and Innovation Hub to manufacture RATs and other diagnostic tests is set to be established. Planet Innovation - Australia’s leading healthtech innovation and commercialisation company - and Lumos Diagnostics, a rapid point-of-care diagnostics company, with support from the Victorian State Government, will establish a $17.2m Rapid Diagnostics Manufacturing Facility and Innovation Hub in Victoria to locally manufacture RATs. Subject to necessary approvals, including those from the Therapeutic Goods Administration (TGA), the facility will produce one million tests in April 2022 and scale up to three million per month by July 2022. At full capacity, the facility will be able to make 50 million RATs each year. Beyond COVID, the facility will be able to produce a variety of diagnostic tests including those for tropical diseases, flu/ influenza, reproductive health, and chronic disease management, ensuring its long-term viability. Planet Innovation Co-CEO Stuart Elliott says the business is delighted to collaborate with Lumos Diagnostics in support of the Victorian Government’s initiative to establish a strong, sovereign capability for the manufacture of rapid diagnostics. “PIanet Innovation will bring its breadth of medtech expertise to create a world-class operation that will support Victoria through the current COVID pandemic and into the future, with the capabilities to produce a range of diagnostic tests,” he said. “In conjunction with Lumos and the Victorian
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Government, Planet Innovation will also initiate steps for building a powerful innovation ecosystem in rapid diagnostics that will engage a range of local organisations in the advancement of Victoria’s medtech manufacturing sector.” In addition, the project will create approximately 70 ongoing jobs, adding to Victoria’s thriving medical technology manufacturing sector that already employs thousands of Victorians across the state. Premier Daniel Andrews said of the agreement: “Manufacturing rapid antigen tests in Victoria will protect and secure the state’s supply chain and create local jobs. “Being able to scale up production so quickly shows the strength of Victoria’s advanced manufacturing capabilities.” Lumos’ COVID-19 RAT test CoviDx™ will be manufactured at an existing space provided to Lumos via Planet Innovation, its founding shareholder. Lumos Diagnostics Executive Chair Sam Lanyon said of the deal: “As a global leader in rapid point-of-care (POC) diagnostic technologies, we’re proud to work with Planet Innovation and support the Victorian Government, to manufacture and deliver critical, rapid diagnostic tests. “Lumos will leverage its global experience, that has seen it create critical infrastructure and world-class technology in North America, to support the establishment of a Victorian manufacturing hub for rapid diagnostics. www.planetinnovation.com
INDUSTRY NEWS
SPEE3D named inaugural winner of US Military Expeditionary Manufacturing Award AMTIL member SPEE3D has won the inaugural Expeditionary & Tactical 3D Printing Excellence Award from the US Defense Strategies Institute for deployable additive manufacturing. The outstanding contribution SPEE3D’s technology has made to furthering the manufacturing capability of Defense was recognised by the US Defense Strategies Institute (DSI) at their 6th Military Additive Manufacturing Summit, which took place in Tampa, Florida. At the summit, SPEE3D was announced as the inaugural winner of the Defense Strategies Institute’s Award for Expeditionary & Tactical 3D Printing Excellence. The Defense Strategies Institute (DSI) is a non-partisan Institute designed to assist in advancing the mission critical goals of the United States' Military and Government. They are also the organisers of the Annual Military Additive Manufacturing Summit event which enables thought leaders and key policymakers across military services, Defense agencies, and civilian organisations to come together for actionable discussions and debate. The 2022 Military Additive Manufacturing Summit focused on advancements made in the 3D printing space, as well as how the DoD is working to quickly integrate AM technologies in order to supply durable, affordable equipment and parts to the Warfighter in the battlespace. “We had an incredible number of entries this year from various esteemed government, Defense industry and Defense prime organisations based in the US, and internationally,” states Richard Giordano, Director of Programs at the Defense Strategies Institute. “The 3D Printing Awards is dedicated to recognising individuals, or groups, that have exemplified an outstanding achievement in
3D printing in support of DoD mission priorities. We would like to congratulate all of the recipients making waves in the Advanced Manufacturing space to improve Defense sovereign capability.” Since 2020, SPEE3D, and the Australian Army, have conducted several field trials, taking their WarpSPEE3D tactical printer far out into the rugged bushland of Mount Bundey, and Bradshaw Training Areas. At these locations, the Australian Army’s Additive Manufacturing Cell (AMC) technicians manufactured dozens of case studies, proving that it is possible to 3D print, replace, validate, certify, and put to use metal applications in the field. Steven Camilleri, CEO of SPEE3D, remarked: “SPEE3D is very proud and humbled to be recognized in the US for our work with Defense. We must acknowledge that the Australian Army’s dedication to pursuing new innovation with us has been the backbone of our success. Their commitment to this project helped develop the groundwork for a better sovereign manufacturing future for Defense forces worldwide”. Developed in Australia, SPEE3D’s metal 3D printing technology offers the world’s fastest and most economical additive manufacturing capability. It is also the world’s only proven capability that is able to be successfully deployed, and instantaneously 3D manufacture and supply metal parts on demand in remote, harsh environments. www.spee3d.com
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Lithgow marks a new era of precision manufacturing for regional NSW Thales Australia’s Lithgow Arms business on 21 February marked the beginning of a new industrial era for its Lithgow facility and 140-strong workforce, with a sod turning ceremony to commence construction of a new $6.5m building, the first phase of an industrial plan to transform the Lithgow Arms facility in regional New South Wales. Building on $70m of investment by Thales Australia in the Lithgow facility that has included new equipment and product development over the past decade, Phase 1 of this new industrial plan will establish a modern manufacturing and integration hub for the design, development and precision manufacture of next generation weapons systems for the Australian Defence Force, industrial partners and export customers. The ceremony was attended by leaders from local, state and federal governments including: Paul Toole MP, Deputy Premier of NSW and Member for Bathurst. Toole said: “This is a momentous occasion for both Thales and Lithgow today. The $6.5m investment by Thales in a new facility here in Lithgow shows that Thales is going to be in Lithgow for a long, long time. Today marks the future, and a new era that not only secures existing advanced manufacturing jobs here in Lithgow, but will continue to create new jobs into the future.” Since 1912, the Lithgow small arms factory has proudly supported Australia’s soldiers in every major conflict, and employed over five generations of local workers. This industrial transformation plan will harmonise the steadfast traditional precision manufacturing of yesteryear with the introduction of new digital technologies, and globally benchmarked high precision manu-facturing techniques. A necessary step in achieving the company’s Industry 4.0 ambitions. New technologies will include 3D printing, as well as the installation of automated electro-plating and other metal treatment capabilities. A new purpose-built live firing test and evalua-tion capability will support systems integration of existing and new technologies for
developmental advanced weapons systems such as the Digital Battle Rifle, and the acceleration of research and technology development of other digitised small-arms and weapon system platforms. Corry Roberts, Vice President – Land at Thales Australia & New Zealand, said: “We are a company that loves to make complex stuff, and we take our stewardship of this strategic manufacturing facility very seriously. This factory doesn’t only have a great history – it has a great future as well. We are excited today to be celebrating the commencement of a new era for the Lithgow factory, and the continuation of delivering truly Australian, truly sovereign weapons and weapons systems capabilities now, and into the future.” The new development will expand the capability of Lithgow Arms to also support new sovereign manufacturing partnerships for strategic ADF programs, including the recently announced partnership with Rheinmetall Defence Australia. Coupled with the company’s recent announcement to expand its partnership with Fuller Global and Outdoor Sporting Agencies (OSA) to help grow its export markets by 300% in the next two years, Lithgow Arms will create a possible 4050 new jobs in regional NSW. The precinct will also provide facilities to enable collaboration across research institutions, SME partners, and key industrial partners to create the soldier systems and small arms of the future, and secure the next generation of manufacturing and engineering skills in Lithgow and across the Central West. www.thalesgroup.com.au
NSW to power local manufacturing with locally built electric buses The New South Wales (NSW) Government is supporting the creation of local manufacturing jobs in Western Sydney with a $70m investment to transition the state’s bus fleet to zero-emissions technology. Western Sydney-based company Custom Denning has been awarded a contract to design, manufacture and assemble 79 new electric buses. Premier Dominic Perrottet and Minister for Transport and Veterans David Elliott toured the St Mary’s factory on 14 February to inspect the production line and meet workers. “This is a true Western Sydney success story and our government is proud to have played a part in this business producing the first locally-built electric bus,” Perrottet said. “Custom Denning employs 160 workers at their St Mary’s factory and this investment will now provide more jobs to ensure our buses are built to the highest standard. “Our government is getting closer to securing a cleaner, healthier future for the people of NSW and at the same time this electric bus transition will generate hundreds of local manufacturing jobs, which is an amazing outcome for our state.”
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Elliott added that the $70m investment takes the number of bus orders placed with Custom Denning past 100, which will help drive a post-pandemic jobs recovery and a boost for local manufacturing. “The NSW Government’s commitment to transition the entire 8,000-plus bus fleet is super-charging jobs and manufacturing in Western Sydney,” Elliott said. “Bus customers are already experiencing the benefits of electric buses from Penrith to Bondi, and we will continue to back local manufacturing. I’m committed to exploring opportunities to secure more local manufacturing, component supply and workforce skills development to boost our economy.” Once built, the 79 buses will operate services in Sydney’s inner west. Transport for NSW, in collaboration with its contracted bus operators, have ordered 101 electric buses from Custom Denning. www.custombus.com.au www.nsw.gov.au
CoroMill® MH20 High feed pocket milling P
M
S
Features and benefits Time to level up with best-in-class high-feed pocketing
New cutter body material increasing the strength, and inserts with high edge-line security, assure a longer tool life and reliable machining with less scrap. Thanks to its light-cutting action, in combination with a robust shank design, CoroMill® MH20 ensures secure and vibration-free machining, even with long overhangs. This is a versatile tool with a large application area,
• High-feed concept. suitable for many milling operations, helps to reduce the number of tools and therefore the cycle time • Internal coolant for optimal chip evacuation and high productivity in ISO S applications • Optimized edge-line security for reliable corner machining and pocket milling enables unsupervised machining • A sloped insert edge for gradual cutting engagement into the workpiece ensures a gradual chip load on the cutting zone and improves chip formation
but is primarily designed for pocketing applications in ISO S, M and P materials. For more information please contact:
SANDVIK COROMANT AUSTRALIA 10B/ 84-90 Lakewood Boulevard, Braeside,Victoria, Australia, 3195 Telephone : 1300 360 938 E-mail : CoromantSEAO@sandvik.com Website: www.sandvik.coromant.com/au
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Economic Accelerator – Transforming research into world-leading business A new $1.6bn economic accelerator will turn Australia’s leading research into world-beating businesses as part of the Morrison Government’s focus on building the country’s resilience. Australia’s Economic Accelerator (AEA) features as part of a $2.2bn package to focus the commercialisation of the six national manufacturing priority areas – Resources and Critical Minerals, Food and Beverage, Medical Products, Recycling and Clean Energy, Defence and Space – bringing the country’s brightest business and academic minds together. Together with a new $150m expansion of CSIRO’s Main Sequence Ventures, the AEA will reshape research funding to emphasise projects with high potential for commercialisation that are directed at National Manufacturing Priorities and industry engagement. The Prime Minister said the AEA would invest in projects as they progressed through the stages of their development. “Stronger commercialisation of research and ideas will mean a stronger economy and a stronger future for Australia,” the Prime Minister said. “This is about funding projects to bridge the ‘valley of death’ where early-stage research is often not progressed due to higher levels of risk and uncertainty. “The AEA will drive our universities and businesses to work hand-in-glove through the stages to prove projects’ viability and potential. “Expanding the CSIRO’s Main Sequence Ventures program then takes this further, incentivising the additional venture capital investment support needed to progress innovative new products and technologies through to market to become the new businesses and employers of the future.” Acting Minister for Education and Youth Stuart Robert said the AEA would boost investment in two critical stages of experimental development: proof of concept and proof of scale. “The AEA will become a critical source of competitive funding support for innovating new projects with high commercial potential, and will take a lot of the risk and uncertainty for universities out of the equation,” Minister Robert said. “We will start with a big range of contenders – a contest of ideas. “But as we progress to stage two, the number of applicants will diminish and the value of the funding to each will increase. “For example, stage one will involve nearly 100 grants a year of up to $500,000. Recipients will be required to engage industry through in-kind support or even co-location. “In order to be one of the 36 recipients attracting up to $5m in funding as part of ‘stage two’ projects, industry will need to put more skin in the game with a 50% co-investment. “At stage three, up to 50 companies will be supported through the Main Sequence Venture, where we are providing $150m in two successive co-investment funds. “This investment is about new jobs, increased wages, and creating products that make life easier, more efficient or even more interesting,” Minister Robert said.
“By working with industry and researchers, the government is helping to ensure our economy benefits from our world-class research, both now and well into the future” “The Morrison Government is prioritising investment in research and action to turn Australia’s best ideas into new industries and strengthen our future prosperity,” Minister Price said. “The expansion of the Main Sequence Ventures will further support the development of spin-off and start-up companies with high commercial potential arising from local research. “Over the past four years, Main Sequence Ventures has invested in 39 companies that are commercialising deep tech opportunities that have created more than 1,200 technology-related jobs. “Our new investment in this program will ensure it can play a bigger role in our economy and help develop the next generation of great Aussie companies and products.” Minister Robert said the Morrison Government would also invest $296m in industry-focused PhDs and fellowships to support its research commercialisation goals and drive greater universityindustry collaboration. “This new scheme will generate 1,800 industry PhDs and over 800 industry fellows over 10 years to fundamentally reshape the workforce of Australia’s universities,” Minister Robert said. “PhD students will benefit from the experience of undertaking research within industry settings, creating employment pathways beyond academic roles.
Minister for Industry, Energy and Emissions Reduction Angus Taylor said the grants were an investment in Australia’s future industries and smart manufacturing within the Morrison Government’s National Manufacturing Priorities. “By working with industry and researchers, the government is helping to ensure our economy benefits from our world-class research, both now and well into the future,” Minister Taylor said.
“Industry will benefit from the opportunities to host PhD students, bolstering their ability to harness ideas and concepts for innovation, as well as to open the pathway to the recruitment of high-calibre graduates. This will be further enhanced by a new suite of ARC Fellowships that will recognise and reward our academics who collaborate with industry, helping to drive the translation of their research, creating new pathways for their work.
Minister for Science and Technology Melissa Price said the $150m expansion of the CSIRO Main Sequence Ventures program would back start-up companies and help create commercial opportunities from Australian research.
“These initiatives will change the culture and the focus of research across Australia’s universities – building greater engagement with industry and ensuring that innovation is at the core of our economic future as a nation.” www.pm.gov.au/media
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GOVERNMENT NEWS
New Victoria Local Jobs First Commissioner appointed Victoria’s new Local Jobs First Commissioner will champion local businesses and workers getting roles in the state’s big infrastructure, manufacturing and services projects. Moana Weir started as Victoria’s new Local Jobs First Commissioner in January and brings a wealth of experience to the role. She has been a senior officer at companies including SEEK, REA Group, and an executive at Bupa. An experienced lawyer, she is currently Chair of the Victorian Equal Opportunity and Human Rights Commission. The Local Jobs First Commissioner advocates on behalf of Victorian small and medium-sized enterprises and promotes the employment of Victorian apprentices, trainees and cadets on government construction projects. The role also oversees compliance with local content commitments that maximise opportunities for local industry. Ms Weir replaces the inaugural commissioner Don Matthews, who retired in 2021. The Victorian Government is the largest procurer of goods, services and construction works in the state and helps to develop local industries, create jobs and boost economic activity. Under its Local Jobs First policy, the Victorian Government has set local content requirements for 227 strategic projects since December 2014.
“Ms Weir’s expertise will help to deliver the Government’s Local Jobs First policy as we continue to put Victorian businesses and workers first.” Minister for Industry Support and Recovery Martin Pakula
Victoria’s Local Jobs First Act 2003 is Australia’s oldest legislation on mandatory local content, requiring all Government departments and agencies to apply local content for contracts valued at $1m or more in regional Victoria, or $3m or more in metropolitan Melbourne. It also requires job opportunities to be created for Victorian apprentices, trainees and cadets on projects worth over $20m. www.localjobsfirst.vic.gov.au
Cairns manufacturing sector boosted with Hub funding The future of far north Queensland manufacturing gets a boost with the Palaszczuk Government announcing permanent funding for the Cairns Manufacturing Hub, as part of a $17m state-wide boost for manufacturing. Minister for Regional Development and Manufacturing and Minister for Water, Glenn Butcher, said the Palaszczuk Government’s investment in Manufacturing Hubs and Made in Queensland Grants has created and supported nearly 6,000 jobs to date. “The work done at these hubs is vital to building and strengthening Queensland’s booming manufacturing sector. “Manufacturing already contributes $20bn a year, to the state’s economy and employees and we want to see that grow even further,” Minister Butcher said. Minister Butcher was joined by his far north government colleagues at Status Signs, in Portsmith, to make the funding announcement. Cairns MP Michael Healy said the Cairns Manufacturing Hub has already shown great results. “I know the team at the Cairns Manufacturing Hub has worked really hard to get support for local business and working with a group like Status Signs brings many rewards.” Barron River MP Craig Crawford said the Cairns manufacturing sector contributed about $780m annually to the state’s economy and employed more than 6,000 workers locally. “We cannot underestimate the value of manufacturing in the Cairns region,’’ Mr Crawford said. “It is one of our most important sectors and we want to see manufacturing continue to thrive.’’ Speaker and Mulgrave MP Curtis Pitt is confident the ongoing Hub funding and associated grants will help far north businesses be recognised as global leaders. “This funding will ensure Queensland manufacturers continue to receive the services offered by the Hubs, remain nationally and internationally competitive, and are in a position to take advantage of growth opportunities,” Mr Pitt said. Status Signs Director Rhys Carmady said the Manufacturing Hub and the team had been very helpful in securing a grant that has increased the capability of the business.
“With the help of the great team at the Cairns Manufacturing Hub we have secured a grant of more than $130,000 which we have been able to use to buy a CNC routing machine, which cuts objects into 3D shapes, a 3D UV printer, a CNC laser cutter and some automated software. “It’s going to be absolutely vital in helping our business grow.” Mr Carmady said the team had helped with training and courses for his staff and this has been vital for not only adding skills to the business but also helpful with staff retention. “The courses and training have been exactly what we’ve needed and the Manufacturing Hub team, Andrew and Sandra, have been fantastic to deal with,” he said. Funding of $17.75m will enable the Hubs, including Cairns, to continue to support regional manufacturers to grow their businesses and create local jobs. Each Hub has established itself to build on the current economic strengths of their regions. “The Manufacturing Hubs are bringing together the industry partners, state and local governments, local businesses and educational institutions to collaborate and grow regional manufacturing,” Mr Butcher said. The Manufacturing Hubs build stronger and sustainable regional businesses and develop connected industry ecosystems to increase national and international competitiveness, lift productivity, stimulate sustainable job growth, and attract private sector investment. www.qld.gov.au
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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY
Leadership principles to drive manufacturing forward In the last issue of AMT, Jack Parr examined the history and evolution of manufacturing leadership. Now he looks at what the future holds and how manufacturing leaders can face the challenges to come. My previous article described the development of leadership principles in the 20th Century, ending with the question “What are the new principles to drive Australian Manufacturing to 2030?” With help and advice from several industry colleagues, I have sought to answer that question. First, howevever, it is important to contextualise today’s conditions compared with earlier halcyon times. While onshore manufacturing is currently front of mind, the sector is no longer the driver of Australia’s economic prosperity, accounting for just 6% of GDP. Neither political party seems to have the determination to create a more progressive industrial landscape to underpin and accelerate a decade-long rejuvenation plan.
productivity; innovation is the key, so the onus is now with the company to provide people with tomorrow’s skills and capabilities. The new question is how to train and develop. One colleague rightly pointed out that ‘attention spans are lower today’, so learning methods must adapt and utilise practical workplace applications. The challenge is to identify these capabilities, develop learning protocols and delivery methods, and integrate capability development into normal company practices. •
Principle 3: Everything is about innovation. It has always been my belief that manufacturing is like “walking up a down escalator – stand still and you go backwards!” Today, you must be looking to innovate, to use technology and people’s capability to maximise productivity. But innovation is not about invention! It is about continuous improvement, the use of the latest technologies and integrated computer systems to automate processes and provide better data to measure and manage. It is about the paperless factory. Electronic integration with the customer will become the service innovation for both process and product management. One colleague is already using electronic condition monitoring to improve product servicing. Industry 4.0 and even 5.0, while having high entry costs, will become ubiquitous. Innovation is also about empowerment of people; the distribution of information to aid capability, leading to distributed authority and more task autonomy for individuals or teams. Management should no longer be about control, but about motivational support and leading continuous improvement.
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Principle 4: Advocacy for the industry. Manufacturing encompasses a range of industries who all use things made from metal, supplied by manufacturing SMEs who provide everything from components to capital goods. Yet this sector and these companies lack a ‘collective voice’ – let alone a ‘collective mind’! Manufacturing is not only an essential economic sector, but one that can offer rewarding, challenging careers. The sector can only grow if more people appreciate its value and choose it as a career. The industry needs to advocate as both a collective body top-down, and at an individual company level upwards. It has to start ‘marketing’ itself to graduates, school students and the general public. How many companies offer open days to the local community, or even employees’ families? How many promote themselves and the industry to local schools? Do industry bodies really promote the attraction of manufacturing? How visible is their advocacy and how are they building the ‘collective voice’?
Technology has changed industry. Automation and technological integration are driving the replacement of manual work with ‘knowledge work’. Technological change has outpaced our education system, particularly tertiary. STEM is struggling for priority in an increasingly crowded school curriculum. Despite technology, peoples’ pace of life has increased – counterintuitively with longer working hours. Societal standards have also changed. Work-life balance is a growing factor in career choices, with service industries offering greater appeal, to manufacturing’s detriment. Harassment and bullying are no longer tolerated, and triggers for anxiety are much lower, demanding an innovative approach to people management and ‘social responsibility’. There are existential environmental and ecological threats to the planet. The net effect of these pressures means manufacturing can no longer be inert, insular and individualistic. Companies must become progressive, innovative, and more attractive. Management must evolve from controllers to people motivators and skill- and knowledge-providers. Companies must become collective and collaborative, while acting as advocates for the industry itself! Within that context, I offer four key principles for the future of manufacturing leadership: •
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Principle 1: Transition to ‘Collegiate Management’. Management needs to take a fresh approach to divisions of work; inflexible rules; fixed hours, salary or wages, on-site or off site working, differing ‘hygiene’ standards – all should be up for transition. It is time for a collegiate approach to people management. Enterprise bargaining agreements (EBAs) epitomise the issue. A bargain is “agreement between two groups”. Should a company not be one team with benefit for all? This is not an analogue transition, but the place to start is with existing employees who demonstrate the attitude and skills the company values. Such people are also marketable, so they need be fully engaged by using a ‘flexibility toolkit’ – including, of course, total remuneration. The other issue is to recruit well. Several colleagues expressed the view that HR’s role in recruitment needs rethinking. The new social compliance processes can lead to ‘appropriate choice’ but ‘inappropriate fit’ to actual need. Principle 2: Capability is now your responsibility. The industry faces both manufacturing and engineering skills gaps. To meet technology-driven skills demands, some enlightened (and frustrated) companies have set up their own apprenticetraining schools or joint training ventures. One such visionary said “We send them for one day (for the TAFE Certificate) and the other four days, we retrain them!” Capability is a driver of
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Leadership and management over the next decade should be through a collegiate relationship rather than a subordinate one. It must be looking to use capability and empowerment as a driver of productivity. It should look to develop collective innovation through collaborative knowledge sharing. Finally, leaders must have a collective and individual purpose to ensure a growing and sustained future for the manufacturing sector. 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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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY
Attract and retain talent during a labour shortage With global headlines reminding employers of the ‘tight’ labour market, businesses are faced with a difficult question: ‘How best to retain and attract staff in a competitive labour environment?’ By Andrew Nicola. It is more important than ever for employers to have an effective and cost-efficient strategy to attract and retain key staff. In the current environment, this means offering competitive remuneration packages potentially applying a number of ‘levers’ to achieve the best result for the employee and the employer, this may include: • • • •
Short term incentives Salary packaging Equity incentives, including ‘phantom share schemes’ Communication of total remuneration
Short-term incentives Examples of short-term incentives include cash bonuses and payrises. These incentives are simple to implement and quite flexible, however the potential downsides include: • •
The employee’s bonus is subject to tax at their marginal rate There are various employer on-costs (i.e. payroll tax, WorkCover, etc.) Do the bonuses incentivise the employee or align the employee interests with the employer? Is there an expectation the bonuses will continue?
establish, is flexible with how the award is calculated and does not have the Corporations Act obligations of a normal equity plan.
Salary packaging
Another option gaining attraction are loan-funded share plans. These arrangements generally involve the employer providing an interest-free limited recourse loan to enable certain employees to acquire shares in the business at market value. The limited recourse feature of the loan means that the employee is protected from downside risk if the value of the shares falls below the outstanding loan balance.
Salary packaging is broadly where an employee arranges to receive less cash salary in return for certain benefits. The types of benefits that can be effectively packaged will depend on the employer, the industry and certain individual circumstances. Common benefits salary packaged include:
When implemented correctly, these arrangements should not have adverse tax outcomes to the employee or employer. However, these arrangements are complex, and it is critical that appropriate documentation be prepared otherwise unintended tax outcomes can arise.
• • • •
Total remuneration approach
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Motor vehicles. Computers and other devices. Tools of trade. Car parking.
Due to the concessional tax treatment of certain benefits, salary packaging can often provide employees with a greater after-tax cash position, while not costing the employer any more. Furthermore, employment on-costs such as payroll tax, workers compensation and superannuation guarantee can sometimes be reduced.
Equity incentives Equity incentives are a component of an employee’s remuneration package that provide employees an opportunity to owning a portion of the business, usually via shares and options. Equity incentives can: • • •
Help the business attract and retain talent. Promote the company’s long-term success by aligning interests between owners and employees. Improve an employee’s remuneration package without impacting the business’ short-term cash flow.
While used extensively by public companies, equity incentives can be more difficult to implement for private businesses. For example, it may be that a private business owner is uncomfortable to offer ownership to a non-family member or the structure does not facilitate this – ie the operating entity is a Discretionary Trust. A recent trend within private businesses are ‘Phantom Share Plans’, which aim to replicate the benefits of share ownership without granting actual ownership to the employee. These plans seek to deliver a cash bonus to a participating employee, linked to the increase in the value of the business and/or other key business metrics. A Phantom Share Plan can be administratively simple to
Another trend is communicating ‘total remuneration’ benefits to employees, where financial and non-financial benefits are quantified and made visible to employees. Quantifying the total remuneration will better inform employees of their current package. The following components may be included in the ‘total remuneration’ approach: • • • •
Fixed salary. Variable performance incentives – both short- and long-term. Equity holdings (if provided). Other non-financial benefits, which may include: - Flexibility to work between the office and home - Training and development initiatives - Parental leave - Income protection insurance - Non-cash benefits (e.g. phone, carparking, free gym membership etc).
Research indicates that employers who adopt a ‘total remuneration’ approach can see an increase to employee engagement, decrease in staff turnover and a boost to the employer’s brand. Australian businesses are faced with labour shortages in a time of continued economic uncertainty. This is forcing many to think outside the box and implement financial and non-financial incentives to attract and retain staff. With many options available there’s no one-size-fits-all approach. It’s important to talk to your trusted tax advisor if you are considering any of the above options, to identify and implement the most suitable and effective remuneration strategy for your business. Andrew Nicola is a Tax Director at William Buck www.williambuck.com
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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY
Rubbish in rubbish out: the importance of documenting: performance vs operational Whether your business is expanding, automating, or recently established and is embarking on the design and construction of a new facility, countless hours will have been spent planning the benefits and commercial drivers of your new project. Failure to communicate and articulate your project’s specifications in accordance with the relevant performance criteria can be catastrophic. By Victor Borzillo. Most well-drafted construction contracts will provide mechanisms to administer contractual disputes by providing clear and structured frameworks as to how you (as the owner/principal) and the contractor should respond to common issues including warranties, variations, delays, performance requirements and testing and commissioning expectations. However, these provisions will be of little value to you in circumstances where the specifications: • • • •
Have not been appropriately or correctly identified or referenced to form part of the overarching contract. Are outdated (commonly caused by referencing superseded design revisions or iterations). Have been developed without reference to, or contemplation of, relevant performance requirements of the proposed facility. Are otherwise incorrect.
Assisting you in developing specifications for your project Some recommendations to assist you in developing and documenting specifications that align with relevant operational and performance requirements are as follows: • • •
Deficient specifications often mean that contractors can rely upon otherwise clearly drafted contractual provisions to justify additional variation costs and delayed project completion.
Negotiated risk allocation can provide a false sense of security Contractual risk allocation and responsibility aside, deficient design briefs or unclear contractual specifications can be extremely costly to overcome. Even if your contract terms afford you the protection of consequential loss (which is becoming increasingly less common and will most certainly increase construction costs to provide “contingency” for contractor risk), delayed commencement of operations at your new facility can cause irreparable harm to your company’s reputation and revenue. Further still, an election to accept an increased project price (reflecting contingency risk) to obtain additional protection from your contractor will not always achieve the intended outcome. Reliance upon contractors’ indemnities and insurance coverage can often lead to a false sense of security, for example, in circumstances where: • •
The contractor’s financial position may not withstand a claim for loss and damage by your company. The contractor’s insurance does not respond to the category of loss claimed, or worse, is otherwise voided due to warranties or commitments proffered by the builder which are specifically prohibited.
In these situations, the contractual security you have relied upon (and paid a premium for) may ultimately prove to be worthless.
Risk mitigation as a stitch in time The commercial benefits of building a new or upgraded facility will have already been considered by the time you are ready to progress to project design and delivery phases. The real question at this juncture is, how can you mitigate identified risks? As is the case with most commercial endeavours and transactions, the devil is in the detail. The old adage “measure twice, cut once” rings true from the simplest task to the most complex of major projects. There is absolutely no substitute for careful and informed planning to ensure the comprehensive documentation of your project’s specifications and operational requirements.
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Establish an internal steering committee comprising key stakeholders/representatives from within your business. Minute steering committee meetings to record key commercial, operational and practical considerations. Develop a risk assessment matrix which contemplates relevant issues including: - key operational considerations; - commercial/contractual obligations to your customers; - operation and maintenance risks; - operational cost expectations and requirements; - environmental impacts and requirements; - funding and grant requirements; - approval pathways and requirements; - legislative requirements; - project planning considerations; and - project delivery issues. Engage experts and consultants with appropriate qualifications and industry experience. Engage lawyers with practical project delivery experience to compliment your own project team. If your own in-house team does not include someone with practical experience in delivering construction projects, engage a project management consultant to work with your legal advisers and your own project delivery team. Ensure your planning and design phase is adequately resourced commensurately with the size, complexity, and value of the project and/or the expected commercial output of your completed facility.
When preparing specifications and inputs, ensure your design team understands the expected commercial outputs of your product or service, along with all other key requirements that arise from or incidental to your project. These considerations often include your own customers’ expectations, feedstock parameters and limitations, finance terms, grants, facility design life, environmental obligations and ongoing operational and maintenance expectations. If not considered from the outset, any one of these issues can result in project failure and protracted (and expensive) rectification and dispute resolution processes. All of these potential risks are unnecessary and can be avoided or significantly reduced by implementing appropriate and comprehensive project planning procedures.
If you remember one thing ‘Rubbish in rubbish out’ should serve as a simple prompt to remind you of this key message: there is absolutely no substitute for careful and informed planning to ensure the comprehensive documentation of your project’s specifications align with the relevant performance and operational requirements of your business. Victor Borzillo is a Principal And National Head of Group at Macpherson Kelley. www.mk.com.au
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VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY
How global demand and pricing are impacting Australian aluminium suppliers The COVID-19 pandemic continues to cause profound disruption to global supply chains across a range of industrial sectors. One area experiencing turbulence is in the supply of aluminium, writes Tony Dragicevich of Capral Limited. If you’d sat behind the desks of the CEOs of Australia’s leading industrial fabrication, transport and marine businesses in March 2020 as the first wave of COVID-19 restrictions rolled out, you’d never have predicted the turn of events these industries would experience over the coming 24 months. Many were forecasting reduced demand, industry downturns, staff reductions and operational stand-downs. Fast forward two years and as an industry we are riding a collective wave of strong demand. Local manufacturers are benefiting from the reduced presence of imported aluminium products, spurring increased demand for locally fabricated aluminium products. The strong growth in demand has created a different type of challenge for local businesses that use aluminium, who are now faced with supply challenges due to material shortages and supplier capacity, while subject to unprecedented aluminium pricing pressures. In fact, capacity to supply aluminium products within Australia has never been pushed so hard, with pricing impacts and supply shortages affecting everything from beer cans to car parts, not to mention plate and rolled products. Capral Aluminium is Australia’s largest producer and distributor of aluminium products, supplying to a wide range of industrial sectors as well as commercial and residential building. It is also Australia’s largest aluminium supplier to the transport, marine and general aluminium fabrication sectors. Capral has seen a significant change in requirements for local aluminium supply over the past 18 months – we are noticing growing market share against import products. Of course, the Australian industrial, transport and marine sectors are currently very buoyant, and our customers supplying these industries are under pressure to meet the strong demand. Australia is not the only country where the economy has been boosted by government stimulus. In addition to supply pressures there has been a significant lift in global commodity demand and prices, including aluminium. Aluminium pricing can be complicated to understand for those of us who don’t delve into the world of commodity markets. However, there are three core elements impacting on the price of aluminium, all of which are experiencing record highs and ultimately impacting on price of fabricated aluminium products. 1. LME. LME is the market-traded price of aluminium on the London Metal Exchange and is used globally (outside China) as the primary cost of aluminium. LME prices reached $4.40/kg in early February, their highest since 2008, up a massive 60% from the start of 2021. 2. Billet Premiums. Aluminium extrusion manufacturers, including Capral, extrude the aluminium profiles from a billet, being the base material extruders use for production. Billet is purchased from primary aluminium smelters both in Australia and internationally, where smelters add a number of base premiums for extrusion billet supply. Over the past decade base billet premiums have been stable due to a reasonable supply/ demand balance for billet across the globe. The situation has changed dramatically for 2022. Global demand for billet in 2022 has outstripped supply and has led to up to 350% increases in premiums for 2022 smelter supply contracts.
3. Extrusion Supply. With record levels of local extrusion supply, and many extruders operating a full capacity, it is likely that Australian industrial, transport and marine fabricators will see the cost increases of aluminium raw materials experienced by the local extruders passed on through the supply chain. No doubt this will also place pricing pressures on these businesses with the cost of materials set to rise over the coming year. So what is the forecast for 2022? Industry experts expect the cost of aluminium to remain relatively high throughout 2022. Global factors play a large part in this scenario, not least the impact of government directives in China and Russia, who have traditionally been strong suppliers of aluminium to the global market. In August 2021, Russia imposed at 15% export tax on aluminium. This further increased regional market premiums and presents an upside risk on prices. As China decarbonises, increasing smelting cuts have been taken to meet regional energy consumption and energy intensity targets under China’s five-year plan to reduce emissions. China aluminium cuts are now around 2.3MT/year with risk of further cuts in coming months. Combined with other factors already described, this has driven up LME metal prices to multi-year highs Finally, freight costs and availability continue to place pressure on the local supply of imported billet, with spot prices for containers increasing by more than 200% in 2021, and the shortage of containers is expected to persist in 2022. Costs for importers to ship to Australia will also increase significantly. Therefore, from a profitability perspective, aluminium smelters may be able to generate higher margins in alternative markets, such as the EU and US, relative to Australia with strong product and market premiums. To maintain the flow of billets in Australia, the product premiums have substantially increase. From a local perspective, this is a double-edged sword for Australian extruders. We have excellent demand, but costs continue to rise. At Capral we are working very hard to ensure our plants are operating at full capacity and maximum efficiency so we can mitigate any unnecessary cost increases for our customers and meet their expectations around timely supply. We are committed to supporting our customers in these areas and have worked very hard to establish the additional capacity needed to supply local manufacturers. Throughout 2021 we made a number of capital improvements and have even brought an additional extrusion press online to meet demand. There are few industries who are not facing unprecedented times in response to COVID-19 and the changes it has brought to our economy. The industrial, transport and marine sectors are no different. I hope they will continue to support our local manufacturers well into the future. Tony Dragicevich is the Managing Director of Capral Limited. www.capral.com.au
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TECH NEWS
Australia: Decarbonisation tech instantly converts CO2 to solid carbon
lotus leaves, then coated with a protective layer of PDMS, a siliconbased organic polymer. The bioplastic not only repels liquids and dirt effectively, but also retains its self-cleaning properties after being scratched with abrasives and exposed to heat, acid and ethanol.
Researchers have developed a smart and super-efficient new way of capturing CO2 and converting it to solid carbon, to help advance the decarbonisation of heavy industries. Designed to be smoothly integrated into existing industrial processes, the new, modified tech is radically more efficient and can break down CO2 to carbon in an instant. The work is built on an earlier experimental approach that used liquid metals as a catalyst. The “bubble column” method starts with liquid metal being heated to about 100-120°C. CO2 is injected into the liquid metal, with the gas bubbles rising. As the bubbles move through the liquid metal, the gas molecule splits up to form flakes of solid carbon, taking just a split second. It’s the extraordinary speed of this chemical reaction vs alternative methods that makes this technology commercially viable.
RMIT
RMIT
USA: Is 3D printing ready for the factory floor? Metal 3D printing start-up Seurat Technologies has raised another $21m to help accelerate the roll-out of its proprietary Area Printing technology - a process in which a laser containing over 2.3 million pixels, is used to ‘micro-weld’ metal powders into thin layers on a print bed. According to Seurat, its approach is unique, as it ‘decouples’ print rate and resolution, allowing it to overcome 3D printing’s “speed, quality, scale and cost trade-offs.” It is said to be “infinitely scalable,” and potentially offers cost savings compared to traditional die-casting processes for manufacturers operating in all industries. Seurat says that its system will offer users major speed and cost efficiency, especially compared to traditional production methods. At launch, the machine will be capable of 3D printing at a cost of $300/kg, but the firm intends to lower this to $150/kg by 2025, giving it casting-level capabilities. 3D Printing Industry
China: Biggest amphibious aircraft in the world USA: Creating the “impossible”: Lightweight material stronger than steel A new substance is the result of a feat thought to be impossible: polymerising a material in two dimensions. Using a novel process, chemical engineers have created a new material that is stronger than steel and as light as plastic, and can be easily manufactured in large quantities. The new material is a 2D polymer called a polyaramide that self-assembles into sheets, unlike all other polymers, which form one-dimensional chains. Until now, scientists had believed it was impossible to induce polymers to form 2D sheets. For the monomer building blocks, melamine is used. Under the right conditions, these can grow in two dimensions, forming disks. These disks are stacked, held together by hydrogen bonds between the layers, which makes the structure very stable and strong. MIT
Australia: Lotus effect: Self-cleaning bioplastics Inspired by the always immaculate lotus leaf, researchers have developed a self-cleaning bioplastic that is strong, sustainable and compostable. Easily integrated with industrial manufacturing processes, the bioplastic is made from cheap and widelyavailable starch and cellulose. Most compostable plastics require complicated industrial processes and high temperatures; this one does not. The secret lies in the lotus leaf’s surface structure, which is composed of tiny pillars topped with a waxy layer. Any water that lands on the leaf remains a droplet, simply rolling off. Researchers synthetically engineered a plastic made of starch and cellulosic nanoparticles. The surface of this bioplastic was imprinted with a pattern Magnified 2000 times, the pillared that mimics the structure of structure of a lotus leaf (left) and the new bioplastic.
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The size of a 737, China’s AG600 will be the biggest amphibious aircraft in the world after testing of its prototype is completed. Designed by AVIC (Aviation Industry Corp. of China), previous iterations were trialled in 2017 and 2020. This craft will increase China’s maritime coverage to the entire South China The AG600 during a previous test Sea. China, however, claims it will be used in maritime patrols and search and rescue operations. It can take off and land in 2m waves, can cruise at speeds of 500kph with an endurance up to 12 hours. While not combat-ready, it can carry personnel and equipment and can ferry up to 50 passengers. When arriving on land, the aircraft swings out the rear wheels that are lined up along the fuselage, while the nose wheel emerges from the keel of the boat. Interesting Engineering
USA: Creating a better plastic Thermoplastics which are melted down, weaken with each reuse which is a barrier to recycling. But a group of chemists has discovered a method to break down plastics to create a new material that is stronger and tougher than the original. The stability of carbon-hydrogen bonds makes it difficult to turn natural products into medicines and challenging to recycle plastics. But by modifying these bonds, the life span of polymers could be expanded beyond single-use plastic. With a newly identified reagent that could strip hydrogen atoms off medicinal compounds and polymers, the chemists made new bonds in places previously considered unreactive, enabling many valuable transformations on a wide range of important compounds. “It could change the way we look at plastic”. University of North Carolina at Chapel Hill.
TECH HEADING NEWS
USA: New soft robot material: Reversible plasticity
Australia: Fighting fire with nuclear science
Researchers have discovered a new approach for shape-changing using rubber, metal, and temperature to morph materials and fix them into place with no motors or pulleys. By observing the strength of kirigami patterns, the team created a material architecture of a repeating geometric pattern. Next, they needed a material that would hold shape but allow for it to be erased. Here they introduced an endoskeleton made of a low melting point alloy embedded inside a rubber skin. Normally, when a metal is stretched too far, the metal is bent, cracked, or stretched. However, when stretched, this composite would hold a desired shape rapidly, perfect for soft morphing materials that can become instantly load-bearing. Finally,
At the Lucas Heights nuclear facility, a team of scientists is building the firefighting uniform of the future - specifically for Australian conditions. They have fashioned an ultra-light fireproof material that could revolutionise firefighting gear and protect household items with a simple coating, and after six years of research are ready to commercialise it. The scientists investigated a family of two-dimensional transition metal carbides: carbonites and nitrides, known as MXenes. Protective suits made with traditional retardant use as much as 40% carbon compounds, making them heavy. Because this material uses very low concentrations of the material, it comprises only about 1-5% of the total weight. And because it can be applied as a post-treatment, it doesn’t complicate the manufacturing process. The maximum fire reduction is 50-70%. The versatile material could also potentially be used in energy storage devices. The Age/ANSTO
Ground-based robot morphs into flying drone
the material had to return the structure back to its original shape. Heaters were incorporated next to the mesh which cause the metal to be converted. The applications for this technology are only starting to unfold. By combining this material with onboard power, control, and motors, the team created a functional drone that autonomously morphs from a ground to air vehicle. Virginia Tech
Australia: Technology increases detection of wound infection A new study has found fluorescence imaging technology, an advanced diagnostic device which allows clinicians to see into a wound, can increase the detection of infection by 11-fold. Developed by MolecuLight, the device is poised to change post-surgical wound management. The study shows that pathogenic bacterial burden is present in most surgical wounds, but is largely asymptomatic and therefore goes undetected. This device quickly and reliably detects bacterial burden at the point-of-care. This is the first study reporting the use of an advanced diagnostic device for the visualisation and diagnosis of infection in surgical wounds. University of WA
Moleculight's advanced diagnostic device which allows clinicians to see into the wound.
Germany: Revolutionising steel construction with laser welding An alternative for conventional steel construction has been developed which facilitates gentler machining of high-strength materials, and significantly reducing energy consumption and costs while greatly increasing process speed. The energy input required can be reduced by up to 80% and subsequent straightening of the component is eliminated entirely. A large proportion of the energy expended in conventional gas or arc welding is lost in the form of heat. Researchers have developed an energy-efficient alternative – the laser multi-pass narrow-gap welding (MPNG), uses a commercially available high-power laser and reduced number of layers with drastically reduced seam volume. The high intensity of the laser beam guarantees that the energy input is highly localised at the welding point, whereas the surrounding areas remain comparatively cold. The new process also excels in terms of weld seam quality – the seams are significantly slimmer and the edges are virtually parallel, whereas in conventional welding processes the seams are V-shaped. Fraunhofer The laser beam is positioned at the joint between the two sheet edges to be welded, and a filler metal is inserted in front, resulting in a high-quality welded seam.
“If you can do it in Australia, you can probably do it on the moon” Dr Brad Tucker from the ANU Research School of Astronomy and Astrophysics citing Australia’s “world class” mining sector as being instrumental in the acquiring of a NASA Rover deal. Included in Australia’s expertise is working in harsh and remote environments (Australia has the longest autonomous train in the world, in the Pilbara). Australia also leads the world in soil extraction and sample analysis. The new home-bred built Rover will pick up and transfer lunar samples to NASA’s in-situ resource utilisation system on a commercial lunar lander.
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PRODUCT NEWS
Kaeser launches DN 37 C XL booster Kaeser Compressors has announced the launch of the DN 37 C XL booster. Part of the powerful, energy-efficient turnkey DN C series of boosters, this model is designed for applications that require high air demand up to 25 bar. Powerful, compact and quiet, DN C boosters from Kaeser Compressors deliver uncompromising performance, dependability and energy efficiency. These innovative complete systems come into their own when, due to technical reasons, specific points in a production process require compressed air at a higher pressure than that supplied by the main compressed air network. They can therefore often be found in PET bottle production, process air applications, nitrogen compression and the provision of high pressure for testing facilities. The recently launched DN 37 C XL model, has been specially designed for high air demand. Kaeser’s largest compressor block, the DN 37 C XL, is the perfect choice for applications with high air demand up to 25 bar, delivering the highest possible flow rate available for this product series. Energy-efficiency comes as standard with these boosters; Premium Efficiency (IE3) drive motors, equipped as standard, contribute to energy-efficient performance, as does the generously dimensioned axial fan, which also ensures reliable temperature control.
monitoring. This is a huge advantage for keeping installation time and costs to a minimum. Kaeser Compressors is the first manufacturer in the booster sector to offer such a user-friendly complete solution, all neatly contained within a single compact enclosure.
The DN C series boosters also feature separate cooling air flows for the compressor block, drive motor and control cabinet, which are drawn in through openings in the right-hand side of the enclosure. Once they have been used for cooling, the separate air flows are combined and then discharged upwards through the exhaust air outlet in the top of the enclosure. This clever design reliably prevents cool inlet air from mixing with warm exhaust air – for enhanced efficiency. Thermal overload is therefore kept to a minimum and a separate, energy-consuming cooling system for idling is only necessary under extreme conditions.
All maintenance-relevant components, such as cylinders and venting valves, filters, condensate separators, oil drain and filler openings are easily accessible thanks to large maintenance doors. Time-saving features such as these streamline and accelerate maintenance and service work, which translates into lower operating costs and increased availability.
DN C series boosters are delivered as complete turnkey systems, precisely matched to the upstream compressor. Thanks to the Sigma Control 2 controller, they are ready for connection and self-
These new booster systems are perfectly matched for seamless networking with their “suppliers” – making them fully compatible with Industry 4.0 environments. The DN 37 C XL booster from Kaeser Compressors is available air-cooled or water-cooled, and produces flow rates from 11.54 to 18.9 cubic metres per minute. Initial pressure 7.5 to 13 bar, and final pressure 25 bar. au.kaeser.com
Cooke Industries upgrades laser cutting capability with SLTL Rapid G Based in Auckland, New Zealand, Cooke Industries has brought together excellence in design, engineering, products and support to offer clients true solutions and services in a range of field including air handling, heating, cooling, acoustics, dehumidification, and air diffusion & distribution. To maintain its position as a market leader the company is constantly looking at process improvements. With this in mind, Cooke Industries recently looked to upgrade and enhance its capabilities with the addition of a laser cutting system. The system was needed to meet increased customer demand for high quality and quick turnaround. After extensive research the team settled on a SLTL Rapid G system supplied by Nichol Industries of Melbourne. The Rapid-G is specifically designed to fulfill the varied needs of the heating,
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The SLTL Rapid G laser cutting system.
ventilation, & air conditioning (HVAC) duct fabrication industry. It is a perfect solution for sectors that need speed and accuracy. The fibre laser technology provides extensive productivity and speed for the HVAC cutting operations. The new laser cutting system was delivered and installed over the Christmas shutdown and is now further improving Cooke Industries’ capability and service levels. “We have been very impressed with the support and assistance we have received from the supplier, Nichol Industries and the manufacturer, SLTL,” said Andrew Cooke, Managing Director of Cooke Industries. www.nichol.com.au cookeindustries.co.nz
PRODUCT NEWS
Walter Supreme thread milling with new DeVibe technology Unstable conditions and long overhangs often lead to vibration, poor thread surfaces or even fractures during thread milling processes. With the TC630 Supreme orbital thread milling cutter, Walter is presenting the first solid carbide thread milling cutter on the market with DeVibe anti-vibration technology. Incorporating an antivibration land on the flank face into the design, the tool is stabilised during machining which suppresses vibration. The patent-pending DeVibe technology ensures excellent operational smoothness and enables usable lengths up to 4×DN, which is ideal for small threads, long overhangs, unstable conditions or difficult materials. Also in these difficult areas of machining, creating and maintaining dimensional accuracy is desirable and this is where the cutter’s overall design and geometry deliver exceptional results. With only one row of cutting edges is engaged at a time, tool deflection is addressed and the thread remains cylindrical. The moderate number of teeth also enables a high feed per tooth, enhancing the wear resistance already created by the carefully selected cutter substrate and coating. The Supreme milling cutter for blind-hole and through-hole threads has a broad application range that covers all ISO materials up to 48HRc. Metric thread sizes from M1.6 to M20 are in the standard program, while also in the range are cutters for metric fine pitch
threads, UNC, UNF and STI UNF. The latter is primarily suited to aerospace applications. With the TC630 Supreme, users can take advantage of a range of benefits that the thread mill design delivers, such as a high level of process security and reliability in unstable machining operations. This enables it to be applied to lathes with driven tools, long overhang applications or instances where reliable chip removal is required - even in deeper thread applications where the optional internal coolant (from M5) applies. Process stability is also assured for high feed processing and fewer cutter radius corrections are required to deliver time savings and stable, repeatable processes. As well as the cutter design and grade already mentioned, a broad product program and tool shank options ensure that it can be used universally. Areas of application include medical engineering, precision engineering, the aerospace sector as well as electronics and general mechanical engineering. www.walter-tools.com
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PRODUCT NEWS
Kennametal introduces lightweight version of EV tooling solution Kennametal has introduced its next-generation 3D-printed stator bore tool for the machining of aluminium engine housings for electric vehicles. This latest version of the tool features a newly designed arm structure, a larger centre tube made of carbon fibre, and a further weight reduction of more than 20% over the original design. The complex tool is capable of machining three large diameters in just one operation, saving set-up time and machining time for automotive component manufacturers and delivering the highest accuracy and surface qualities. The newly redesigned tool recently won MM MaschinenMarkt’s Best of Industry Award in the Production and Manufacturing category based on votes by readers and industry experts. “As our automotive customers expand their offerings of hybrid and electric vehicles, we continue to respond to their need for lighter weight tooling solutions,” says Ingo Grillenberger, Product Manager at Kennametal. “By leveraging advanced manufacturing techniques like 3D printing, we’ve reduced weight a further 20% over the firstgeneration tool, while improving chip control and increasing tool rigidity—innovations that help our customers machine faster and more efficiently.” Machining three diameters in one operation, the stator bore tool ensures the alignment and concentricity of the machined surfaces
while reducing the cycle time significantly. The lightweight 3D-printed combination tool enables a faster tool change and spin-up even on less powerful machines. The surface specifications and component tolerances are achieved without constraints. Hassle-free chip removal is ensured by means of airfoil-shaped arms that are through-coolant-featured to ensure precise and powerful coolant supply to the cutting edges and guide pads. This would be difficult or impossible to economically produce with traditional manufacturing, but 3D printing enables even such complex internal features. Additionally, the Kennametal RIQ reaming system features easy diameter adjustment and a trouble-free setup of new inserts. www.kennametal.com
OMAX unveils OptiMAX, its most advanced waterjet ever OMAX has introduced the OptiMAX, a new generation of waterjet designed to quickly turn prints into parts while relying less on highly experienced operators. The OptiMAX is OMAX’s most advanced waterjet ever. The culmination of three decades of OMAX engineering expertise and real-world operator experience, it is designed for manufacturers in need of a versatile, easy-to-use cutting system. It offers OMAX’s intuitive software for optimised cutting capability and power, along with improved automation to maximise uptime. Companies can complete a greater range of work, more efficiently, and deliver finished products faster. New and improved features include: •
IntelliMAX premium software, designed for incredible ease of use and operation quickly following installation. Incorporating decades of proprietary waterjet cutting models, no other system can consistently produce parts as rapidly or capably.
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IntelliVISOR console with key metrics to optimise operations and complete system monitoring to avoid unplanned downtime.
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EnduroMAX pump that automatically sets the correct pressure and minimises fluctuations to improve component life, while offering the most efficient waterjet pump technology in the market.
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IntelliTRAX drive system with advanced motion control for further increased system robustness and reliability. Requires virtually no maintenance compared to more conventional ball screw and rack and pinon drive systems.
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New garnet delivery system to further minimise downtime.
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Combined with an optional Tilt-A-JET taper compensation head, the new OptiMAX is the most accurate system on the market. In addition, it provides advanced optional usability features such as water level control, under bridge lighting, and a machine status indicator, along with fast, accurate, and efficient cutting. “The OptiMAX represents the pinnacle in abrasive waterjet cutting,” says Arion Vandergon, Waterjet Product Marketing Manager. “It builds upon everything OMAX has learned during the past three decades to deliver the most capable and efficient waterjet cutting system available today, so our customers are able to easily achieve optimal cutting outcomes.” All OptiMAX products include comprehensive after-sales service, unlimited free training, and software upgrades, as well as a host of efficiency centred resources to maximise uptime and keep customers cutting. www.omax.com
Made in Melbourne With increasing innovation and automation, the challenges for manufacturers to continually improve and maintain a profitable, competitive business is a fine balancing act that can be steadied with the right guidance.
For more information or to book your William Buck Hour, please contact us.
William Buck are the accountants and advisers to Australian Manufacturing Techology Institute Limited (AMTIL) and preferred supplier to its members, chosen because of the dedicated manufacturing team that specialises in a range of services customised to the needs of the Manufacturing industry. Some of the services William Buck can help you with include: — R&D tax incentive applications and eligibility advice — Application of feedstock, supporting activities and substantiation advice relating to R&D — Export market development grant applications Cost accounting for accurate pricing — Employee incentive structuring — Financial risk assessment — Profit forecasting on projects — Commercialisation of R&D — International import or export tax structuring — International operations tax structuring — Merger and acquisition due dilligence — Exit strategies — Business valuations — Succession Planning — Separating and protecting family and business wealth — Initial Public Offering (IPO) — Outsourced CFO roles — Audit of external financial reports — Strategic business planning — Business industry benchmarking — Monthly financial reporting, preparation and analysis
Want to know more? Book your William Buck Hour
Jeremy Raniti Manager Business Advisory Ph: 03 8823 6838 jeremy.raniti@williambuck.com
Ian Cattanach Director Business Advisory Ph: 03 8823 6975 ian.cattanach@williambuck.com
William Buck offers a one hour session to check your business is operating at it’s maximum capacity and asking the right questions is important in determining the direction a business will take. We will guide you through a detailed discussion structured around a range of key fundamentals including financial management, funding, people, regulatory requirements and personal wealth strategies. The end result is a fresh perspective and a focused strategy to help you move forward.
williambuck.com
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PRODUCT NEWS
BOGE: Refrigerant compressed air dryer with sustainable, efficient, smart operation The new refrigerant dryers from BOGE’s DS-2 series are more environmentally friendly than their predecessors, with refrigerant R 513 A as standard, which has much lower global warming potential than the refrigerants previously used. However it is not just their remarkably low CO2 footprint that gives the new refrigerant dryers the edge; they also offer economic advantages. The smart control perfectly adjusts to the actual demand and reduces power consumption at a constant pressure dew point. Other components also ensure efficient operation. Economical in every detail, BOGE’s new DS-2 refrigerant compressed air dryers feature a smart control that automatically switches off the cooling compressor at partial load as soon as the required dew point has been reached. The cooling temperature is stored in the heat exchanger. This cold reserve cools the incoming compressed air until the dew point rises again. The cooling compressor only starts up again to maintain the required temperature level, and thus only begins consuming energy at this point. This principle allows energy savings of up to 79% compared to a dryer in continuous operation. The new frequency-controlled fan ensures a stable condensation pressure and reduces energy consumption by up to 25%. Furthermore, the patented design of the heat exchanger combined with low differential pressures and a low refrigerant requirement results in lower power consumption. The high-efficiency components reduce pressure losses to a minimum, which prevents over-compression. The new refrigerant compressed air dryers are highly environmentally friendly. With a
GWP (Global Warming Potential) of 573, the new devices exceed the requirements of F-Gas Regulation EU 517/2014, which stipulate a significant reduction in emissions of fluorinated greenhouse gases (F-gases) by 2030 to protect the environment. Furthermore, the models of the DS series require a very small amount of refrigerant to begin with. Moreover, thanks to the hermetically sealed refrigerant circuit and a CO2-equivalent less than 10 tons, the entire series is exempt from the leak tightness test stipulated in the F-Gas Regulation. Therefore users save the costs of testing by certified refrigeration technicians. Using refrigerant R 513 A results in a better eco and cost balance with maximum supply reliability. The new control further reduces the consumption and costs of BOGE’s refrigerant compressed air dryer. In this way the control integrated as standard allows perfect adjustment to real operating conditions. It responds to temperature fluctuations immediately, which minimises power consumption. The smart control also offers convenient, intuitive operation via a high-quality 11cm touchscreen. It can even be easily incorporated into an existing infrastructure thanks to various interfaces. Communication takes place by Modbus RTU, USB ports or optionally by Modbus TCP/IP. Other new components such as electronic hot gas bypass valves, in conjunction with the installed scroll compressors, ensure efficient drying and reliable operation. www.boge.com.au
WIDIA introduces its next generation in versatile end milling WIDIA has announced the launch of the WCE solid end milling platform, delivering affordable performance and reliability for small to medium machine shops. The initial release of the WCE platform features WCE4, a fourflute geometry which combines advanced, high-performance features with a brand new, versatile grade offered at a highly competitive price. “With its new design, the WCE4 delivers the next generation of versatile end mills to help our customers be more productive and efficient,” said Tamir Sherif, Solid End Milling Global Portfolio Manager at WIDIA. “The WCE4 is an attractively priced tool for small-to-medium shop floors where reliability and consistent tool life are high priorities.” Two key features of the tool are its asymmetrical index and variable helix. The combination of the two reduce vibrations and enable heavy cuts, while the new grade, WU20PE, enables versatility on steel, stainless steel and cast-iron applications. These design features, coupled with the four-flute geometry, deliver an end mill with reliable performance and application versatility – even in demanding operations such as full slots and heavy cuts. The WCE platform includes four-flute, square-end and ball nose end mills with both straight and Weldon shanks and is available in
AMT APR 2022
both metric and inch dimensions. The WCE5 five-flute geometry will be released later in 2022. Orders for the WCE4 end mill, as well as other WIDIA metal cutting tooling, can be placed through WIDIA authorised distribution partners. www.widia.com
PRODUCT NEWS
ViscoTec – High-precision uniform material coating of bore holes and internal threads Combined with different ViscoTec dispensers as a material feeder, the Rotorspray vipro-SPIN enables volumedispensed application of adhesives or viscous greases in bore holes or internal threads. The desired amount of material to be dispensed is applied in precisely defined quantities and with repeatable accuracy all round. The internal contours are wetted evenly and over a wide area. This is a non-contact application. Due to the conical inner geometry of the spinner head, it is possible to use the Rotorspray in both vertical and horizontal orientation. The vipro-SPIN is suitable, for example, for lubricants, greases and anaerobic or other adhesives – from low to high viscosity. A total of four different spin heads are available. For a flexible coating of interior cylindrical surfaces with a diameter of approximately 16mm to 50mm. A plug-in cable, available in different lengths, allows the Rotorspray to be easily integrated into various control unit systems. The vipro-SPIN is always required when adhesives or other viscous materials are introduced into bore holes, internal threads, or ball bearings. Another possible application is to make a shaft-hub connection. This is of particular interest, for example, in automotive engineering, engine construction or general industries, such as vacuum cleaner manufacturing. A volume-dispensed application is possible with the Rotorspray. This means that the volume can be precisely defined via the dispenser, and the layer thickness of the material application is continuously uniform. Over or under-dispensing is avoided by using a volumetric dispensing system instead of time-pressure systems. This is an advantage over the competition because the dispensing
quantity cannot be precisely defined when using ie: simple outlet valves and pressure vessels. The ability to set and spray different volumes on one component offers a further advantage. For example, in an internal combustion engine, there are many bearings and bore holes on which blind caps are placed. These bearings and bore holes are of different sizes and therefore require different dispensing volumes. With the vipro-SPIN, the desired volume for each bore hole or joint can be precisely set and, if necessary, even changed during the process. This is easily set via the dispensing control. In this way, it is also possible to monitor whether and which quantity is being dispensed. In addition to single-component materials, the Rotorspray can even be used to spray two-component materials if required. The adhesive system or other two-component materials are fed mixed to the vipro-SPIN and applied by it to the component. Simple and fast disassembly of the spinner head or the dispenser itself allows uncomplicated cleaning of the components. Martin Höpfinger, Product Manager at ViscoTec, says: “The viproSPIN is an excellent addition to ViscoTec’s product portfolio. It offers an extra solution and enables dispensing and material coating for internal geometries. In combination with a ViscoTec dispenser, this results in another customer-friendly dispensing system from a single source.” www.viscotec-asia.com
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Models to Suit most Applications including Aluminium Manufactured in Japan by Koyo Giken Co., Ltd MySpot® is produced in a variety of sizes and configurations, including pedestal style. Please visit www.koyogiken.co.jp/en/ for detailed information & latest technology
Jim’s Machines and Accessories Authorised Sales & Service Agents Australia and New Zealand Call: +61(0) 414 646 212 Mail: info@jimsmachines.com.au
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PRODUCT NEWS
Hyster’s UT Series – Driver comfort and control lift productivity Materials handling equipment specialist Hyster is expanding its UT Series with the introduction of its H5.0-7.0UT range of 5-7t forklifts, designed for optimum driver comfort and control. The new forklifts follow on from the recent launch of the 4-5t range, with the additional lifting capacity for loading and unloading tasks involving heavier goods. “With the new forklifts, Hyster designers and engineers literally put themselves in the driver’s seat,” says Mark Chaffey, Hyster Area Business Director, Pacific. “For drivers to be productive and safe, they need to be confident in their equipment – and the equipment has to be designed to respond to diverse site conditions, with the features that global experience tells us are the driver’s choice. “The result was a robust and quality engineered forklift, designed to be the ideal solution to meet less frequent materials handling needs, while still offering the outstanding performance and service backup that Hyster is known for globally. Through our global network of authorised dealers, Hyster offers expert local service, spare parts availability and rapid response times, to keep industries moving with minimal downtime or delay.” Forklift drivers that are more relaxed, and experience less discomfort, tend to perform better and stay safer while on the job, so driver comfort was one of the top priorities in the design of the new Hyster UT Series 5-7t forklifts. Stand-out features include: •
A full suspension seat, with an operator presence system fitted as standard, to provide comfort, right from the outset.
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A low step height, with convenient step placing to suit a variety of heights, to provide easy access to the truck.
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A high-strength overhead guard, made from profiled steel, to enhance operator protection.
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A small 300mm steering wheel, with eight degrees of adjustment to suit different operators, and to allow for good maneuverability when working in confined spaces. •
Wide mast view, which delivers excellent visibility of the load, as well as the operator’s forward view, thereby optimising safety and productivity.
“Whether it’s loading or unloading a truck, or moving goods in a retail application, the new UT Series 5-7t forklifts provide the comfort to maximise productivity, efficiency and safety,” says Chaffey. “Another major focus for the new forklift range is low total cost of ownership, with a large range of spare parts that are interchangeable across the broader UT Series, and large access areas for easy servicing. The Hyster dealer and service network extends across Australia, New Zealand, Thailand, Malaysia, Vietnam, Indonesia, Singapore, Philippines, Korea and Taiwan. Chaffey adds: “Hyster authorised dealers are backed by the global Hyster-Yale group with a full product line of lift trucks in operation across hundreds of industries worldwide. Local dealers will carry strong supplies of spare parts and will be ready to provide expert service to local industries.” www.hyster-yale.com
Mitsubishi Electric: SIMPLE graphic operation terminals facilitate remote access Mitsubishi Electric has launched two additional Graphic Operation Terminals (GOTs) to its GOT SIMPLE Series lineup. The 25cm and 18cm widescreen models, which support virtual network computing (VNC), can be used as VNC servers enabling remote access from offices or other remote locations where field engineers may find themselves. This feature will help meet customers’ needs for improved work efficiencies when performing monitoring and maintenance in factories, buildings, utilities and other automation applications. Another key feature of the new GOT models is a 1.5-times increase in onboard memory capacity to 15MB, making it easier to save more screen designs. Furthermore, by using an SDHC memory card, operation logs can be recorded in chronological order to achieve enhanced traceability. This can be useful for validating operations as well as troubleshooting when identifying misoperation or the potential root causes of problems. In addition, these latest models in the GOT SIMPLE Series now support outline fonts, offering clearer visibility of text on the screen by smoothing out edges of textual characters. This increased clarity can help prevent misreading but can also aid reading at a distance.
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Since communication interfaces are also another key factor for users selecting GOTs, Mitsubishi Electric has enhanced the builtin interfaces for these new models. In addition to the standard GOT SIMPLE Series interfaces of Ethernet, RS-232 and RS422 the new units also offer RS-485 support. This facilitates the connect of a wider variety of devices such as temperature controllers and MODBUS peripherals, making it easier for users to implement connected-digital manufacturing strategies in their operations. www.mitsubishielectric.com.au
PREVIEW
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AUSTRALIAN MANUFACTURING WEEK 2022
WHERE TECHNOLOGY MEETS INNOVATION Sydney will be the stage for a showcase of the latest manufacturing technology and cutting-edge innovation in June, as the inaugural Australian Manufacturing Week exhibition takes place at Darling Harbour.
Owned and operated by AMTIL, AMW is Australia’s premier manufacturing solutions event. Under the theme ‘Where technology meets innovation’, AMW 2022 will be held at the International Convention Centre Sydney (ICC Sydney) from 7-10 June. AMW will occupy more than 9,000sqm of exhibition space at the ICC Sydney, with more than 140 organisations taking stands to showcase the latest manufacturing technologies, processes and support services. From its initial launch in 2020, preparations for AMW 2022 have been marked by high levels of interest from across the manufacturing industry. Floor space was almost entirely booked out well before the end of last year. And with registrations opening in February, visitor bookings have already been strong. Thousands of industrial decision makers are expected to attend AMW 2022, taking up the opportunity to see the latest technology up close and learn what it can bring their businesses. “What we’ve seen, with exhibitors booking early and often taking larger stands than at previous AMTIL exhibitions, suggests there’s been a strong appetite across Australian manufacturing for an industry event like AMW,” says Kim Banks, Head of Events at AMTIL. “And now it seems like we’re seeing that sentiment being reflected in terms of advanced registrations from people booking in to visit the show. At this point we’re on track for a very busy show.” While AMW is a brand new exhibition, AMTIL can bring plenty of experience in staging these industry events. Since 2000, AMTIL has operated Austech, Australia’s premier advanced manufacturing
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and machine tool exhibition. The last Austech – held in Melbourne in May 2019 – was attended by industry professionals from across Australia and around the world, with more than 170 organisations showcasing state-of-the-art manufacturing hardware, software and support services. Austech has now been incorporated into AMW, an exhibition encompassing all aspects of the manufacturing industry in Australia. AMW 2022 takes place during a period of resurgence for Australian manufacturing. The COVID-19 crisis highlighted Australia’s vulnerability to disruptions in global supply chains, and reinforced the belief among the general public that a strong manufacturing sector is essential to our country’s future prosperity. The industry was quick to regroup and rebound from the initial shock of the pandemic, and despite subsequent outbreaks and lockdowns, has maintained a steady upwards trajectory ever since. This mood of optimism has been evident in the preparations for AMW 2022 with the early interest both from exhibitors and from people planning to visit the show, suggesting there is strong positive sentiment across the industry and a willingness to invest for the future. AMW will cover every aspect of manufacturing technology, from the largest machine tools down to the smallest precision cutting tools, as well as state-of-the-art support systems, software and accessories, and the myriad services that are essential to any manufacturing operation. AMW 2022 will offer a wider spectrum of technologies vital to the modern manufacturing business than has ever been brought under
one roof at an Australian exhibition before. To help visitors to the show navigate such a diverse line-up of exhibits, AMW 2022 will feature six dedicated zones covering a range of specialised aspects of the modern manufacturing landscape: •
Additive Manufacturing.
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Australian Manufacturers Pavillion.
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Machine Tools & Ancillary Equipment.
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Manufacturing Solutions.
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Robotics & Automation.
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Weld Solutions.
With so much on display, at such a big show, the challenge for visitors to AMW might just be getting round to seeing everything on display. Fortunately, help is available; AMW’s organisers have partnered up with event management software specialists Map Your Show to create a set of online tools to help you plan your visit in advance. There will also be an AMW smartphone app to help you get around when you’re on site. More information is available via the AMW 2022 website, so you can start mapping out your movements at AMW right now. “I think it’s safe to say that every aspect of manufacturing today will be on display at AMW 2022,” adds Banks. “There’ll be something there for anyone involved in manufacturing. Just make sure you set aside enough time to see it all.” www.australianmanufacturingweek.com.au
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PREVIEW Inaugural tech event Generate22 builds bridges for the next generation Industry experts, educators and enthusiasts convene at the inaugural Generate22 robotics and AI conference in Lilydale, Victoria. As a major sponsor, ANCA continues its commitment to the growth and development of young people entering the robotics industry in Australia, to empower the next generation to strike up an interest in advanced technology. The two-day conference staged in late March in Lilydale Victoria, showcased cutting-edge developments in robotics and AI and featured a host of industry expert speakers to inspire the next generation of tech gurus. Victoria’s Lead Scientist Dr Amanda Caples delivered a keynote speech for the landmark event, while ANCA’s Head of Engineering Matt Mannix spoke on an expert panel, discussing the challenges students face transitioning from education settings to the workplace. Mr Mannix said ANCA’s involvement aimed to open the eyes of young participants to the world of Science, Technology, Engineering and Maths (STEM). He explained the biggest barrier to pursuing careers in the field was often due to a lack of exposure, particularly for girls and women. “The great thing about engaging students at a younger age where social constructs are not as ingrained is that both girls and boys are openly exposed to all the possibilities and equally encouraged to participate,” Mr Mannix said. “It gives them an opportunity to really take a look at STEM industries, and it also allows us to generate excitement for young girls and nurture pathways to greater equality and diversity,” he said. The maiden convention encourages enthusiasts aged 12 and over to get hands on with technological design and development in the Robotics and Automation Competition. Competing as an individual or as part of the team, contenders can choose their brief, build and code a robot from scratch or add to an existing robotic system, or create a machine that makes a simple task complicated and fun. “It’s important for people within the industry to grow our networks at events like this so we can ultimately inspire young people to embrace studies and careers in advanced technology,” Mr Mannix said. Event organiser Exaptec Robotics CEO Nicci Rossouw said there was a huge appetite from automation, robotics and AI experts to develop a platform to inspire a new generation. “Generate22 is a fantastic opportunity for all these stakeholders to have open and constructive discussions about Australia's growing tech industry,” said Rossouw, “and how we are going to support it in future years for generations to come.” www.generateconference.com.au
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Headland Machinery – Showcasing the latest TRUMPF tech At its stand at Australian Manufacturing Week, Headland Machinery will be showcasing some of the latest innovations in sheet metal fabrication from TRUMPF. Last year, TRUMPF launched a range of exciting new technology at Blechexpo, Europe’s leading sheet metal processing trade show. A big focus was expanding the existing portfolio with entry-level solutions for welding, tube processing, bending and 2D laser cutting. TRUMPF now offers every customer a customised solution, filling a gap to enable smaller companies to enjoy the benefits of automation. One of the new entry-level machines for automated laser welding is the TRUMPF TruLaser Weld 1000. Today’s systems tend to be large, complex to operate and expensive for small fabricators. For the first time, smaller sheet metal fabricators can now enter the world of automated laser welding at an attractive entry-level price. TRUMPF also launched a new 2D laser cutting machine for beginners. The TRUMPF TruLaser 1000 series increases your productivity with an improved feed rate of up to 70%. On top of that, the new CoolLine technology automatically sprays water mist onto the sheet for optimum cooling, enabling the cutting of fine details in Mild Steel sheets up to 25mm. The TruLaser 5030 fibre laser cutting machine has been upgraded with a new EdgeLine Bevel process, automatically preparing countersinks and welding preparations on the machine. The new technology eliminates process steps. Even with complex contours, the TruLaser 5030 ensures impressively high processing speed and reproducible part quality. With TRUMPF’s TruLaser Tube 3000 fibre, you can take your tube processing to the next level now with RapidCut and bevel cut of up
to 45 degrees. These functions provide considerable productivity and capability gains. The machine allows an entry-level into tube processing with easy handling and pays off even if not fully utilised. Production at shorter notice, but with greater flexibility, makes the TRUMPF TruLaser Tube 3000 the ideal machine to serve new customers or new markets. Furthermore, TRUMPF has launched a new TruBend Center 7020 machine with increased automated panel bending speed and 60% more box height, from 220mm to 350mm. You can now achieve much faster cycle times thanks to the new rotary manipulator. A two-axis manipulator allows for production of narrow profiles much more flexible. Headland Machinery Pty Ltd Stand MT25 www.headland.com.au
Austech – The showcase for machine tools & ancillary equipment AMTIL’s background as an organiser of manufacturing industry exhibitions will recognise the name Austech. Between 2000 and 2019, AMTIL operated Austech, Australia’s premier advanced manufacturing and machine tool exhibition. The event was historically co-located with the National Manufacturing Week (NMW) exhibition, run by Reed Exhibitions. When Reed decided in 2020 to cease the operation of NMW, AMTIL saw an opportunity to create AMW, a more extensive event demonstrating the full scope and diversity of the manufacturing industry in Australia today. Austech has now been incorporated into AMW as a specialist zone showcasing the latest metalworking, machine tools and ancillary equipment. The Austech zone will cover a vast spectrum of advanced manufacturing products and processes, including: •
CNC Machinery, Lathes, Mills.
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Contract Manufacturing/Precision Machining.
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Cutting Tools, Tooling & Tool Holding.
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Forming & Fabricating Machines.
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Plasma, Laser, Waterjet & Ultrasonic Machines.
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Ancillary equipment suppliers.
A diverse range of companies will be exhibiting within the Austech section of AMW. Founded in 1952, ISCAR has grown from its origins as a small blades factory to one of the world’s leading
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manufacturers of metalworking tools, and will be showcasing its vast range of innovative cutting tools for metalworking. Romheld Automation supplies high-quality workholding equipment, machine tool accessories and automation tooling to all types of manufacturing industries, from medical clean rooms to foundries. Meanwhile, Sheetmetal Machinery is dedicated to providing the latest leading-edge solutions from a number of reputable innovative European machine tool manufacturers. “Austech has been at the core of AMTIL’s activities on behalf of Australian manufacturing since we were founded in 1999,” says Shane Infanti, CEO of AMTIL. “So as we moved forward with AMW, it was very important to us to maintain some continuity with that heritage within the metalworking and machine tool space. We’ve got a lot of longtime Austech exhibitors coming to AMW, and they will be a big part of AMW.”
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3D Metalforge – End-to-end additive manufacturing services 3D Metalforge is a leading, unique provider of end-to-end additive manufacturing (AM) services. Established in Singapore in 2015, with production facilities in both Singapore and Houston, USA, 3D Metalforge floated on the ASX in February 2020. The company is now growing its footprint within Australia, and in particular, in the oil and gas, mining, defence, energy and marine sectors. 3D Metalforge provides proven bespoke solutions to clients wishing to maximise operational benefits by implementing parts supply chains based on leveraging one of several AM production technologies. During Australian Manufacturing Week (AMW) 2022, 3D Metalforge will be showcasing its capability in delivering end-to-end AM services, sample components in a variety of typical materials and our portfolio of AM technologies. End-to-end AM services include a number of optional steps along the path to providing a customised solution for clients. It involves auditing client parts inventory to identify those parts both technically and commercially viable for 3D printing; material and physical part redesign to deliver weight reduction or component integration benefits; and manufacturing parts in a wide range of materials to customer specifications –including all post-production machining, finishing and treatment services. 3D Metalforge is also a market trailblazer in establishing on-site, dedicated AM production facilities for clients. This provides the client with real on-demand parts production and virtually ‘zeromile’ delivery. This approach includes the delivery of all design, equipment, operatives and a cloud-based digital parts library.
The benefits of AM to traditional manufacturing methods such as machining and casting is starting to have a positive impact in the general manufacturing market, for example in the production of dye moulds in injection moulding and difficult to source or obsolete automotive components, where rapid delivery and reasonable cost provides great client value. AM allows components to be rapidly produced in all the common materials found within the manufacturing sector including aluminium alloys, stainless steel, stellite, duplex, super-duplex, inconel, hastelloy and other exotic materials. New materials designed specifically for AM also offer improved performance over traditional materials. AM delivers major operational benefits including a rapid response to the replacement or repair of parts. The quick turnaround of faulty equipment minimises disruption to production and associated high downtime costs. Representatives from 3D Metalforge will be available during AMW to discuss opportunities for clients looking at AM as a basis for part of their supply chain and the benefits that can be realised from endto-end AM services, including the provision of a client-dedicated on-site AM manufacturing unit. 3D Metalforge (Australia) Stand AM58 www.3dmetalforge.com
BV Products – Surface solutions BV Products is a longtime Australian manufacturer and supplier of edge and surface finishing technologies for the metalworking and manufacturing industries. First registered in August 1979, the company has established itself as one of the leading industrial finishing specialists in the Southern Hemisphere. BV not only maintains inventory of supplies and equipment but is well renowned as process and technology developers and providers. Originally focused on localised manufacture, in recent years the company has started to expand its sphere of operations by forming strategic partnerships with a number of overseas companies who focus in providing equipment based on specific areas of manufacturing such as additive manufacturing/3D printing applications. Mark Riley, Head of Operations & Sales, spoke with AMT about what to expect from BV at AMW: “Bigger and better! We are going
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all out for the newly branded AMW. The business has grown in leaps and bounds the last couple of years and we now have so much on offer for our customers in Australia and New Zealand. “We’ve rebranded the business and are now focusing on being Australasia’s go-to surface finishing specialists – to build a business where customers can come to find a solution to any of their post processing problems. We are not only providing the equipment and solutions for every application, but also the process know how. This is what separates us from overseas competition.” BV Products Stand MS40 www.bvproducts.com.au
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Kaishan – Big air for big applications When mentioning air compressors, most people think of tank-mounted, piston-type models that drive pneumatic tools in backyard workshops around the country, but there a is a vast difference in type, size and output when we talk air compressors for large-scale industrial applications. Compressed air supplies the power to operate all sorts of machinery and processes in manufacturing, engineering, conveyance, robotics, mining and scientific applications – to name a few. It is in this high-capacity, high demand market that the rotary screw compressor is deployed for its reliability and major power output. Single stage, two-stage and more recently, advanced PMV permanent magnet variable-frequency models are current choices – dependent on application requirements. All of these can be used as single units or integrated, multiple inline machines to supply an almost infinite stream of compressed air throughout a plant or operation. The bigger the kW capacity, the bigger the compressor package needed to hold the motor, airend and system mechanics. The bigger the demand for air, the higher the cost of running each compressor becomes. In fact, the energy-in cost of generating compressed air around the world is one of the highest costs to industry. To maintain compressed air as a viable energy source for industry, rotary screw compressor manufacturers around the world have had to find methods of gaining the output a customer needs while reducing the cost of power usage required to meet demands. While capital expenditure rises with greater energy saving technologies, it can be clearly shown that in many cases, the energy cost savings will quickly pay back the additional outlay for a more efficient machine and system. The compressor pictured is a custom-built monster for specialised aquaculture applications with stainless steel cabinet and epoxy coated components for operation in severe marine conditions.
Manufactured by Kaishan Compressors, this advanced 1660cfm, two-stage machine measures 2,500mm high by 5,230mm long and 2,240mm wide with a weight of 8,000kg. This impressive Cummins diesel-powered compressor features modulating control to minimise energy input through application demands without the inclusion of in-line air receivers. In most industrial installations, the compressor must be matched with smart system design and compressed air line configuration to achieve maximum efficiency and energy-saving performance. The right receiver tanks, air filtration, air dryers and other system components can ensure highly efficient, low-maintenance operation for many years of service. Kaishan offers a range of off-the-floor rotary screw compressors up to 400kW. As the company’s CEO Mark Ferguson states: “We have the design, manufacturing and installation capabilities to supply advanced energy-saving technologies in larger-capacity, custommade compressors to suit any application demand”. Whatever type, size or capacity of compressor, they will only continue to perform at peak efficiency with regular monitoring, preventative maintenance and servicing by expert technicians. With a ready supply of spares parts and specialised lubricants, Kaishan supports its machines through a nationwide fleet of mobile technicians, trained and experienced in keeping all types, sizes and brands in top running order. Kaishan Australia Pty Ltd Stand WT20 www.kaishan.com.au
Rigby Cooke – Manufacturing is their market For Rigby Cooke Lawyers, Australian manufacturers have been the backbone of the firm for decades. AMTIL corporate partner Rigby Cooke consistently fulfils its marketleading reputation by providing its manufacturing clients with highquality advice backed by an understanding of the sector. The company has a long history of acting for Australian manufacturers in a variety of commercial matters. This has given the Rigby Cooke team valuable experience and insight into the sector, which it brings to every matter. Rigby Cooke provides legal guidance through every step of the manufacturing lifecycle from concept through to exit, and can help with such issues as: •
Assisting you to negotiate and conclude commercial contracts, including terms and conditions of trade.
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Assisting in the acquisition of new businesses, products or rights.
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Dealing with ever-changing employee rights, employer obligations or challenging employees
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When an opportunity or concept is identified, Rigby Cooke can assist you in making an acquisition (including performing all required due diligence).
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While you establish your business or build your product, Rigby Cooke can help you to comply with laws and regulations.
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Once you’re in full flight, Rigby Cooke can help you to manage the unexpected and unpleasant side of things, such as helping you resolve disputes, skilfully steering you through the court process.
Finally, when it’s time for you to exit, Rigby Cooke can assist you to prepare the business or concept for sale and manage the legal due diligence with a potential acquirer. Rigby Cooke Lawyers Stand MS31 www.rigbycooke.com.au
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ePol – Ensuring supply connects with demand With a completely online, on-demand platform, ePol provides customers with a simple method to access a comprehensive range of technical stock shapes of engineering plastics from anywhere in Australia. While the engineering plastics industry has historically been a supply chain driven through bricks & mortar and reps on the road, ePol noticed clients were becoming more sophisticated and more demanding over time. This has resulted in a customer base who are highly knowledgeable about exactly what product they require to complete their machining operations. In most cases drawings already call for a material specification. That means clients know what they need, and they want to get their hands on it as quickly as possible, without the time delays and overheads of calling suppliers to request pricing and stock availability. The industry has also struggled in providing the same service regardless of where customers are located, which has left rural businesses at a disadvantage. The ePol business/supply model was born from a need to offer industry ‘a better way’ – the status quo simply wasn’t meeting customers’ needs anymore, so the ePol team reimagined the model to create a future-ready platform that puts customers first. With the ePol platform, customers can log in to a secure system and gain immediate access to stock on hand for rod and sheets product for POM/Acetal, Cast Nylon, HDPE, UHMWPE, PEEK, PTFE, PETP (commonly known as Etralyte) and Polycarbonate (AR2 Abrasion Resistant). ePol’s completely transparent approach to showing pricing and real-time stock levels, including stock availability and incoming stocks forecasting, puts clients in the driver’s seat. It enables them to take complete control of purchasing requirements, gaining certainty around manufacturing deadlines by being able to monitor progress using ePol’s comprehensive notification system, including order confirmation, dispatch, and realtime track-&-trace functionality. ePol wanted to offer customers a best-in-class logistics experience. It partnered with all-Australian company Freightmate, which is pioneering class-leading online reporting tools to provide goods shipped on premium road freight Australia-wide. Combine all this with ePol’s nationwide ‘free into store’ delivery service, it gives industry all over Australia access to the stock they need when and where they need it. ePol has negotiated exclusive supply relationships with Okulen and Dynex, to ensure customers have the world’s best-quality materials on hand.
Building on a long tradition of German engineering precision, Okulen has been developing world-leading engineering plastics for over 40 years. Okulen’s experienced team of engineers work closely with industry to develop high-tech polymers tailored for specific environments and applications. Today, lowfriction Okulen plastics are already replacing metals and non-ferrous metals in many applications, saving weight and energy, and creating extra value to provide an edge in competitive markets. Specialists in highly wearresistant PE-UHMW, Okulen’s comprehensive product portfolio, combined with state-of-the-art treatment and moulding processes, makes them a preferred supplier to technical industries around the globe. Dynex has been a leading manufacturer of high-quality engineering plastic in the APAC region since 1965. Dynex's highly qualified experts constantly pursue research and development and have pioneered a number of technological achievements, to meet specific customer and industry needs. Dynex utilises a ISO9001certified quality management system to ensure the highest quality manufacturing standards are met, while providing the most efficient delivery logistics for their clients. With a product range encompassing a raft of high-performing polymer materials, Dynex supplies an array of semi-finished thermoplastic stock, in the shape of rod and plate to the engineering industry globally. ePol understands that time is money, which is why you can transact on the ePol platform 24 hours a day, seven days a week – ensuring that when you need to make material stock purchases they can support your business with product as and when you need it. ePol is a 100% Australian business headquartered in Melbourne, with a hand-picked, highly trained support team to assist with any enquiries that can’t be resolved through the ePol platform online. The team at ePol is so confident that you’ll see the immediate benefits of utilising the ePol platform, they’ve issued a promotional code to enable your business to access materials at a discounted rate for 30 days (EPOL02). Why not let your business reap the benefits of on-demand engineering plastics supply and stay ahead of your competition? Engineering Plastics Online Stand MS15 www.epol.net.au
Robotics & Automation – Smart manufacturing Robots are often thought of as the technology of the future, but they’re actually quite old – in fact they recently celebrated their 100th birthday. The word “robot” was first coined in Czech writer Karel Capek’s play ‘R.U.R.’, written in 1920 and first performed in 1921. The play begins in a factory that makes artificial people, called roboti (robots), whom humans have created. Initially happy to work for humans, the robots revolt and cause the extinction of the human race. While ‘R.U.R’ was the first countless works of science fiction in the century since that have depicted robots as sources of menace or wonder, the reality today is much more down to earth. Modern robots have become a feature of many modern workplaces, but nowhere more so than in the manufacturing industry. In today’s factory, robotics and automation systems have liberated human personnel from an ever-growing array of repetitive and dangerous tasks.
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At AMW 2022, the Robotics & Automation Zone will showcase the latest state-of-the-art equipment and processes for the optimisation and digitalisation of manufacturing operations. While some of the world’s leading robot brands will be on display, there will also be exhibits from systems integration providers who specialise in helping manufacturing businesses adopt these technologies. In addition, the Zone will feature several companies that supply the software that brings these machines to life.
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SWI Engineering – Leaders in slitting and folding Australia’s SWI Engineering is a world leader in sheet metal slitting and folding technology – specifically for roofing manufacturers and sheet metal fabricators. In Australia, USA and New Zealand, corporations using SWI equipment include Kingspan, Stratco, Stramit, Metroll, Metalcraft, Metal Sales Manufacturing, Central States Manufacturing, Lysaght, Roofing Industries, Dimond, Steeline, Freeman Roofing, and hundreds of other roofing leaders. All SWI equipment is 100% manufactured by SWI at its hi-tech facility in Warrnambool. In the Americas, SWI equipment is sold and serviced by its staff in Atlanta, Georgia. Approximately 50% of all SWI equipment goes to customers in the USA, with many of its American customers having multiple machines around the country. SWI’s line-up of equipment includes Duplex Long Folders, Simplex Long Folders and ‘Marxman’ slitters, as well as integrated machinery software taking orders directly from construction site to the production floor. Flashing and trim manufacture is automated by SWI’s database software that links all the machines to ERP software such as MYOB, Arrow, SAP, and many other business accounting packages. This eliminates duplication of data, greatly reduces data entry at the machines, and provides a simple framework for growth. SWI’s system also has available a comprehensive price calculation module that allows invoice costs to be automatically calculated and sent directly to your MYOB accounting software. The highly automated Marxman Pro slitter is the only slitting & blanking line in the world that includes the convenience of intermediate part-cut technology as well as automatic labelling, coil consumption tracking and barcode linking to downstream folders – which can all be linked directly to the ERP system. Production statistics show the Marxman Pro consistently produces up to 200
parts per hour of operation, all cut to size, labelled and ready for folding. The Marxman Plus has proven an exciting addition to the SWI line-up. Released in 2016, it has already become the most popular selling Marxman model. All SWI’s Marxman slitting lines are designed to allow a full set of slitter blades to be changed in less than 20 minutes. The passive safety systems incorporated into the SWI Duplex Folder prompt the machine to automatically slow from its high speed when operators approach the danger zone. While other makes are becoming faster and more dangerous, SWI have developed a sustainable, safe compromise that allows high-speed operation with first-class, certified operator protection. The SWI Duplex is regarded as a leading performer in the USA for safety, ease of use and reliable operation. Some of SWI’s US customers have over 20 Duplex folders. SWI Engineering Stand MT20 www.swimachinery.com
Visit us at AMW Stand AM58
Home of intelligent additive manufacturing With considerable experience and proven capability in delivering additive manufactured parts, 3D Metalforge has the resources and technical know-how to make parts rapidly, precisely and for various environmental conditions. Working with a wide range of materials, component sizes and geometries, 3D Metalforge can create the quality parts you need cost-effectively and on time to avoid unplanned downtime. Ask about our end-to-end additive manufacturing services.
Call +61 0410 851 018 Email: david.green@3dmetalforge.com www.3dmetalforge.com
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Bystronic Australia – Productive bending Bystronic is a world-class manufacturer of high-quality laser cutting and bending machines, automation systems and software that streamline the process chain, minimise waste and increase profit. As a single-source solutions partner, Bystronic Australia provides sales, service and support to customers throughout Australia and New Zealand. At Australian Manufacturing Week 2022 Bystronic will be showcasing its Mobile Bending Cell 80 – combining the bending performance of the Xpert 80 with the productivity of the Mobile Bending Robot, to achieve bending automation with a minimal footprint, and help meet the demands of customers’ production orders without worries on setup hassles and operator shortages. Bystronic’s bending solution empowers users to achieve greater machine flexibility, availability, and productivity. Due to manpower shortages, fabricators are often challenged in finding press brake operators to run their equipment, or find enough of them to run multiple shifts. Purchasing additional press brakes to meet production demands does not make sense if you can’t find operators to run them. Bystronic’s bending solution will help to reduce the number of skilled operators required and enable operators to manage multiple bending cells. Older press brakes require additional set-up time, and this limits the capacity of available bending time. However, with Bystronic’s bending solution, most set-up tasks required by older machines are either eliminated altogether or reduced to very little time. Without these time-consuming tasks, this efficient press brake system not only eliminates the need to increase equipment, but also saves time and money. Bystronic’s press brake automation technology specifically focuses on easier set-up and programming, allowing easy management of day-to-day production needs. Only simple programming is required to program all bending jobs offline using the Robot Manager software solution for macro programming of bending robots, based on the data of parts to be bent that are programmed in BySoft Cam. Subsequently, users can simply import all the data into ByVision Bending without interrupting running manufacturing processes. For overall productivity and flexibility, adding Bystronic’s robot press brake automation system greatly changes the status quo. Bystronic machines will not sit idle during meal breaks, lavatory breaks, and shift changes. There will be consistency in production planning and meeting customer delivery deadlines. With Bystronic’s Mobile Bending Cell, users will have the option to manually bend complex
small series or use fully automatic bending for large series, offering the highest degree of flexibility for fluctuating order situations. Users can achieve more with less: greater productivity with less labour, improved part quality, higher productivity, and increased revenue with fewer machines. Bystronic’s bending system gives users more available bending time to generate better revenue by utilising the same number of brakes but with increased capacity for handling additional business opportunities; capable of bending two times more parts per unit of time than older press brakes. The results are a much lower cost per part, higher throughput capabilities, and additional capacity to take on even more business, all producing higher revenue streams. Bystronic Australia Pty Ltd Stand MT76 www.bystronic.com
WorkGuru.io – Improve your profitability on every job WorkGuru.io was created out of necessity. Australian SMEs needed something to fill the gap between spreadsheets and a full-scale ERP solution to run their business. After years of consulting to businesses who wanted both stock control and job costing, without the exorbitant expense of an ERP solution, founders Michael Davis and Tony Harcourt took the leap to launch WorkGuru.io to fill that gap. WorkGuru.io is driven by the practical, demonstrated needs of real businesses. “Every feature is based on conversations and feedback with business owners and functionality we’d always wished our consulting clients had access to from day one,” says Harcourt. Created for Aussie manufacturers, WorkGuru.io gets you back in control of your profitability with the tools you need to manage job costs in real time. It goes well beyond job costing and stock management, with CRM, quoting, invoicing,
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asset servicing history and reporting tools, as well as features like quote sign-off tools and custom forms. Davis and Harcourt will be at the WorkGuru.io stand at Australian Manufacturing Week, where visitors will be able to see first-hand how much control you can get from a platform built for the industry’s needs. The team will have a demo set up offering a hands-on look at WorkGuru.io’s dashboards, reporting and easy project tools, so visitors can see how well it could work for their teams. WorkGuru.io Stand MS34 www.workguru.io
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Open IIoT – Using the Internet of Things to manage COVID-19 threats on the factory floor Much has been said of the rapid uptick in manufacturers integrating Industrial Internet of Things (IIoT) technologies since the beginning of the COVID-19 pandemic, as many were forced to adapt or be left behind in the face of massive disruption. Less, however, has been said about the possibilities of using IIoT to mitigate the immediate threat of COVID-19 transmission on the factory floor. As social distancing is an essential component of stopping the spread of the virus, manufacturers can require that employees use wearable trackers when on the factory floor – enabling realtime tracking of staff movement and interactions during their shift. Should the worst happen and a COVID-19 outbreak occur, these records can assist with contact tracing. Wearable trackers can also be used to alert employees when they are coming within 1.8m of one another and alert the monitoring system that a possible breach may have occurred. As there is much emphasis on the monitoring and real-time visibility of data as a benefit of IIoT integration, this feature can also be used to capture the employee and time records when certain materials are handled. This data can then be checked against the system to flag any possible cross-contamination between employees during material handling.
without actually lowering risk of catching an illness. Some doctors have said that the excessive cleaning and disinfection of surfaces (as was especially prevalent at the beginning of the pandemic) is unnecessary given that the virus is primarily spread via air transmission. As employers, manufacturers have the responsibility of taking every precaution possible to ensure the safety of their staff and that this includes extensive sanitation procedures – no matter how minor the risk may be. Luckily, IIoT tracking technologies can be used here too, to help cleaning crews detect areas that may not have been sanitised, or sanitised adequately after service cycles. In sum, the real-time monitoring and analytics of health and location data made possible by IIoT integration can help manufacturers identify high-risk areas on the factory floor so that they can take preventative measures to address these risks.
Manufacturers can then take IIoT material monitoring a step further by identifying the most frequently used assets on the factory floor, such as tools or machinery, and flag these for extra sanitation processes in between use to reduce the risk of COVID-19 transmission.
From ensuring business continuation, to allowing for better remote monitoring, to using the technologies to reduce the risks of COVID-19 outbreaks, there is not a single drawback to manufacturers who choose to integrate IIoT into their operations during this period of disruption and uncertainty.
Some critics have said that the COVID-19 pandemic has caused a spike in ‘hygiene theatre’ – a term used to describe the practice of taking hygiene measures to give off the feeling of improved safety
Open IIoT Stand RA55 www.openiiot.com.au
Focus on 3D printing – the Additive Manufacturing Pavilion As additive manufacturing continues to revolutionise the manufacturing industry, this exciting emerging technology will be given a comprehensive showcase at Australian Manufacturing Week. The Additive Manufacturing Pavilion will be an unmissable part of AMW 2022. The boom in interest in 3D printing continues to gain momentum, and AMW visitors will get a chance to see the latest innovations in this area first-hand. The Additive Manufacturing Pavilion will feature demonstrations of the latest 3D printers and services from a range of companies and organisations that lead the field of additive manufacturing. One highlight of the Additive Manufacturing Pavilion will be RAM3D. Based in Tauranga, New Zealand, RAM3D has been leading the way in metal 3D printing in the Southern Hemisphere for more than 10 years. From its high-tech manufacturing facility it creates parts for a variety of world-wide industries; from titanium knives used by the Team NZ Americas Cup crew, to customised handlebar extensions for the
New Zealand Olympics Cycling team. It produces inconel and titanium parts for aerospace and defence customers, and can also print in Stainless Steel 155ph and 316L, Titanium 64, Inconel 718 (high temperature alloy) and Aluminium (AlSi10Mg). “Advances in 3D printing have the potential to revolutionise every segment of the manufacturing industry,” said Shane Infanti, CEO of AMTIL. “The Additive Manufacturing Pavilion is a testament to AMTIL’s ongoing commitment to promoting this groundbreaking technology, showcasing the very latest innovations, and highlighting the potential it can offer for Australian manufacturing businesses.”
Looking to secure a sustainable supply chain and combat long lead times? watch our webinar on-demand to learn more about ECI M1® AMT APR 2022
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CADPRO – Partnering in success CADPRO Australia will be exhibiting at Australian Manufacturing Week 2022 along with its advanced manufacturing client Romar Engineering. The CADPRO team will be showcasing the partnership with Romar, along with its advanced manufacturing capability, software, and services. CADPRO’s team of 30-plus CAD/CAM technical industry experts cater to the advanced manufacturing market in Australasia and are passionate about enabling manufacturing clients to improve their business processes with technology and support. CADPRO assists its manufacturing clients to program and machine high-tolerance, complex parts. It also supports clients to attain high levels of automation in their businesses with the use of design to machine programming (CAD/CAM) and advanced manufacturing.
It also specialises in post processors for Autodesk advanced manufacturing software and highend machines. CADPRO’s local experts are specialists in product data management with Autodesk Vault Professional and have a track record of integrations between ERP and manufacturing software. With a focus on client success, it regularly conducts business and technical workflow assessments for manufacturing companies. Further to this, CADPRO offers software development services through its in-house development team, who specialise in automation and customisation of Autodesk software, integrating various types of software and systems across its customers’ businesses. CNC post processor development and customisation is an additional strength of CADPRO’s development team. This provides a unique and broad skillset within the Australasian CAD/CAM software industry.
CADPRO’s partnership with Romar has seen the company catapult its ability to 3D print metals for missioncritical markets and streamline its end-to-end design processes with Autodesk software. Romar provides advanced manufacturing and processing solutions for a wide range of highly regulated industries including aerospace, aeronautical, medical, defence and automotive applications. The firm is a competitive player in Australian manufacturing, CADPRO services the defence and and its recent acquisition of a GE M2 aerospace industries with advanced Steve Milanoski, Head of Advanced 3D metal printer has expanded its manufacturing solutions and Manufacturing at Romar Engineering. offering to laser powder bed fusion support. It works with the Australian for material parameter development in multiple 3D metal printing Government’s Department of Defence, Science and Technology modes. This is unique service in the Australian market, currently and is aligned with the Australian Industry and Defence Network, only seen in academia. along with AMTIL. CADPRO’s advanced manufacturing services across Australia and New Zealand include multi-axis, simultaneous machining software, CAD/CAM technical expertise, consulting, and training.
CADPRO Systems Australia Pty Ltd Stand MS80 www.cadprosystems.com.au
Raymax – High-end equipment for numerous applications As a supplier of high-end technology that includes lasers and laser systems, spectrometers and hyperspectral imaging cameras, Raymax Applications offers knowledge and expertise across a wide field of systems and applications. High-power diode lasers by Laserline are experiencing rapid uptake in heavy industry workshops across Australia to fill a growing demand for cladding and repair of metal parts. Using Laserline lasers for welding is proving popular due to the high-quality finish that reduces post-processing time. Also, suited to aluminium welding of lightweight components in aeronautics and welding copper used in battery cells of mobile devices or accumulators of electric cars, high-power diode lasers can provide optimal solutions for varying welding tasks. If you are looking for micro-machining, excimer lasers from the OPTEC/LASEA Group are well established in the field of medical manufacturing. Using ultrafast femtosecond lasers offers the ability to machine materials at very high levels of specificity useful in manufacturing medical equipment such as intralocular implants (IOL), stents and catheters. If a TEA C02 laser is more suited to your
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needs such as precision drilling of controlled release pharmaceutical capsules, we can advise on LightMachinery’s lasers from Canada. A recent addition to Raymax’s range of quality technology is the outstanding HySpex NEO camera from Norway. Hyperspectral imaging is used in diverse industries due to the capacity to combine the power of digital imaging and spectroscopy collecting image colours thousands of times what the eye can see. Attached to a UAV for scanning fields, mounted on a tripod or included in a laboratory set-up, successful applications are currently found in detecting food quality of fish, identifying mineral deposits at mining sites or identifying different plastic types in recycling plants. It has even been used by the Louvre Museum in Paris to find faults and degradation in art work. Raymax Lasers Stand MS35 www.raymax.com.au
Unrivalled Performance The Extreme Dynamics of KIMLA’s POWERcut series reduce production cycle times while maintaining the highest accuracy. With a wide range of flexible material handling and working areas means KIMLA can provide the right solution for your needs. • 6g Acceleration • 5m/s Trajectory Speed • 0.001mm Repeatability of positioning • Linear drives with KERS • Flexible material handling options • Material storage options • Third pallet table • Print head option
Scan the QR code to learn more or visit www.laserthings.com.au
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www.LaserThings.com.au sales@laserthings.com.au | 03 9770 4910
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Leussink Engineering – Exciting applications The Leussink team is excited to be taking part in Australian Manufacturing Week and will be showcasing its Demmeler welding and fixturing solutions, and Tomelleri portable metrology arms. At AMW 2022 Leussink will demonstrate the Demmeler modular welding & fixturing table and how it can work across a variety of applications. Demmeler modular welding systems not only achieve a quick return on investment but also increase productivity. Leussink customers have reported a 50% improvement in productivity with a faster turnaround, better accuracy, quality and efficiency, and less rework with a Demmeler system. A versatile jig and fixtures solution, the Demmeler system can be used for all types of welding and fabrication work, including sheet metal processing, cobot technology, assembly and measuring equipment, laser welding, laser cutting, prototype construction, body construction, and more. Demmeler modular welding systems are durable and versatile, and can meet all horizontal and vertical requirements. Throughout AMW the Leussink team will also be able to provide expert opinion on the full Demmeler system offering and wide range of accessories. Leussink will also demonstrate Tomelleri portable metrology arm at AMW. Tomelleri portable metrology arms sense discrete points on the surface of the object with a probe. The dimensions are immediately digitised and transferred to a CAD system, where surfaces are developed and drawings are finalised. Leussink is the exclusive distributor of Tomelleri metrology equipment in Australia, and offer a range of sales and after-sales support, including set-up & training, ordering of accessories, complementary software, and calibration services. Leussink can calibrate the Tomelleri metrology system in Australia, which
eliminates the high costs and delays involved in sending equipment overseas to be calibrated. Leussink works with clients to complete a variety of engineering projects, large and small, from initial design and prototyping to reverse engineering of obsolete parts, to full-scale manufacturing of componentry. The family-owned company has been in business in the Illawarra region for more than 40 years and is an active part of the local Illawarra industry and community, employing more than 50 people. Leussink Engineering Pty Ltd Stand WT70 www.leussink.com.au
Australian Made – Backing Aussie manufacturing The ‘Australian Made’ claim has never been more powerful than it is right now. It tells consumers that products which carry the mark are made to some of the world’s highest manufacturing and safety standards, with inputs often sourced from Australia’s clean green environment. It also makes a compelling statement about generating local jobs and economic activity. With this in mind, it’s no surprise that ‘Australian Made’ products are viewed positively, even more so in the current COVID and disasteraffected environment. In fact, recent Roy Morgan research found 73% of Australians had a favourable opinion of businesses that partner with the Australian Made logo, with 75% likely to purchase from them. Underpinned by a third-party accreditation system, the logo ensures the products that carry it are certified as ‘genuinely Australian’. It is Australia’s only registered country of origin certification trademark and has helped thousands of brands communicate their Australian credentials to consumers, businesses and all levels of government for more than 30 years. Roy Morgan’s research found that almost all Australians (99%) know the iconic Australian Made green and gold kangaroo. With 97% associating the green and gold kangaroo with the support of local jobs and employment opportunities, 95% with safe and highquality products, 89% with the use of ethical labour and 78% with sustainability. Renewed pro-Australian sentiment presents an opportunity for Aussie manufacturers to capitalise on their ‘Australian Made’ story and expand their markets. Nine in ten (89%) of Australians now believe Australia should be producing more products locally following the COVID-19 pandemic. And since 2020, three in five (58%) licenced Australian Made businesses have seen an
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increase in customers actively seeking, requesting, or buying more ‘Australian Made’ and ‘Australian Grown’ products. If being recognised as genuinely Australian is important to selling your products, certify them to carry the iconic Australian Made, Australian Grown logo. Australian Made Campaign Ltd Stand MS03 www.australianmade.com.au
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Cincom – Simplifying the quote-to-cash process By streamlining the quote-to-cash process, Cincom removes repetitive, mundane processes so sales reps can focus on higher-value tasks such as building and retaining good business relationships. The quote-to-cash process is an end-toend business process that covers the entire customer lifecycle, including sales processes, order management and billing. In today’s fastpaced economy, the quoting process has moved beyond the basic functionality of a spreadsheet. Customers expect comprehensive, prompt quoting practices from their suppliers. Those who can quote quickly, accurately and efficiently are seeing the strongest sales conversion rates. With this in mind, many businesses are looking for efficiencies in quote-to-cash process so they can shorten the time needed to get back to their clients. CPQ software enables organisations to have better control of pricing and the ability to cross-sell or upsell complementary products with ease. It’s customisable and flexible whatever the sales process, and is designed to reduce complexity. Whatever sales channel used, Cincom CPQ will streamline the entire process so you don’t have to go through multiple processes to get to the same end goal. Doing this can significantly reduce quote times as well as inaccuracies. Cincom CPQ has been proven to reduce quote times from weeks to days, even hours. Furthermore, if a sales model changes, it is easy for the platform to adapt. Cincom is highly invested in the APAC region. With sales, services and support based in Australia, the company can service customers in-country. Operating across a breadth of industries, Cincom works with industry heavyweights such as Toyota Material Handling
Australia (TMHA). TMHA recently selected Cincom CPQ to improve its sales effectiveness and efficiency by automating and streamlining the pricing and quoting of its products and services. Cameron Paxton, Vice President and COO at TMHA, says: “Toyota selected Cincom due to their alignment with their values, especially in regard to their appetite for kaizen or continuous improvement.” With Toyota offering hundreds of products and services, configuring, pricing and quoting is a challenge, and the business had been using an in-house legacy configuration tool. The system lacked integration with TMHA’s ERP, leading to double handling and processing. With hundreds of models of forklifts, sweepers, scrubbers, tow tractors and more, there can be more than 100 possible pricing configurations. It took five years for Toyota to find a solution before selecting Cincom because of the lack of software options that could include both rental and purchase options. “We believe that Cincom CPQ will serve us into the future and as such, we need a partner who will stand the test of time and be devoted to helping us continue to integrate and refine our processes,” says Paxton. “We believe Cincom can and will provide that degree of engagement.” Cincom Systems Stand MS25 www.cincom.com.au
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Visit us at AMW and see the latest developments in workholding solutions and CNC accessories from the world’s leading brands - all designed to optimise the productivity of your CNC machine, and improve worker safety and efficiency.
T: (03) 9771 6121 | E: sales@dimac.com.au | W: dimac.com.au
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SAGE Group introduces TilliT Visitors to the SAGE Group stand at Australian Manufacturing Week will have the chance to learn more about transitioning their manufacturing operations into Industry 4.0, no matter where they are in their digital journey. Backed by thousands of hours of specialist technical expertise, SAGE Group is a global company with more than 600 people across Australia and around the world. Tailoring the right solutions for your digital transformation needs – from automation, data acquisition and analysis, to equipping your workforce with the necessary skills and high calibre experts – SAGE Group provides you with the Digital Key to accelerate your digital journey. TilliT is manufacturing’s do-it-all digital platform – it is a comprehensive digital platform that delivers forward-looking insights, real-time visibility and operational control to your factory. With TilliT, you can manage people, processes and equipment – all in one place – while providing operators and plant managers the tools to optimise efficiencies. Visitors to AMW 2022 can find out more about TilliT, with ondemand live demonstrations continuing throughout the four days of the show.
SAGE Group Stand RA95 www.gotosage.com
Automated Solutions Australia – Composite robotics Automated Solutions Australia will be showcasing its extensive range of robotics technology at its stand, including a specialised capability in composites materials. With unprecedented demand from consumers for caravans, spas and pools, the COVID-19 pandemic has provided a massive boost to the composite industry. This record high demand has placed increasing supply and production pressure on manufacturers, with order books full and lead times increasing. The difficulty of getting parts out the door is compounded by a shortage of skilled workers, particularly those with Gelcoat application and fibreglass lamination experience.
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Material savings and wastage: Reducing waste at the source of origin is the key to material savings. Robots and their dispensing systems are very accurate, with precise trigger timing and constantly repeatable motion dramatically reduces the amount of gel coat, resin or fibreglass used. A robotic application pattern reduces overspray and eliminates the possibility of unnecessary build over the same area multiple times. Closed loop material delivery systems can be included in a robotic solution to monitor and provide consistent fibre chop application, adjusting the amount of fibre material delivered in real time to compensate for minor changes in the material variability and production environment.
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Shorter cycle times: A robot can repeat difficult ergonomic tasks with speed and accuracy. With much greater precision and repeatability, a robot is able to apply the material at a higher rate, with increased application speed all while accurately controlling the trigger ON and OFF points to save material. Operating between 600 and 800 mm/s, the robot is able to change the spray pattern, material delivery rate and target distance on-the-fly. This is what enables the robot to reduce cycle times when compared to manual application. A robotic solution is able to operate across multiple shifts, amortising the value of the equipment and the factory when competing on a global scale.
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Increased employee safety and environmental protection: Removing manual operators from potentially hazardous fumes in a resin or fibre chop application can support improvements in workplace safety and overall morale. The Fanuc range of fibreglassing robots are designed to operate in hazardous and explosive areas. This removes operators form the hazardous working environment, reducing the exposure of employees to potentially harmful substances.
That’s where manufacturers are turning to proven robotic application technology from Automated Solutions Australia. Increasing environmental regulations, rising material costs, and pressure to innovate are driving boat, swimming pool, shower stall and caravan manufacturers to turn to robotic solutions for fibreglass and gel coat applications within the composite sector. By leaning on technology proven in the automotive painting sector, the composite industry can expect gains in product quality and reliability, material savings and wastage, reduced labour and improved cycle times. With the additional added benefit of much improved employee safety and reduced environmental impacts. Fanuc fibreglassing robots are industry-proven. With demonstrated capability to apply a consistent gelcoat film build day-in and dayout, manufacturers are seeing less rework, fewer scrapped parts and significant materials savings. By installing Fanuc fibreglassing robots, the pressure to find expertly trained operators is eased, allowing existing operators to be deployed in other critical areas of the operation. Fanuc’s fibreglassing robots offer: •
Product quality and reliability: Gelcoat is critical to the appearance and function of the product. If the application is applied too thickly, the surface becomes susceptible to cracking – too thin and the gelcoat won’t cure correctly, resulting in durability and appearance concerns. Automated Solutions application and process engineers optimise the robot’s path and spray parameters to ensure consistency in thickness and appearance. The film build and coverage uniformity are validated in the buy-off process to ensure they meet the material supplier’s specifications. Once this process has been completed, the robots are ready to repeat the task, 24 hours a day, seven days a week.
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Automated Solutions Australia Stand RA37 www.automatedsolutions.com.au
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AW Bell – Casting solutions experts AW Bell will be showcasing some of its latest casting offerings, including a new aluminium alloy for electronics enclosure designs and structural components. AW Bell is known for its casting solutions, from investment casting, sand casting, 3D printing, production machining to heat treatment, destructive and non destructive testing, and its OEM division for aftercast solutions. Over the years, it has developed advanced processes and technologies such as the Aluminium Billet Equivalent (ABE) process, which produces aluminium parts with a casting factor of 1.0. This enabled them to transition from the automotive industry into the aerospace and defence market, where it is now a prominent leader in producing lightweight, high-strength complex metal parts. Its latest advancement is a previously unknown aluminium casting alloy that displays an improvement in thermal conductivity of at least 20% above legacy alloys, improving performance by allowing electronics to run cooler. The new alloy is also able to be anodised, marking a first for heat treatable aluminium castings. This revolutionary alloy is particularly well suited to components where thermal management is critical - such as electronics enclosures. The team at AW Bell pride themselves on working in collaboration with their customers to take products from concept to the marketplace. AW Bell has a demonstrated record of accomplishment in achieving significant success in the global arena through exporting products and services, recently being the recipient of the Export of the Year Award for Manufacturing and Advanced Materials. AW Bell Australia Pty Ltd Stand MP33 www.awbell.com.au
Australian Manufacturers’ Pavilion – Aussie manufacturing in the spotlight Showcasing the best of manufacturing in this country. Especially dedicated section of the Australian Manufacturing Week exhibition that spotlights Australia’s precision engineering and advanced manufacturing industry, the Manufacturers’ Pavilion is now an integral part of AMW, with 12 manufacturing businesses signed up to exhibit this year. “We’ve worked very hard over the years to make the Manufacturers’ Pavilion a key feature of AMTIL’s exhibitions, and it’s been really satisfying to see it establish itself,” says Shane Infanti, CEO of AMTIL. The Australian Manufacturers’ Pavilion showcases the capabilities of component manufacturers, precision engineering firms, toolmakers, advanced manufacturers and general engineering companies. Marand Precision Engineering designs, manufactures and sustains complex and innovative equipment and products primarily for the defence, aerospace, mining, rail, and renewable energy industries, while Marsh Alliance is one of the most recognised and trusted names in spring, wire form and pressed parts manufacturing. The Pavilion will help businesses like Marand and Marsh promote their capabilities connecting them with potential clients, partners, and other organisations such as government, research and training bodies.
Looking to build a more sustainable business? Do it with equipment finance. Angus Macdonald 0459 864 726 amacdonald@interlease.com.au Clare Sainsbury 0450 167 619 csainsbury@interlease.com.au
www.interlease.com.au
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The Rural City of Wangaratta – A hub for opportunities There has never been a better time to invest in the Rural City of Wangaratta. Opportunities exist for commercial development, relocation and expansion across a range of manufacturing industries, in the transport, warehousing and logistics sector, and in health and agriculture. Wangaratta has a population of 29,000 and local workforce of 13,000, with access to a further 50,000+ strong workforce in the neighbouring local government areas of Wodonga, Albury, Benalla, Indigo and Alpine shires. Located on the main road and rail transport corridor of eastern Australia, 2.5 hours north-east of Melbourne, one hour from Albury, and 6.5 hours from Sydney, Wangaratta is ideally placed for business. Wangaratta is a hub for surrounding regional activity within 45 minutes of Wodonga’s Logic Centre and STC Rail Freight distribution. The Wangaratta Aerodrome provides the opportunity to unlock the potential of additional industries as export producers. The Rural City of Wangaratta is home to a range of manufacturing success stories, from innovative agricultural, to beverage, textile, wood and construction manufacturers. This range is illustrative of the capacity, depth and potential on offer in Wangaratta. Alongside manufacturing, there is growing strength in a diverse range of economic sectors in Wangaratta that are supporting a deeper, more diverse economy often exploiting synergies with existing businesses. Wangaratta is growing and continues to be a significant agricultural hub, and opportunities exist for value adding to primary production. Wangaratta’s largest employer is the health industry, growth in this area is attracting a skilled workforce. Its education facilities are expanding with university hubs now based in Wangaratta supporting ongoing growth in education, services and outcomes for the regional population. The ongoing strength of these sectors presents opportunities for innovative business development.
The Rural City of Wangaratta offers a blend of city life and welcoming villages, native bushland, pastoral landscapes and snow-capped peaks. With a growing population, diverse economic base, thriving economy across a range of sectors and stunning natural environment, the Rural City of Wangaratta will continue to deliver business, lifestyle and investment opportunities into the future. Rural City of Wangaratta Stand MT35 www.investwangaratta.com.au
Hexagon – Putting data to work
Weld Solutions – Constant innovation
A global leader in sensor, software and autonomous solutions, Hexagon is putting data to work to boost efficiency, productivity and quality across manufacturing, industrial, infrastructure, safety and mobility applications.
The Weld Solutions Zone will highlight advanced processes and provide high-quality interactive experiences that demonstrate the latest developments and applications in the welding sector.
Hexagon’s technologies are shaping urban and production ecosystems to become increasingly connected and autonomous—ensuring a scalable, sustainable future The main industry focus for Australia is construction, mining and agriculture where we provide technologies that convert data into intelligent information that enables smart planning and efficient execution.
The history of welding dates back thousands of years. The earliest examples of the technique stem from the Bronze and Iron Ages in Europe and the Middle East. According to the ancient historian Herodotus, iron welding was “singlehandedly invented” by the Glaucus of Chios, a Greek sculptor in metal, around 500 years BC.
At the HEXAGON (MSC Software) stand at Australian Manufacturing Week 2022, a range of core MSC solutions for finite element analysis (FEA) simulation will be on display. Products to be featured will include: . • • • •
Motion/Controls • Thermal Materials – Digimat • Acoustics CFD • Manufacturing – Simufact Engineering Lifestyle Management
HEXAGON (MSC Software) Stand AM10 www.mscsoftware.com
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Today, welding is an essential manufacturing process used across a range of settings, from medical devices and electronics, to largerscale applications such as mining or shipbuilding. It continues to advance to new levels of technological sophistication. Robot welding has today become commonplace, and researchers and companies continue to develop new welding methods and to gain greater understanding of weld quality. The Weld Solutions Zone will provide a comprehensive showcase for this critical part of the manufacturing world. As well as offering a chance to see some of the latest, state-of-the-art welding technology, it will feature an array of exhibitors supplying ancilliary equipment, safety systems and gases.
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McNeall Plastics: The industrial plastics partner you need With the world’s number-one nylon and Australia’s biggest large-capacity precision CNC machining centre, McNeall Plastics brings performance, strength and size to Australian Manufacturing Week. McNeall Plastics is an Australian-owned plastics manufacturing and engineering business with an unrivalled 50 years of experience. They are a true one-stop shop that supplies everything from standard material orders through to a complete and integrated plastics engineering service that includes design, custom casting and formulation, bespoke product development and more. A key feature of McNeall Plastics’ showcase at AMW 2022 will be its exclusively manufactured AustLon (PA6G) highest-grade cast nylon. An engineering plastic used in a vast number of industries for its superior mechanical, physical, chemical and electrical properties, it is replacing aluminium, copper, bronze, steel, brass and other metals in many applications with superior advantages. According to Josh Budd, Managing Director of McNeall Plastics, AustLon is a tougher and more wear-resistant engineering plastic that is proving to be the preferred material where issues stemming from abrasive wear, impact strength, bearing strength, noise, weight and corrosion have been difficult to resolve. “We’re excited to showcase AustLon at AMW and show visitors how this material can make a true difference to their business,” he says. “Lighter, harder and more durable than other materials on the market, AustLon has unrivalled mechanical properties that have proven time and time again to outlast all other materials on the
market, even in the toughest conditions.” “The superior performance of AustLon and its ability to deliver reduced maintenance and downtime and overall whole life costs helped us save an international mining conglomerate over $3.4m in just one financial year. We are excited to explore how we can help more businesses save time, reduce costs and improve their project profitability.” McNeall Plastics will also feature its newly launched large-capacity precision CNC machining division. With the largest manufacturing capacity in the Southern Hemisphere, McNeall Plastics is the only company in Australia with the capacity and capability to pour large and complex products up to a size of 3,000mm by 3,000mm and manufacture products up to 4,000mm by 3,000mm, whether it be a plate, tube, bar or completely custom part. Budd says the addition of this capability has completed the creation of a true one-stop plastics manufacturing and engineering shop: “Unrestrained by size or design constraints, our team can work collaboratively with organisations to design, engineer and manufacture custom cast parts. If you can envision it, we’re here to help create it.” McNeall Plastics Stand MT93 www.mcneallplastics.com.au
The Surftest SJ-210 is a user-friendly surface roughness measurement instrument designed as a handheld tool that can be carried with you and used on-site
Easy to use • 2.4-inch colour graphic LCD with backlight • Simple key layout The Surftest SJ-210 can be operated easily using the keys on the front of the unit and under the sliding cover.
Highly functional • Advanced data storage capabilities • Optional memory card • Password protection • Multilingual support • Stylus alarm An alarm warns you when the cumulative measurement distance exceeds a preset limit.
Contact MTI Qualos today to learn more about the SJ-210 Series.
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Extensive analysis and display features • Complies with many industry standards The Surftest SJ-210 complies with the following standards: JIS (JISB0601- 2001, JIS-B0601-1994, JIS B0601-1982), VDA, ISO-1997, and ANSI. • Displays assessed profiles and graphical data In addition to calculation results, the Surftest SJ-210 can display sectional calculation results and assessed profiles, load curves, and amplitude distribution curves.
M.T.I. Qualos Pty. Ltd. 1300 135 539 or email sales@mtiqualos.com.au www.mtiqualos.com.au
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Objective3D – $2m-plus investment underpins aggressive additive manufacturing strategy Objective3D, the largest provider of Stratasys additive manufacturing (AM) solutions in Australia, has invested more than $2m to advance AM at a production scale, including new innovative material offerings and an expanded AM software ecosystem with the availability of new polymer 3D printing systems for the Australian market. The investment includes the latest Stratasys technologies and newly constructed manufacturing pods at the Objective3D Additive Manufacturing Centre located in Carrum Downs, Victoria, making it the largest showroom and AM service bureau in the region. The new technologies are the Stratasys F770, J826, J35Pro, H350 and Origin One, and will cover fused deposition modelling (FDM), PolyJet, selective absorption fusion (SAF) and P3 programmable photopolymerization. “These new technologies represent an opportunity to seriously tackle production manufacturing using additive”, said Matt Minio, Managing Director of Objective3D. “Our greatest growth today comes from customers who either wish to manufacture serious production volumes on their own additive system or have Objective3D manufacture for them. These latest in-house technologies and new materials further enhance the ability for customers to manufacture greater production volumes using additive, producing components that are representative of injection-moulded parts for their strength and surface finish. With the current disruptions to global supply chains, this technology couldn’t have arrived at a better time.” A range of technologies will be on display at the Objective3D stand at Australia Manufacturing Week. The first 3D printer in Stratasys’ new H Series Production Platform, powered by SAF technology, the new H350 printer delivers production-level throughput for end-use parts. It is designed to give manufacturers production consistency, a competitive and predictable cost per part, and complete control for the production of thousands of pieces. Applications include end-use components such as covers, connectors, hinges, cable holders, electronics housings, and ducting. The new Stratasys Origin One 3D printer, designed for end-use manufacturing applications, uses proprietary P3 technology and a software-first architecture to produce parts at volume in a wide range of open, certified third-party materials with industry-leading accuracy, detail, finish repeatability, and time to part. The Origin One is suited for the production-oriented segments, including automotive, consumer goods, medical, dental, and tooling applications. The new versatile J35Pro 3D printer accommodates everything from concept modelling to high-fidelity, realistic, fully functioning models. This unique all-in-one, multi-material desktop 3D printer is
ideal for the engineering and design office setting. With the J35Pro, users have the option to combine a variety of materials, including Vero UltraClear, that can be printed simultaneously, giving engineers and designers the versatility to produce parts that match their exact needs. In addition, the printer can incorporate up to three materials printed as single material parts or combined on the same model part, on the same tray. Applications include over-moulding, filling simulation and printing in full greyscale. The J55Prime goes beyond full-colour printing with new tactile, textual, and sensory capabilities. In addition to the existing highly realistic visual models, the printer utilises multiple materials that cater to design, functional and biocompatible prototyping, such as Elastico Clear and Elastico Black for flexible, soft-touch printing, Digital ABS Ivory for moulds, jigs, fixtures and functional prototypes, VeroContactClear, a translucent material designed for prolonged skin or bodily contacts such as medical devices, sportswear, or wearables and a range of Ultra-opaque colours for better plastic simulation, raising the bar in 3D printed multi-material models. Other technologies available at the Objective3D stand will include direct laser melting sintering (DMLS) from GE Additive, lithographybased ceramic manufacturing (LCM) from Lithoz, handheld touchscreen 3D scanners from Artec3D, and world-leading AM software from Materialise. Objective3D P/L Stand AM30 www.objective3d.com.au
Manufacturing Solutions – Meeting all requirements The manufacturing industry would not be able to function effectively without a diverse array of ancillary technologies and support services – and these are all reflected in the Manufacturing Solutions Zone. The Manufacturing Solutions Zone offers optimised solutions to the most common challenges experienced by manufacturers, covering everything from materials handling technologies, to integrated manufacturing and safety solutions. The Manufacturing Solutions Zone is where you can get advice and support when it comes to some of the most common challenges experienced by manufacturers. It encompasses everything from equipment for warehousing & logistics, through to the latest software for streamlining manufacturing operations.
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Sponsored by Commonwealth Bank, the Manufacturing Solutions Zone also features an array of specialist service providers in areas such as law, finance, and skills, training & recruitment. It’s also where you can talk to AMTIL’s corporate partners: Interlease, Rigby Cooke Lawyers, Sterna GL and William Buck.
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Sutton Tools: Australian expertise Sutton Tools, the Australian family business renowned for its high-quality cutting tools, will be back at Australia’s premier advanced manufacturing and machine tool exhibition this year showcasing its range of tooling for a wide range of specialised industrial applications. Sutton Tools’ team of experts will be on hand to walk visitors through their range of high-performance tools, their diverse offering to the CNC machining industry, and their customer service and technical support. The exhibit will feature a range of Sutton Tools offerings, plus agency products from Walter Tools, SupplyPro and the Hoffmann Group - just three of the many agencies Sutton Tools now represents. Here’s a sneak peak of what visitors will get to see at the Sutton Tools stand: •
Sutton Tools. A selection of Australian-made Sutton Tools solid carbide milling cutters and drills, in addition to various Australian-made tapping solutions. Sutton Tools can provide solutions for all your special tool needs, with fast quoting, manufacturing lead times for both indexable and solid carbide requirements.
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SupplyPro. A 10-drawer SupplyPro inventory management system called SMART drawer will be on display. Visitors can gain a better understanding of the benefits of inventory management through this affordable and flexible system, which can be adapted and expanded to suit any working environment.
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Hoffmann Group. Product highlights will include both the GARANT and HOLEX ranges of machining, clamping, measuring, grinding, workstations and storage or personal
protective and safety equipment. A selection of toolholding, workholding and tool storage products – including Zero Clamp – will be on display. •
Walter Tools. With around 45,000 standard tools for turning, milling, holemaking and threading, Walter offers an extensive range of high-quality precision tools from the Walter, Walter Titex and Walter Prototyp brands. The Walter brand comprises carbide indexable inserts and PCD tooling systems for milling, turning, grooving and holemaking, of which a selection will be on display during AMW. Sutton will be also demonstrating the Walter Innotime web-based tool list generator, which can be used to quickly find the right machining solution for your component – simply upload the 3D data for your component and obtain a valid quote in record time.
Sutton Tools Stand MP15 www.suttontools.com
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Exhibitor List AMW 2022 Sydney Exhibitor list – 7th April, 2022 Company Stand 3D Metalforge (Australia) AM58 AC Australia CAD CAM Solutions MT04 Accurpress Australia MT17 ACL Industrial Technology MS40 Acra Machinery Pty Ltd MT03 Additive Australia AM32 Additive Engineering Pty Ltd AM79 AI-NC MT87 Air Liquide Australia Ltd WT12 Alfex Additive MT86 Alfex Laser MT85 All Manufacturing Personnel MS47 Altair MT98 Amada Oceania Pty Ltd MT02 Amiga Engineering Pty Ltd AM18 AMTIL MS01 Anca Motion Pty Ltd RA72 Andrew Donald Design Engineering Pty Ltd RA90 Applied Machinery Australia Pty Ltd MT46 Australian + New Zealand Defence Directory MT44 Australian Made Campaign Ltd MS03 Autodesk Australia Pty Ltd MS80 Automated Solutions Australia RA37 AW Bell Pty Ltd MP33 BAC Systems Pty Limited MT36 Barload Australia MT14 Benson Machines MT88, MT91 BG Precision MP20 Bilby 3D AM50 Bolts & Industrial Supplies MT54 Brilliant Digital MS02 BusinessHub MS27 BV Products MS45 Bystronic Australia Pty Ltd MT76 Cadpro Systems Australia Pty Ltd MS80 Camco Cutting Tools Int'l Pty Ltd MT63 Camplex Pty Ltd MT05 Capral Ltd MT33 Carl Zeiss Pty. Ltd. AM11 CGB Precision Products Pty Ltd MS55 Cincom Systems MS25 CMTS Sheetmetal Machines MT15 Commonwealth Bank MS41 Complete Machine Tools MT40 Connect Steel MP10 Cross Technology Croup AM74 Cryocut MT61 CSIRO RA70 Dimac Tooling Pty Ltd MT06 DMO Solutions MS38 EASYkleen Pty Ltd MP11 ECI Software Solutions MT83 Elexon Electronics MS07 Emona Instruments AM38 Engineering Plastics On Line MS15 Ensitech MP31 Epicor Software RA32
AMT APR 2022
Company Stand Fantech Pty Ltd MS39 Fanuc Oceania Pty Ltd RA60 FES/DAVI MT01 Ficep SPA MT99 Fladder Danmark A/S MT09 Formlab Inc AM51 Global Shop Solutions MT94 Glycol Sales Australia MT32 GoProto (ANZ) Pty Ltd RA10 Gravotech Australia MT07 GWB Machine Tools Pty Ltd MT67 Haas Automation Inc. MT75 Hare & Forbes Machineryhouse MT10, MT11, MT26, MT30 Headland MT25 Hexagon (MSC Software) AM10 Hi-Tech Metrology Pty Ltd MT43 HMS Group of Companies MP38 Inductotherm Group Australia MS50 Industrial Laser Pty Ltd MS57 Industry Capability Network MS06 Industry Update Media MT34 InfraLaser Pty Ltd MT68 Innofocus Photonics Technology Pty Ltd AM16 Integra Systems MP45 Interlease Company Pty Ltd MS33 Invest Wangaratta MT35 ipLaser MS09 Iscar Australia MT60, MT61 Iscar / Matrix MT62 Kaishan Australia Pty Ltd WT20 Kobot Systems Pty Ltd MS14 Kolarc Welding WT94 Konica Minolta RA40 Kraftech Australia MT80 Laser 3D MP30 Laser Machines Pty Ltd MT12 LaserThings Pty Ltd MT31 LatheSafety MS36 Lawrence & Hanson MT72 LEAP Australia Pty Ltd MS10 Leussink Engineering Pty Ltd WT70 Lightwave Technology AM52 Lincoln Electric RA85 Livetools MT23 M Gamer Pty Ltd MT64 Machinery Forum (VIC) Pty Ltd MT79 Marsh Alliance MP37 McNeall Plastics MT93 Microscopy Australia MT95 Modern Tools (VIC) Pty Ltd MT27 MTI Qualos Pty Ltd MT53 Multicam Systems Pty Ltd MT22 MYOB MS17 NH Micro MS04 Novarc Technologies RA78 Objective3D P/L AM30
Company Stand OMAX MT08 OneCNC Australia MT55 OneKloudX Pty Ltd MT13 Open IIoT RA55 PIMA (Plastic Industry Manufacturers Australia) MS29 Power Machinery Australia Pty Ltd MT38 Precision Specialty Tooling Pty Ltd MT65 Pressure & Safety Systems WT35 Project 3d AM56 ProShop ERP MT92 Protube Engineering MT24 Prytec Solutions MT70 Punchtech Australia Pty Ltd / Amtronics (Aust) Pty Ltd MT73 QHDC Blickle Australia Pty Ltd MS82 Q-tech Toolings Pty Ltd MT96 RAM3D AM59 Raxo Machine Tools Pty Ltd MT47 Raymax Lasers MS35 Recruit Australia Pty Ltd MS76 Rigby Cooke Lawyers MS31 RIVETLAB PTY LTD MS85 Robert Bosch Australia MT71 Romheld Automation Pty Ltd MT45 Ronson Gears Pty Ltd MP47 Rootstock Cloud ERP + Nagarro MT97 Sage Business Solutions Pty Limited MT74 SAGE Group RA95 Salvagnini Italia S.p.A. MT79 Scan-Xpress Pty Ltd AM12 Schmalz Australia RA20 Sheetmetal Machinery Australia Pty Ltd MT50 Sheetmetal Tooling Tech Pty Ltd MT78 SLTL Group (Sahajanand Laser Technology Limited) MT82 SolidCAM ANZ MT69 Stamac Engineering MT89, MT90 Sterna Global Logistics MS32 Successful Endeavours MP35 Supagas WT30 Sutton Tools MP15 SWI Engineering MT20 Techni Waterjet MT49 Tesuco Pty Ltd WT37 Thunder Laser MT77 Trotec Laser MT16 TXM Lean Solutions MS86 Ultimate LED MS87 ViscoTec Asia Pty Ltd MT84 Weld Australia WT75 Whitelaw Engineering Machinery MT52 Whitelaw Tooling Supplies MT51 William Buck MS30 WMSSoft Pty Ltd MS37 WorkGuru.io MS34 Your Maintenance Coach MS22
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066
ROBOTICS & AUTOMATION
Automating cricket ball production Global cricket ball manufacturer Kookaburra made innovative use of automation to develop a machine-tending robotic system for efficiency and upskilling. Under the laws of cricket, it is illegal for players to rub any substance other than saliva and sweat onto the ball, let alone scuffing it with their fingernails. Similarly, strict rules apply to the manufacturing of cricket balls. Cricket ball manufacturer Kookaburra designed its first ever machine tending robotic system to produce the perfect ball, with the help of industrial robot supplier TM Robotics and its Australian partner MAP Services. Machine-tending is repetitive work. The job of loading and unloading machines with parts or materials is usually done by humans. In the production of cricket balls, workers would place covers – the outside leather of cricket balls – onto trays after being pressed into shape to form half of a cricket ball. These trays are then placed into a rack and moved to the next process – trimming excess leather from the pressed cover. Originally, when Kookaburra approached MAP Services, the distribution partner for Shibaura Machine’s industrial robot ranges in Australia, its system for manufacturing cricket balls involved having human operators at the next stage of production. Workers would manually remove these trays from the rack, bending and twisting to place at the tray and trimmer every couple of minutes. Workers would then pick and place each cover into a trimming machine, which uses a sharp blade to remove excess leather from the ball. Not only is this process highly repetitive, but it also puts workers at risk to major hand injuries by being in close proximity to a blade. Rather than this longwinded manual process, MAP Services suggested an automated robotic system for loading and unloading the trimmer, including a tray dispensing system. The plan was to place the full trays of cricket ball covers into the dispenser, feeding trays automatically to the TVL700 robot to load and unload the trimming machine. This requires only one operator to load a set of trays every 20 to 25 minutes. To do this, MAP Services required robotics equipment and approached Shibaura Machine partner and authorised distributor TM Robotics. The global manufacturer supplied a TVL 700 Shibaura Machine robot, which was integrated with MAP Services’ vision system for the project — never seen before for this unusual application.
Vision systems for automation MAP Services designed an automatic racking system, where six trays carrying between 80 and 90 cricket ball covers are placed onto a conveyor. This part of the application usually scatters the covers in random locations, meaning a vision system is required to ensure the robot can accurately decipher where each cover is and how to pick it up. While CAD-based systems can identify items scattered onto a conveyor or workspace, the challenge is recognising the position of each item when presented in a random order — let alone determining the best method for the robot to pick them in. The vision system uses high-speed cameras to continuously capture images. Using intelligent software, the system can process these images and identify the exact position of an item. In this case, cricket ball covers. The system then determines the most logical order to pick up each cover and does so with sub millimetre accuracy, with the same ease as a human worker.
AMT APR 2022
Kookaburra’s new machine-tending robotic system incorporates a TVL 700 Shibaura Machine robot, supplied by TM Robotics, which was integrated with MAP Services’ vision system.
Using Shibaura Machine’s robot, the vision system is easily integrated to help identify the position of each cricket ball cover and share its exact co-ordinates with a single-axis Cartesian, before travelling to pick up covers at the position identified by the vision system. The robot grabs the cover off the Cartesian and puts it in the trimming machine, before empty trays are fed into an accumulation bin for collection. With an operator required only to load trays every 20-25 minutes, other workers can upskill and be redeployed in the company, rather than carrying out these laborious, repetitive jobs. All while the robot and trimmer continue to produce covers before daily shifts start, after daily shifts end and even during breaks.
ROBOTICS & AUTOMATION
“This application is about automating processes, speeding up production and getting more consistent results,”
Professional Measuring Instruments
See us at Stand MT64, AMW Sydney 2022
Choosing a robot TM Robotics suggested the TVL 700 robot for this application due to its high speed and six-axis articulated movement. These features ensure an easy change of direction, without limiting the range of motion. In fact, it is the quickest robot in TM Robotics’ TVL range, with a reach of 700mm and a payload of 4kg. The TVL robot range, consisting of the TVL 500 and TVL 700, is specifically designed to save on space, while delivering all the functionality required from a six-axis robot. “This application is about automating processes, speeding up production and getting more consistent results,” said Shane Gallagher, director at MAP Services. “The cricket balls made by Kookaburra are used in all international one-day and T20 cricket matches. The manufacturing process needs to be fast but safe, as it includes a pressing machine that has a hydraulic plunger and a blade. Ensuring operators are away from the blade immediately removes risk of serious injury or harm.”
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.
Due to the success of this project, Kookaburra placed more orders for another machine tending application, with some slight differences. Gallagher added: “On the second robot, an expanded IO module is used for additional inputs and outputs. There are now six processes this single robot performs, which is rare, but its flexibility and IO module allows us to achieve more actions. “This application involves having an injection moulding machine that waterproofs the ball. When injecting a cover with the liquid, it must come out of the machine in eight seconds, otherwise it freezes. The TVL 700 is ideal for this, as it can perform this action at a high speed in a confined space. And with the expanded IO module, it is able to communicate with other pieces of equipment to help complete the more complex cycle.” After all, producing the perfect cricket ball is no mean feat to manufacture. With the help of TM Robotics and MAP Services, Kookaburra could design its first ever machine-tending robotic system, with the unique addition of a vision system — ensuring cricket balls are made quickly and reliably. www.tmrobotics.com www.mapserv.com.au www.kookaburrasport.com.au
Available now at:
www.accud.com.au AMT APR 2022
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ROBOTICS & AUTOMATION
Bringing Australian-made agility to automation worldwide Despite challenges due to the pandemic, Agile Robotic Systems has continued to grow the number of successful overseas installations of its Australian-designed and Australian-made range of CNC machine-loading systems. The compact, easy-to-use, flexible and affordable Agile Flex has established a solid foothold in the US market, offering local manufacturers and machine shops a truly agile machine toolloading solution as well as an antidote for staff shortages and sick leave absences. Success in North America includes a few successful installations in Canada. Now the company is entering the UK market through a recent appointment of a local distributor, also with an eye on the greater European market. While many workshops across the globe are realising the productivity benefits of installing an Agile Flex on their CNC machine tools, the Agile Flex is also developing significant attention in the Australian market due to its reputation for best-in-class software and maximum productivity out-of-the-box at a market-leading price. To get an Australian perspective, we interviewed Derek Hyde, one of the owners of Melbourne-based Jodek, to find out more about his company’s choice to invest in not just one but two Agile Flex 12D systems. AMT: What was the main reason behind investing in machineloading automation? Derek Hyde: Increasing machine efficiency and minimising the amount of repetitive, manual labour for our staff. AMT: What is the specific manufacturing task involved? DH: Loading and unloading steel billets – approximately 250 pieces per shift weighing 3kg each. AMT: How did you work before you decided to employ machine loading automation? DH: One operator would normally operate two machines, which often led to inefficiencies in the production cycles. AMT: What was the challenge that brought you to consider an Agile Flex?
Andrew Payne, Jodek’s Business Development Manager, highlights the enhanced ability to meet urgent customer requirements through very fast set-ups and small batch runs.
AMT APR 2022
DH: With the high-volume work we do it’s difficult to keep staff motivated and engaged when they know they will need to stand in front of a machine eight hours per day loading and unloading billets. AMT: What were the determining factors that lead you to choose an Agile Flex? DH: The Agile Flex was already proven in the field. We were confident the Agile Flex would be installed and be up and running with minimal fuss or downtime. AMT: Were there any unexpected benefits that resulted from employing an Agile Flex? DH: Staff are very happy to see we are investing money to make their lives easier and they understand the automation will not replace their jobs, but rather enable them to move into more interesting roles. AMT: What has improved and what advantages do you have now? DH: We are able to run more machines, more efficiently with the same number of staff. I expect to see the number of lights out unmanned hours increase as we build more confidence.
Investing for growth Husband and wife team Derek and Jodie Hyde started Jodek in 1996 as a part-time machine shop located in Cheltenham, in a 400sqm shared workshop with two manual machines. Since then, the business has grown to 25 employees, with 22 CNC machines and a 2,400sqm manufacturing facility. From simple metal parts fabrication to complex designs, Jodek produces a wide range of components across various industries, including transport, mining, defence, aviation, medical, white goods, and specialising in construction. Both Jodek’s Agile Flex 12D systems are equipped with a Fanuc M-10iD/12 robot, three drawers, and a top pallet for a fourth layer
ROBOTICS & AUTOMATION nine unique parts. These two larger models will handle workpiece weights upwards of 8kg with a maximum diameter of 150mm and a maximum length of 300mm. Three Agile Flex models are specifically tailored for smaller CNC machine tools and smaller workpieces. The Agile Flex 12P and Agile Flex 12D models boast all the features of the larger Flex models, including the easy-to-use software package requiring no robot experience, but in a smaller overall size and at an even more affordable price. The Agile CoFlex 15P, featuring a Fanuc CR-15iA collaborative robot, allows the operator and machine to work even closer together, removing all requirements for safety scanners and barriers. All three of the smaller models will handle workpiece weights of 4kg and greater, with a maximum diameter of 100mm and maximum length of 300mm. The workpiece capacity for the complete Agile Flex range is superior to competitive machine tool loading products. One of Jodek’s Agile Flex machine tending systems.
of parts. Each of the three drawers and top pallet can be configured with a unique product, allowing a single run to include up to four unique product types and eight unique CNC programs to be called up without any operator intervention, for runtimes exceeding 24 hours. Jodek’s CNC machines were fitted with the Agile Robotic Systems AutoDoor, a servo-controlled automatic door opener typically more economical than an OEM option and faster to deploy. Developed to add lights-out machining to any brand of CNC machine, the Agile Flex range consists of five models. Two of the five models are tailored for large CNC machines: the Agile Flex 35P (pallet), which is an affordable system for large and heavy parts; and the Agile Flex 35D (drawer), which is a multi-layer drawer system that increases overall capacity and unmanned run-time. The drawer system can have up to eight drawers, and when combined with the optional top mounted pallet, it allows for the processing of
The Agile Flex is one of three levels of machine-loading automation. Agile Modular offers a variety of configuration options from a comprehensive range of pre-engineered modules and Agile Engineered caters for special purpose machine loading requirements. All Agile systems feature the state-of-the-art Agile Cell Controller software, also Australian-designed and Australian-made, allowing for new parts with complex robot motion and sequences to be configured in just minutes. Specifically designed to be intuitive for the CNC machine tool operator, the parametric-style, wizardguided system requires no robot programming knowledge. Agile Robotic Systems is part of the John Hart group and draws upon a heritage of more than 70 years in machine tools and over 30 years in automation and robotics to bring agility to automation of machine tools. www.agilerobotics.com.au www.jodek.com.au
SMART CAD/CAM
Ultimate Nesting Efficiency
Software to drive nearly every cutting, punching, routing, tube, and bending operation with greater savings and efficiency, with modular solutions from quoting to production to delivery.
www.sigmanest.com
AMT APR 2022
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ROBOTICS & AUTOMATION
Rockwell Automation expands technology suites to meet new opportunities A world leader in industrial automation and information technology, Rockwell Automation is expanding its operations and technologies in Australasia and Southern Pacific nations in response to emerging new efficiency, flexibility, and sustainability opportunities as the world transitions into a post-COVID-19 era. “COVID has been a game-changer in many negative ways over the past couple of years, but it has also delivered many positive opportunities by accelerating change in key Australian and New Zealand industries,” said Anthony Wong, Regional Director – South Pacific at Rockwell Automation. “These ongoing efficiency and innovation gains will be most pronounced in key local industries – such as food and beverage manufacturing, mineral processing, oil and gas production, and public infrastructure.” Wong outlined a series of Rockwell Automation’s initiatives in an exclusive interview with AMT magazine, saying the new technologies and capabilities will have major relevance to its readers. Rockwell Automation – which employs over 24,000 people and has customers in more than 100 countries – is best known for its FactoryTalk software and Allen-Bradley automation systems, incorporating its programmable logic controller (PLC) and programmable automation controller (PAC) ranges from large to small and even micro applications. The company continues to win global and local awards. FactoryTalk Edge Gateway solution software, for example, was selected this year as the winner of the “Industrial IoT Solution of the Year” award in the sixth annual IoT Breakthrough Awards – which recognise individuals, companies, and organizations involved in producing Internet of Things (IoT) products, solutions, and services. Rockwell Automation is a multiple IoT Breakthrough Award winner having won “Industrial IoT Innovator of the Year” in 2020 and “Industrial IoT Company of the Year” in 2021.
an environment where everyone can – and is equipped – to do their best work, which is fundamental to our success.”
Expanding capabilities Rockwell Automation is expanding its suite of brands and capabilities here as Australasia and the South Pacific moves to meet and take advantage of COVID-19 and post-pandemic challenges, such as strengthening supply chains, building a rapid response to trade opportunities, and improving safety and sustainability of operations. Recent product launches in the region include: •
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Plex Systems. Welcomed to the Rockwell Automation family in 2021, Plex is a Smart Manufacturing Platform that connects people, systems, machines, and supply chains. Plex offers manufacturing execution system (MES) capability that connects to companies’ enterprise resource planning (ERP) software, as well as quality management and asset performance management, among other advantages. The platform deals with more than 8bn transactions a day and has an A security rating. Using Plex, a large food manufacturer made an US$500,000 (approximately AU$700,000) inventory write-off saving and was able to complete mock recalls within minutes. Fiix Computerised Maintenance Management Software (CMMS). The Fiix platform allows users to plan, track and optimise maintenance in one system. Fiix connects teams, tools, data, and processes to get critical
Further awards include being crowned one of “The World’s Most Innovative Companies” by Forbes, Cisco’s “Acceleration and Transformation” award, Dow Jones’ “Most Sustainable Companies” award, a “World’s Most Ethical Companies” award, and “America Business Ethics” award. “We have also been recognised as a best global company for innovators to join, as well as for our commitment to diversity and inclusion, which are all very important because we believe that people are the foundation of all we do,” said Wong. “Through our stream of innovation coming to Australasia and the South Pacific, we aim to sustain our people advantage of creating
AMT APR 2022
Rockwell Automation FactoryTalk software is built for supporting an ecosystem of advanced industrial applications, including the Internet of Things (IoT).
insights, scale maintenance programs, and boost asset performance. For example, a supplier of dried egg products to food, beverage and sports nutrition markets was able to see a 42% reduction in after-hours call-ins and a 54% drop in reactive maintenance by implementing Fiix and a building automation system (BAS).
SaaS makes automation available to companies of all sizes With Plex and Fiix, Rockwell Automation offers Software as a Service (SaaS) solutions to customers, providing them with greater agility and closer alignment to where technology is heading, without large up-front investment costs. “Previously, having sophisticated software and automation systems in place required data centres, infrastructure, large migration costs and other up-front capital costs,” said Wong. “Plex and Fiix even the playing field and allow companies of any size to capitalise on the latest technologies to enhance their manufacturing plant and processes, without needing to have a big budget. It’s the manufacturing equivalent of moving from DVDs to Netflix. Companies can receive daily updates and add or remove features any time to suit their specific needs.”
Making industrial data more accessible and consumable Industrial data is generated in such large volumes and at such high speeds that it’s difficult to capture accurately. Even if you could, its use is likely limited by
ROBOTICS & AUTOMATION a lack of both context and ability to be easily consumed. With operational data locked within disparate devices or siloed in systems of record, data scientists expend significant effort on data preparation and are hard-pressed to extract actionable industrial performance insights. Rockwell Automation’s FactoryTalk Edge Gateway solution software breaks down siloed systems and drives the convergence of Information Technology (IT) and Operations Technology (OT) by simplifying and automating the collection of industrial data across machines, devices, and assets. “Manufacturing, machine building, and precision engineering companies can use this quality and easily consumable data to improve operations and asset health, or look for opportunities to improve energy use,” said Wong. “It sounds like a simple and logical process but has mostly only been done with bespoke custom applications, and with significant investments in technology and software. FactoryTalk Edge Gateway requires no customised coding and enables a seamless transition to get data analysis up and running swiftly. “Plex, Fiix, and FactoryTalk Edge Gateway each allow companies of any size to capitalise on the benefits of a connected Internet of Things (IoT)-enabled factory, without the large up-front investments
advanced manufacturing can support ESG reporting, Moret said: “Intelligent devices, combined with innovative sustainability and energy management software, provide new levels of insight to reduce energy demand and increase efficiency. Real-time energy management is within reach, from simple monitoring to embedded AI tools that enable closed-loop optimisation.
Anthony Wong, Regional Director – South Pacific at Rockwell Automation.
that were previously a requirement to use technology this advanced.”
Leveraging technology to drive sustainability goals Wong also foreshadowed pioneering technologies and solutions in advanced manufacturing related to environment, social & governance (ESG) concerns and opportunities: “We understand that companies operating in the manufacturing industry are looking for new ways to leverage technology to reduce their environmental footprints.” This is a focus that extends throughout the Rockwell Automation organisation and is led by its global Chairman and Chief Executive Officer Blake Moret. In a recent World Economic Forum article on how
“By creating a standard energy data model in context to production, energy intensity and other key performance metrics can be measured and improved. In one instance, an automotive company found that 40% of one machine’s energy consumption occurred when it was not producing anything. This simple, yet impactful, insight allowed them to de-energise the equipment when not in use, reducing both costs and greenhouse gas emissions.” Wong added: “The company is in an extremely exciting stage. For over 100 years, our plant floor technology has been trusted by our customers. In recent years, we have made a strategic move to invest in software offerings so we can truly connect whole industrial enterprises, from OT to IT and beyond. These investments, as well as our unrelenting focus on sustainability products, will drive our business into a successful future.” www.rockwellautomation.com/en-au
scanCONTROL LLT3010
Smart Laser Line Scanners for Precision Scanning in Metal Additive Manufacturing scanCONTROL compact laser line scanners reliably detects the finest details in an object. It comes with an intelligent integrated evaluation for automated measurement of profile properties without the need for PC • • • •
High-speed measurement of up to 10kHz Measuring area up to 200x300 mm High-powered & blue laser options HDR data acquition and improved autoexposure for difficult surfaces
Contact us below to speak with our engineers or visit www.bestech.com.au. Email: enquiry@bestech.com.au
Phone: (03) 9540 5100
GLOBAL TECHNOLOGY LOCAL SUPPORT AMT APR 2022
071
072
FORMING & FABRICATION
Wazer Desktop waterjet: An innovation success story Waterjet cutters have been around for a long time – however their size and cost have put them out of the reach of individuals or small businesses. The first desktop waterjet, WAZER cuts any hard or soft material with digital precision, using a high-velocity jet in a combination of high-pressure water and abrasive particles. The co-founders of WAZER, Nisan Lerea and Matthew Nowicki met at Penn Engineering in the US when they were building custom racing cars for the Formula SAE international competition. Their quest for a solution to make precision cuts in hard materials sparked their interest in low-cost waterjet technology. In 2012 Lerea led a team of undergraduate students on research in developing the technology and in 2015, the project had advanced to the point where both he and Nowicki quit their jobs to continue developing the waterjet.
By January 2016, the team temporarily moved to Shenzhen in China to join the Hax Accelerator, the world’s first and largest hardware accelerator. Most of that year was spent in Shenzhen to develop the business and refine the design and engineering of WAZER. During that time an engineering team was assembled to assess market needs, subsequently building five generations of prototypes and testing performance across on a wide variety of materials. The design of the final prototype considered the need for production processes and involved building relationships with
The WAZER concept: How did it start? In the words of Nisan Lerea: “I met my future WAZER Co-founder, Matt Nowicki during orientation of my freshman year of college at the University of Pennsylvania. All of the extracurricular clubs had lined the main walk on campus and were trying to recruit new members. “Parked on the side of the path was an open-wheeled, Formula 1-style race car. Matt, a senior and clearly the leader of the club, explained that the Formula SAE Team builds a new car each year and races it in an intercollegiate competition in Michigan. I didn’t love cars, but I knew this is where I would really learn how to make things. I immediately joined the team. “I would go on to spend hundreds of hours in Penn’s machine shop, CNC-milling metal parts for the race car, for research labs, or for my own coursework. Because of all the set-up and breakdown time that machining necessitates, I would regularly work late into the night making a part. “Whenever possible, the engineers would avoid the shop because of the time commitment and instead would design parts that could be laser-cut, which was faster. The downside to using a laser was the parts had to be made in acrylic or MDF, because as is the case with lasers at most makerspaces, ours could only cut certain soft materials. “What we really needed was a waterjet for cutting sheet metal, but Penn never had one because they were so big and expensive. In 2011 my professor suggested that we attempt to build a small waterjet for our yearlong senior design project. “I loved the idea for many reasons: it was an engineering challenge, it involved my passion for making things, and I knew that there was real potential for the product — and I always wanted to be an entrepreneur. By May of 2012, our team had built the first small-scale waterjet, capable of cutting through quarter-inch aluminium and eigth-inch steel. After we graduated, I felt this could be more than a school project, but I figured it would be beneficial to get some real-world experience working as an engineer before embarking on this adventure. “Matt, who had been working for the start-up BioLite called me and said they were looking to hire a mechanical engineer. I signed up and worked there for two years and was involved in two complete product-development cycles designing portable camping gear.
“In 2014 Hackaday got wind of our senior design waterjet project and published a blog post about us. Hundreds of people emailed, asking if we had plans to commercialise the technology. It was eye-opening for me because it wasn’t just engineers who were asking; there were artisans, makers and small businesses who had enquired. “By 2015 I was ready to make the leap to start a waterjet company. But I needed a partner and Matt, who had since moved on from BioLite, was looking for a change. It wasn’t hard to convince him to join me as co-founder and CTO. “We started out by researching the market from my parents’ basement and testing the Penn Nisan Lerea (top) and waterjet prototype in the backyard. Matthew Nowicki, Then we googled ‘hardware (above) co-founders accelerator’ and discovered Hax, of WAZER. an accelerator for hardware startups in Shenzhen, the electronics capital of the world. We joined Hax in January 2016, hired Dan Meana and Christian Moore — two engineers from the Penn race car team — and moved to China. “We were amazed by the speed and affordability of prototyping at Hax. WAZER utilises a lot of off-the-shelf hardware like hoses, fittings, valves, solenoids, and motors. We found that commodity hardware near Shenzhen was roughly one-tenth the cost of that in the US. At Hax we were surrounded by entrepreneurs with whom we could share ideas and receive unbiased feedback. “We launched WAZER in September 2016. The campaign was a huge success, but we knew it would be difficult to transition from prototype to production. After qualifying vendors and redesigning the machine for volume production, our team established WAZER’s headquarters in the Brooklyn Navy Yard, where we are part of a mission to revitalise manufacturing in New York City.” www.wazer.com
AMT APR 2022
FORMING & FABRICATION
HBS-Bolt
™
Class 8.8 | Hot Dip Galvanised
Blind & Hollow installation High shear capacity and large grip range make the HBS-Bolt™ suitable for many steel connections.
ONE SIDED INSTALLATION BEFORE
AFTER
Today, the WAZER team comprises mechanical, electrical and manufacturing engineers who collectively have led the designs of multiple products both at start up and large companies.
KBB88GH
M8 - M20 2202021
key manufacturing suppliers. When the final prototype was shown, market response exceeded expectations and a few years later, the founders decided to focus full-time on manufacturing the first desktop waterjet.
The WAZER small-format waterjet can cut through sheets of any material including metal, stone, ceramic, composites, plastic, rubber and foam. It is great for professional-grade fabrication. Users have been attracted by its simplicity of set-up, which can operate through standard connections to electricity, water and drainage infrastructure. The unit’s compact size fits in any workspace and brings professional-grade fabrication into any workshop. It is ideal for on demand cutting of custom parts and its in-house capabilities reduce costly outsourcing. Available in Australia from Hare & Forbes/Machinery House, WAZER has already attracted high levels of demand from small manufacturing businesses, research & development facilities, universities and technical departments where it is used for prototyping, manufacturing, fine art and instruction. www.machineryhouse.com.au
QUALITY FASTENERS SINCE 1935
hobson.com.au Bolt Tension | Anti-Vibration | Product Reliability | Traceability
AMT APR 2022
073
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FORMING & FABRICATION
Applied rolls out expanded Yawei range and innovative new Fanuci welder For over 15 years, Applied Machinery has been supplying Yawei precision sheetmetal machinery to local manufacturers and job shops, maximising their productivity, boosting quality and broadening their capabilities. “Increased sales growth and demand across Australia has resulted in us steadily expanding the Yawei range, which today includes CNC fibre lasers, tube lasers, pressbrakes, turret punch presses, guillotines and smart-factory automation solutions,” said Applied’s Sales and Marketing Manager, Daniel Fisher. “The value for money and performance aspect is why so many companies have opted for Yawei. The competitive price of Yawei machines has enabled many local manufacturers to bring their fabrication work back in-house. It has also allowed job shops to expand their range of services and capabilities enabling them to secure new business opportunities.”
a far superior, smoother weld line. It features low heat input, small deformation, large penetration depth and good repeatability. The unit offers low energy consumption and is virtually maintenance free.
Two new models recently introduced further add to the impressive line-up: a laser punch combination and a panel folder.
The new HPML Laser Punch Combination combines the forming capabilities of a turret punch press with the flexibility of a fibre laser cutter - all in the one machine. The machine features class-leading components which are a hallmark of all Yawei machines; these include a Siemens 840D controller, IPG laser source and Precitec auto-focus cutting head.
Fanuci’s wobble welding technology ensures that operators can achieve a consistent and aesthetically pleasing weld. The quality of the weld presentation can eliminate the need to clean-up the weld with a secondary process, which in turns saves time and money. Fanuci fibre laser welders are all manufactured to CE/TUV standards. The range includes 1,000W, 1,500W and 2,000W models. “Given its capabilities, build quality and unique features, we expect to find a ready-made market for the Fanuci fibre laser welder in Australia,” said Fisher. “Companies can now take their welding to the next level with a far superior weld, coupled with increased productivity and reduced operating costs.” While the new products add to the impressive rage of machines that Applied Machinery distributes, it is the expert advice, service backup and support provided by Fisher and his team that has won them many new customers over the last few years.
“Forget tedious slow punching,” said Fisher. “Companies can now boost their productivity with this versatile two-in-one machine. For fabricators that want to take their manufacturing to the next level, the new laser punch combination will allow them to do just that.” The other new Yawei model is the innovative new FB Series CNC Panel Folder, which offers fast speed, high efficiency panel folding with automation options available to maximise productivity. “These two new models will further cement Yawei’s reputation for providing Australian manufacturers with high quality precision sheetmetal machinery designed to maximise their productivity, boost quality and broaden their capabilities,” Fisher added. In addition to the two new Yaweis, the recently launched Fanuci handheld fibre laser welder allows for easier, smoother and quicker welding. Handheld laser-welding machines are increasing in popularity for the many benefits they offer compared to conventional welding. The Fanuci fibre laser welder provides high-speed welding coupled with
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“Our number one priority is ensuring that our customers across the country get the machinery they need, with the support they expect,” Fisher said. “We view ongoing service, training and support as critical to ensuring our customers can extract maximum return from their machinery investment. “Unlike some suppliers who are here one day and gone the next, we’re here for the long term. With nearly 30 years’ experience and thousands of satisfied customers across the country we’re a true machinery partner.” The growing list of satisfied customers is evidenced by the portfolio of well-known engineering companies across Australia that have chosen to partner with Applied. These include JC Butko Engineering, Eilbeck Cranes, Wildcat Industries and Alliance Metal Solutions. “One of the outcomes of the COVID pandemic is recognition of the importance of nurturing and assisting local manufacturing,” Fisher concluded. “We’re proud to be able to play our role in supporting Australian manufacturers with high quality, value for money products that will boost their productivity and provide them with a competitive advantage in the marketplace.” www.appliedmachinery.com.au
FORMING & FABRICATION
Speedpanel embraces Industry 4.0 to streamline steel panel manufacturing The Innovative Manufacturing Cooperative Research Centre (IMCRC) grants cutting-edge fire-rated and acoustic panel system manufacturer Speedpanel and Deakin University $100K in funding to refine steel panel manufacturing process. During the 10-month research collaboration, the project team will use new steel forming and joining solutions to further enhance Speedpanel’s production technology, with a focus on reducing waste and optimising and strengthening panel design. This research will also support Speedpanel’s high-volume production output and enable the business to have a more refined platform for continued expansion locally and abroad. Commenting on the project, Lindsay Evans, Speedpanel’s Sales and Operations Manager, said the IMCRC activate funding would assist Speedpanel to further revolutionise the way it manufactures its fire-rated and acoustic systems. “By streamlining manufacturing processes with innovative joining solutions and advanced techniques for material monitoring and process control, we’ll be able to evolve our product offering and bring a more environmentally friendly and sustainable panel system to market,” said Evans. “Tapping into Deakin’s expertise in material analysis and forming process control will enable us to assess and monitor material properties and key production parameters throughout the process to enhance process efficiency, enabling better quality control and reducing waste.” Matthias Weiss, Senior Research Fellow at Deakin University, highlighted the importance of connecting with the manufacturing industry on research and development (R&D) projects.
“Manufacturing large hollow sections of steel represents a major challenge for industry. With Speedpanel and IMCRC, Deakin University is helping to solve this problem by providing extensive support in material parameter monitoring and process control solution development,” said Weiss. “We’re also taking the findings from a previous Deakin University industry collaboration which has established a new and structurally optimised wall panel design and applying them to adapt Speedpanel’s cutting-edge system.” Dr Matthew Young, IMCRC’s Manufacturing Innovation Manager, said IMCRC was delighted to be co-funding the R&D required to advance Speedpanel’s manufacturing process to improve design, manufacturability, and performance characteristics of the wall system to help expand markets and profitability. “Speedpanel has been a market leader in conventional panel manufacturing methods for the past 20 years,” said Young. “In only 10 months, this research collaboration has the potential to deliver transformational change to the business and pave the way for future product developments. Supporting small to medium manufacturing enterprises (SMEs) like Speedpanel to embrace new technologies and the application of Industry 4.0 remains central to creating an Australian manufacturing sector that is thriving and globally relevant.” www.imcrc.org www.deakin.edu.au www.speedpanel.com.au
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Automation according to Salvagnini Rapid industrial developments of recent years continue to set tough challenges. Because industry has changed: flexibility and efficiency are crucial requirements for managing increasingly smaller batches, rapid item turnover rate and tight lead times. And it is precisely in this context that automation is attracting more and more attention. Salvagnini has been designing, producing and selling flexible systems for sheet metal working for over 50 years, and flexible automation has always been part of the company’s DNA. Flexible automation means transforming packs of sheet metal into a wide variety of products, in a lean environment and with no intervention by the operator, in a progressive production process, using proprietary punching, cutting, bending and panel bending technology. Automation therefore has an impact on three successive levels: •
the first level is that of the individual production phase, which horizontally exploits the potential of extremely high-performing, autonomous and intelligent systems;
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the second level is that of activities with low added value, which typically occur upstream and downstream of these individual systems, with preparatory and/or connection functions;
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the third level is that of the process which, where appropriately organised, benefits exponentially from the sum of advantages offered by the previous two levels.
In practice, the result of an automated, organized process can exceed the sum of the benefits obtained in each individual activity and by eliminating any redundant intermediate activities. How? Let’s take a detailed look at the production process.
Optimising individual production phases We have already mentioned the progressive shift from a make-tostock strategy, with large batches, towards a lean, make-to-order, just-in-time strategy based on medium and small batches and an increasingly variable production mix. And the industrial scenario is moving increasingly towards a substantial reduction in work-inprogress, eliminating the intermediate storage of semi-finished parts. To respond to this variability and uncertainty, the market is looking more and more to flexible production systems. Being competitive today does not merely mean having fast single part production: the challenge lies in production efficiency, the ability to move from one production code to the next with the shortest re-tooling time, whatever the geometric and mechanical characteristics of the metal sheet and the type and number of jobs. Flexible systems are a decisive factor for managing production today, but also for improving quality and reducing lead times and scrap. All Salvagnini solutions are designed to increase the efficiency of the specific production phase. There is no need to remind anyone that, since 1977, the year in which Guido Salvagnini designed and produced the first P4 – Salvagnini has been a byword for panel bending. The panel bender is the machine which more than
any other represents the spirit of the Group, precisely because it combines cutting-edge technology with productivity, autonomy, and flexibility. With universal bending tools, the panel bender requires no re-tooling, and machines the whole range of thicknesses and materials, adapting automatically to the size and geometry of the part to be produced, in cycle, without machine downtimes or manual re-tooling. The panel bender adapts completely autonomously even to the varying mechanical and geometrical characteristics of the sheet metal being machined, as well as to the external environment. Similar characteristics also define the other Salvagnini technologies: •
the laser requires no adjustments, thanks to the single-optic cutting head, the process sensors, and a number of artificial vision systems;
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the combined punching/shearing and punching/laser machines are equipped with a multi-press head that can hold up to 96 tools always available for use;
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the press brake automatically adapts re-tooling and tool management according to what needs to be produced, with its ATA, MVM and AU-TO devices, thus extending its flexibility and autonomy.
Eliminating activities with low added value Considering that our production capacity corresponds to the sum of work and waste, the second level at which automation impacts production is that of its ability to reduce, if not fully eliminate, redundant activities or those with low added value which typically occur upstream and downstream of individual systems for preparating, feeding and connecting. Automatic cutting, forming and panel bending systems have become extremely quick and productive, shifting the problem of efficiency to the loading and unloading phases which, increasingly often, risk becoming authentic bottlenecks. In production contexts marked by low volumes and rapid production changeovers, connecting automatic loading/unloading devices to the systems is a winning strategy for recovering efficiency. Salvagnini responds to this need with a wide, modular range of automations, able to configure each system differently to meet different production needs. This includes: •
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automatic loading/unloading and sorting devices, coupled to a store, which are an enabling factor for increasing the autonomy and efficiency of individual systems;
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automatic loading devices ensure that the machine is fed at a frequency consistent with the production speed;
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robotised unloading devices, which ensure that the panel bender is immediately available for the next job after completing the previous one, eliminating waiting times but also recovering efficiency in subsequent phases of the process which benefit from the precision offered by automatic bending and robotised stacking;
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intermediate automation devices that minimise and balance material transfer times from one workstation to the next;
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software solutions facilitating the production process even without large physical devices, lowering the entry barrier into the world of smart manufacturing.
Process management and optimisation Extending the vision to managing and optimising the process as a whole, obliges us to talk of digital transformation and Industry 4.0. A widespread view often reduces Industry 4.0 to the mere integration of the ERP system and the receipt of machine feedback, when in fact this is a minimum requirement, the first step to be tackled, which must then become an enabling factor for solving real problems, simplifying everyday work and helping companies to grow. Salvagnini has been concretely tackling this issue since 1993, when it launched the first OPS, the modular software for managing production. OPS receives the production list from the factory information management system in real-time and delivers an updated version to the programmer. It provides support for the programmer's activities by defining the priorities, automatically generating the machine programs, and sending them to the workshop. It checks the availability of raw materials or semi-finished parts and generates feedback to the factory information management system, updating
it in real time, part by part. It can make autonomous decisions according to a production logic – or according to a multiple mix of production logics – designed to meet the needs of the customer and transformed into an algorithm. It integrates labeling, traceability, and store management upstream and downstream of the cutting, punching, and bending activities. It therefore increases the efficiency of the whole production process, extending its effects beyond the factory boundaries and throughout the whole supply chain. For Salvagnini, that’s what digitalisation is all about: making available solutions that are easy to use, in order to focus on control, production process optimisation and the elimination of all those often invisible downtimes that undermine the efficiency and competitive performance of companies.
A vision of the future There is no point in focusing on extremely high-performing technologies without managing the bottlenecks upstream and downstream of production. Investing to reduce the cycle times of an individual production phase by a few seconds offers no real advantage if the re-tooling times of these technologies cancel out the efficiency regained by the performance of the new system, if this regained efficiency is lost in the intermediate phases between the individual workstations, or if it is canceled out by a burdensome process filled with redundancy, delay, and inefficiency. Salvagnini proposes to replace this purely quantitative approach that focuses only on productivity with another that combines both quantity and quality, shifting from the idea of production capacity to that of production control, where efficiency – and therefore productivity – can be regained. To fully exploit the benefits assured by flexible automation. www.salvagninigroup.com
Blended learning – The best of both worlds. Our blended training solutions combine the flexibility of self-directed eLearning with engaging group-based and tutor-led sessions. We offer a wide range of management systems training courses, with options covering ISO 9001, ISO 14001, ISO 45001 plus many more. Find out more here: www.lrqa.com/en-au/training/blended/
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Dr Mark Dean is the Laurie Carmichael Distinguished Research Fellow at the Carmichael Centre, in the Centre for Future Work at The Australia Institute. He spoke to William Poole. AMT: You were recently the author of a report ‘Rebuilding Vehicle Manufacturing in Australia’. Tell us a little about its findings. Mark Dean: My report shows that Australia has all the key elements to develop an electric vehicle (EV) manufacturing industry in this country. We have rich mineral reserves. We have an advanced industrial base. We have a highly skilled workforce. And we have consumer interest, not just in the purchase of EVs, but also in seeing an EV manufacturing industry in Australia. The one thing we lack is a Federal Government with the political will to create an active, interventionist industry policy to bring those pieces together and develop a plan for the growth of an EV industry, which could effectively be economy-transforming. And I’ve developed four building blocks around areas that would be fundamental to an industry policy for EV manufacturing in Australia. AMT: Would this be a significant export industry as well? In the past Australian car-makers often struggled outside the domestic market. MD: Yes, it would absolutely be an export-focused industry. It would need to be. And EV manufacturing would really form the most critical pillar of what should eventually become an industry that diversifies into electric buses, electric trucks, rail transport, and right into what I call “applied renewable technology solutions”. If we get the industry policy right, what we’re ultimately doing is diversifying our ability to develop solutions for all types of renewable energy applications, and in the process exporting that knowledge and expertise to the world. That all starts with the EV manufacturing industry. I should add that there were times in the past when we were also exporting vehicles. US Police Departments in California, Michigan and Florida were procuring Holdens from Australia, for example. But I take your point that Australia was bad at exporting the units we were producing. We weren’t producing enough to export at scale, and we weren’t meeting local demand for smaller vehicles – Holden in particular. We were always making larger vehicles. AMT: Can you talk a little more about those key advantages Australia enjoys in the EV space? MD: So let’s go through the four building blocks. Number one: vast lithium reserves that at the moment we mostly export as a raw commodity to other countries, who turn them into batteries overseas and sell them back to us at a premium. In 2017 raw commodity exports and lithium generated $2.1bn of revenue for Australia, but the Future Batteries Cooperative Research Centre shows that battery production generated $22.1bn for those countries overseas – more than ten times the revenue from our exports. We need to develop processing capabilities onshore, near the lithium if possible. Perhaps even the Pilbara could become a processing region, with the infrastructure, trains, ports access to shipping. So that’s one piece. Next, the development of supply chains is critical. We need to scale up the SMEs, make them feature more as part of our industry ecosystem, strengthen them to become the major links between processing and manufacture. There’s a huge piece there.
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We have a skills base, but we will need entirely new training packages and units of competency to create the skills for EV manufacturing. My report demonstrates that Australia’s training capabilities in vocational education and training at present still consider EVs as hybrid-only. There’s no training and units of competency that consider training for EV manufacture as a whole new separate entity. That’s a critical skills gap that can be addressed with full, adequate funding of TAFE, because TAFE was critical to manufacturing regions in the past. One of my recommendations is to provide TAFE free as a transitionary labour market policy to help former auto workers retrain and reskill, and to address the shortfall in apprenticeships and traineeships we’ve seen over the last ten years as government funding has been stripped from TAFE institutes around Australia. The fourth point is consumer interest and demand. Not only do a majority of Australians support EV uptake among consumers, they want to see EVs manufactured in Australia. There is majority public support for this becoming how we transform our manufacturing industry and how we address climate change. The public knows we used to manufacture things; it was brought more to our attention during the pandemic with Australia’s inability to produce vaccines, rapid antigen tests and personal protective equipment. These are things we should be self-reliant in. But it’s become clearer to Australians than ever before that when we lost manufacturing capabilities, we lost the ability to do so many things we take for granted. So government would provide incentives for consumers to purchase EVs and create local domestic demand for vehicles that are made in Australia. AMT: Obviously we did have a car industry, but the last car-makers left Australia a few years ago. What would be different now that means this industry would grow and prosper? MD: There are a number of factors here. First, the increasing withdrawal of an active government role in industry policy formation since the 1980s was of great detriment to the manufacturing sector. The idea that market forces would drive continued development was frankly stupid – to think a country as remote as Australia could sustain a global export industry without government support. No other country with an advanced manufacturing sector – and largely that means an auto manufacturing industry – allows market forces to dictate how their industry transforms. Government is active at all levels of investment, at state, local and federal levels, in countries like Germany, the US, Japan. None of them leave their most innovative, R&D-intensive, knowledge-intensive industry exposed to global market volatility. They provide sophisticated assistance through government investment and active intervention in creating and shaping the markets for the industry’s expansion. In the Australian case, what happened is in 2013 Australia had just ridden the wave of the global financial crisis with our commodities boom. But our exchange rate with the US was through the roof. At its peak we were buying a US$1.10 for every Australian dollar. So travelling to the US at that time was fantastic, but it disguised the effect that exchange rate had on manufacturing. We were no
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longer competitive. We had to have the Australian dollar at 75 cents compared to the US dollar for exporting vehicles. At that point, the manufacturing sector was in crisis. And I think we all remember the then-Treasurer Joe Hockey not only refused a loan of $500m to Holden, he actually dared Holden to show its cards and reveal what it was going to do. He effectively dared Holden to leave the country. They called his bluff and left. That $500m stimulus to Holden – and therefore to the manufacturing sector, the supply chains, all the component manufacturers that would’ve benefited – that $500m would have created $23bn of return to the economy. The $500m the Abbott Government was unwilling to provide to our most important manufacturer would have paid for itself many times over, and we would still have a vehicle manufacturing industry. We didn’t need to lose the car industry. AMT: And obviously $500m is a lot of money, but it would be relatively small compared to the support government provides elsewhere? MD: That’s right. During the pandemic the government spent almost $300bn. If it was to front an initial public investment in developing an EV industry of say $10bn-$20bn, that still pales in significance to the money spent through the pandemic. But the Government effectively does understand that industry policy is important, yet it’s picking losers by backing the gas industry. They say that we can’t pick winners when it comes to manufacturing, but it’s picking losers by backing “gas-fired recovery” as it's only industry policy besides defence. So industry policy is something the Government can do; they just don’t seem interested in backing the one sector that could be transformative for the entire economy. But going back to the ways an EV industry would be different now, first of all, EVs are far less complex than internal combustion engine (ICE) vehicles. The batteries are the most complex, expensive component. So what you may actually see is a lot of new skills and jobs focused on battery production, and there would be some important restructuring around batteries becoming the most crucial part. Also, we’re not starting from scratch. Much of the rest of the work, the actual building of cars, is still very much alive in Australia. Many people are surprised to learn that even though Holden closed in 2017, we still have more than 30,000 workers in our vehicle parts manufacturing industries in Australia and our exports of auto parts have grown substantially. They are largely spread throughout the SMEs that previously depended on OEMs that left in the 2010s, like Holden, Ford, Toyota. So the difference now relates to the incredibly important role of SMEs in a new manufacturing industry. We would be seeing a much greater dependence on SMEs, and them stepping up to take on a larger role. AMT: And one of the great strengths of those SMEs is they are incredibly agile. MD: Yes, exactly. What we have now is that not only are a lot of SMEs still making vehicle parts and exporting to global markets, other companies have diversified into different areas of vehicle
manufacture. SEA Electric in Dandenong is building drive trains for electric trucks. ACE Vehicles is building electric buses in Adelaide and Brisbane. The NSW Government has just announced it’s going to build electric buses for its fleets and it wants to do electric ferries and all kinds of things. So a lot of this is happening in Australia, it’s not all being imported, and we should be looking at doing more. We have an industrial base that has eroded somewhat, but we still have the ability to build on that and bolster our SMEs so some of the small enterprises become medium, and the medium enterprises become large enterprises. The OECD has warned that Australia’s industrial structure lacked “the missing middle” – an absence of large or middle-size companies to take up the slack of the lost tier-one suppliers and OEMs and fill that gap. We lack that critical capability. My report suggests ways government can bolster that and develop capabilities and supply chains. Continued next page
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ONE-ON-ONE Continued from previous page
I’m sure your readership is interested in Industry 4.0 as well. Even before we lost auto manufacturing in Australia, those factories were largely automated. I imagine we would be returning to something more advanced than that if we brought EV manufacturing to Australia. And that again highlights the diversification opportunities, for jobs, for the creation of service industries that connect suppliers to customers more directly, for the servitisation of manufacturing. The breadth of the opportunity there could be enormous. The refurbishing of EV batteries, the circular economy principles, and the technological investment needed to drive innnovation are all huge opportunities also. AMT: So why is Australia currently failing to grasp these opportunities? MD: It’s always worth reiterating that Australia had effectively been building cars since the 1930s. For nearly a century, we built cars in Australia. The reason we started building cars is because state premiers and the Federal Government saw the opportunity to transform our economy from lower-level agricultural commodity exports, to diversify and grow our economy, increase standards of living through manufacturing’s creation of better jobs, more services, more diversification in the economy. That didn’t happen because of market forces. That’s a fundamental point. The emphasis on market forces has been to our detriment, particularly where governments have played the most decisive role for manufacturing development in Australia.
We do see signs of that already: growing inequality; younger generations being materially worse off than their parents. These are indications that you can be doing better as a country, and you should be if you want to continue comparing yourself to the rest of the developed world. And developing countries are actually looking at industry policy opportunities; that’s not exclusive to advanced countries. A lot of developing countries are looking at how to induce their own manufacturing industries. But Australia seems to have largely abandoned that, and I’d like to see that reversed if we’re going to continue to be a wealthy country that creates good jobs for its people, excellent business opportunities for its SMEs, is technologically advanced, and addresses climate change. AMT: Beyond EVs, what other opportunities do you see emerging for Australian manufacturers? MD: For SMEs in particular, a lot of opportunities involve diversification into new applications for lithium ion batteries – perhaps home energy storage, battery-powered trains or trams, other things like that. What I see with applied renewable energy solutions is that government supports the pursuit of knowledge in as many different innovative ways as possible, spinoffs occur from EV manufacturing, and end up transforming other areas of the economy. Whether that’s battery-powered agricultural machinery, battery-powered homes and energy grids, even rethinking urban infrastructure, sustainable building, and all the different opportunities from advanced materials.
Government must lead the way in a range of areas, particularly procurement. The private sector will follow government’s lead if government backs industrial development and transformation by removing risk, through co-investing itself, and by becoming a demanding customer. One of my recommendations is to have governments procure an entirely electric vehicle fleet by 2030, and to support state and local governments to meet those targets as well. That is a clear example of the way government would back Australia’s domestic EV manufacturing industry and open up possibilities for private sector investment.
That’s what I mean by applied renewable energy solutions – it’s a way to use EV manufacturing as a lever to open up all those opportunities over the long term. Once we can show the rest of the world we can do EV manufacturing, we begin to show how else we’ve applied that concept to other areas of the economy. And what we end up doing is exporting the knowledge, which is what other countries do – the complexity pieces around how you can assemble diverse knowledge, create innovative new products and have a competitive advantage over other countries. That could be a huge opportunity for Australia.
Consumers want it, industry knows there’s a huge opportunity. The one thing we don’t have is government to actually back it. We have this problem in Australia of thinking that government is the problem. We’ve gone from building a nation through things like Snowy Hydro or an auto manufacturing industry, to losing that vision. This needs to be a nation-building opportunity. This is a policy that can rebuild our nation, restore manufacturing and restore our economy in a post-pandemic world.
Other countries look at our abundance of renewable energy with envious eyes. And we don’t use it, not to the extent we should be, and that means government involvement.
AMT: What are the consequences if we fail to take this opportunity? MD: One measurement I often refer to is Harvard’s Atlas of Economic Complexity. Australia ranks 87th in the world, out of 130 countries. Countries like the US, Japan, Germany, Singapore, Switzerland, the Netherlands, Sweden all sit within the top 10. That’s a reflection of the complexity of their economies, which are knowledge-driven. It demonstrates how able you are not only to diversify your economy, but connect those diverse industries and knowledge pursuits to create innovative new products and services. Australia’s position of 87th reflects our long-term dependence on commodities exports, not adding value to our industrial products. What concerns me is we have everything we need, but without the industry policy to support and advance that development, we will continue to rely on raw commodities exports, and we will actually see our standard of living drop. I’m trying to be optimistic about an EV-driven future, but the pessimist in me worries that the standards of living we have at the moment are built on efforts made in the past: the institution-building in manufacturing, the institution-building in the economy, the hard decision-making, the nation-building. The policy development of the past that we have since abandoned means our lifestyles could very quickly follow.
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AMT: Tell us about the Carmichael Centre and the Centre for Future Work more broadly. MD: The Carmichael Centre is a new centre established in the Centre for Future Work at the Australia Institute. It is named after the legendary trade unionist Laurie Carmichael, and his important role in 20th Century industry policy in manufacturing. This has been my first big research piece around industry policy. I’ll also be looking at TAFE reform, and ideas like a shorter working week. These were all areas of Laurie Carmichael’s passion and interest, and his activism as a trade unionist. The Centre for Future Work is a great home for the Carmichael Centre because it looks at Australia’s economy, labour markets, and improving the future of work for working people – it’s helping to influence the conversation around how we create better jobs, a better economy, a stronger, more sustainable economy that works for working people. AMT: And what is the most satisfying part of the job? MD: Being able to see that my policy research has a direct influence on policy debates is wonderful. I also really love how much my own thinking is challenged by my colleagues. These are often team efforts that are influenced by conversations and debates with colleagues. It’s an environment of big ideas and intellectual pursuits that are grounded in reality, thinking about how to make Australia better for everyone. www.carmichaelcentre.org.au
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MATERIAL REMOVAL
Effective material removal using lasers Lasers are used in a variety of applications in the field of material removal, with a range of machines suited to each process distributed by Raymax Applications in Australia. Laser systems offer two general processes for material removal. One widely used process occurs during manufacturing for the production of new products that require micromachining. The other refers to a removal of surface congestion or contamination in a large industrial environment. For either process, the team at Raymax are able to provide expert advice, installation and on-going support. Precision material removal in the production of medical products can be carried out with an excimer laser produced by the OPTEC/ LASEA Group, a Belgium-based company that works with some of the largest medical manufacturers in Europe. OPTEC excimer lasers are used to manufacture components for electrophysiology (EP) because they can strip or ablate wire as thin as a human hair. Nitinol wire, an amalgam of nickel and titanium that is highly elastic with excellent shape memory, is initially manufactured with a transparent plastic coating. A suitable laser is used in the micro-machining process to cut away the insulative coverage without damaging the nitinol wire. In procedures for cariology or neurology, the recipient organ is accessed using a nitinol guidewire via the vascular system to insert a catheter to clear the blockage and then insert a stent. Stents are also made with nitinol wire after the ablation or material removal process. A second micro-machining material removal application using highprecision lasers is laser ablation of thin layers. This is particularly useful with semiconductor devices that continue to ‘shrink’ in size. Through the combination of the latest generation of femtosecond lasers and ultraprecise scanners with a high dynamic range, excellent quality and rapid ablation are achieved with no spatter. LASEA lasers can ablate material over a narrow thickness and in a highly localised and selective way. Called ‘decoating’, it occurs by vaporising or subliming a layer without damaging the underlying layer. Controlling the energy is critical to this process, so as not to Production of the LDMblue highpower diode laser at Laserline.
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damage the substrate at all, and where thicknesses vary, to optimise the energy per pulse to lessen the impact. This process improves the quality and the rate of production in fields such as solar cell production, OLEDs and microelectronics. Precision material removal can be applied to other sectors including vehicle manufacturing by ablating the metal layer covering windscreens to access electronic sensors; and in the jewellery sector – lasers can ablate the thin layer on a watch face ready for chemical etching, and even create internal or external patterns or designs on containers used in the cosmetic industry by ablating the glass. An industrial application that has recently been tested and confirmed is the use of blue diode lasers for the removal of biofouling on ship hulls and other metal sub-sea structures. This new use of a blue diode laser has only become possible due to advances in conversion efficiency and optical output power developed by the German laser company Laserline. Commenced in 2019 and funded by the German government, the research project FoulLas – ‘Fouling removal of maritime surfaces using laser radiation underwater’ – was undertaken on the North Sea island of Helgoland, to find a more environmentally-friendly process than the toxic effects of biocide coatings applied to ship hulls. A solution is timely, as restrictions on the use of biocide coatings have increased. Operators of ships and offshore facilities are doing all they can to get rid of these unwanted organisms or to ensure they do not settle in the first place. Currently used as a preventive measure, biocidal antifouling coatings have been applied either to prevent the growth of vegetation or to destroy the cell structures of adhering organisms. However, due to their toxic effect on other aquatic organisms, only a few biocides have been approved, and even these will completely be banned in the foreseeable future. One biocide-free alternative is in silicone-based antifouling coatings that create a particularly smooth surface structure. An alternative
MATERIAL REMOVAL Partial ablation of the clear plastic coating on a thin (Nitinol) wire.
amount of new biofouling growth occurs within a very short time. Additionally, marine organisms have developed highly effective strategies for adhering to surfaces – their attachment is almost as robust as industrial adhesive bindings. To find a better removal solution for this unwanted material and prevent further growth of aquatic organisms, the FoulLas research team applied an effective process using the more powerful diode laser sources of the blue spectral range developed by Laserline. With more than 2kW of blue laser power, an underwater irradiation technique was used to damage the cell structures of marine organisms that had settled on a ships’ hull. Once damaged, the marine growth matter is washed away by the current, resulting in a far more eco-sensitive process.
removal method is mechanical cleaning by diving teams, which is expensive and time-consuming. Mechanical cleaning by diving crews releases numerous marine organisms, which then migrate unwantedly into the local ecosystems; as a result, mechanical ship cleaning has been banned in many ports. Experience shows that these measures have only had limited success, coatings appear to simply delay colonisation. Organisms colonise quickly and in large quantities, so that even when coatings are used, a considerable
Today it is possible to apply lasers for material removal across a range of manufacturing processes and in product maintenance. Precision material removal using micro-processing has already been adopted by both the medical sector and the electronics industry. The high power of blue diode lasers has been proven an indispensable tool for maintenance of sub-sea structures and the hulls of ships. These examples show just how effective laser systems can be in everyday usage for material removal. www.raymax.com.au
Vollmer launches new VGrind 360S At the EMO machine tool exhibition in Milan last October, Vollmer delivered the exhibition premiere of its new VGrind 360S grinding machine, for the complete machining of carbide tools. Designed to set a new standard for the complete machining of rotationally symmetric solid carbide tools, the new VGrind 360S offers an impressive solution for manufacturing cutting tools for aerospace, medical, automotive and general subcontract manufacturing sectors. This new five-axis CNC grinding machine can be used productively to machine carbide tools with a diameter up to 25.4mm. Depending on the machine kinematics and the equipping of the grinding wheel packages, it can even be used for tools up to 150mm diameter. The VGrind 360S incorporates wear-free linear induction motors on the X, Y and Z-axes to lower maintenance costs for the machine while demonstrating higher surface quality for the tool and improved precision. The tried-and-tested vertical double-spindle concept from Vollmer now features an oriented spindle-stop for the first time. Also known as spindle indexing, this always stops the spindle at a specific position; the result is a reduction of axial run-out errors and concentricity issues, while offsetting wear in the HSK holding system. Another new feature is a heat plate exchanger to efficiently cool motors and spindles, which in turn leads to increased thermal stability. Furthermore, this effective cooling concept has now been optimised and extended, making it the ideal solution when processing tools to the tightest of tolerances. Simple and intuitive operation is at the core of the VGrind 360S. For customers to fully exploit its potential, Vollmer has created an ergonomic platform whereby users can operate the control panel comfortably while having full visibility of the work envelope. Operation via the keyboard or touchscreen allows for precise machining of the tool, and the multi-function handwheel ensures even more flexibility as it can be freely positioned on the enclosure. This design allows the setting of a required axis without using the control panel. The VGrind 360S incorporates Vollmer’s trusted operating concept and can be operated unmanned around the clock thanks to automation features such as a pallet magazine, free-arm robot or chain magazine. The options for automation include the HP 160 pallet magazine for up to 900 tools with a double gripper to
guarantee fast changeovers, the HPR 250 free-arm robot for the automatic machining of tools with various shaft diameters, and the HC 4 chain magazine, which has space for 39 HSK-63A tools or up to 158 shank-type tools. This automation also extends to the eighttool grinding wheel changer that ensures you always supply the right grinding wheel for the job at hand with no manual intervention. As an option, coolant nozzles can be automatically exchanged with the wheel sets on both spindles. From an options perspective, Vollmer has sought to deliver maximum productivity and performance. The optional features include the flexible loading automation options for carbide tools, grinding spindles available with direct or belt drive, automatic gripper compensation as an in-process solution, wheel compensation probes, automated changing of intermediate sleeves with bayonet, and an automatic stacking unit that enables the abrasive grinding wheel to be opened during the grinding process. Other available features include the simultaneous grinding wheel package and tool change in combination with the HP 160 pallet magazine or the HC 4 to reduce non-productive times during loading and a stable, fully adjustable steady rest with automatic stroke to prevent deflection and ensure optimal grinding results. www.vollmer-group.com
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Real-time machine productivity for APT with Okuma Connect Plan In Melbourne’s south-eastern suburbs, advanced precision engineering company Australian Precision Technologies (APT) is achieving amazing real-time machine productivity thanks to Okuma’s latest Connect Plan Machine Monitoring. As part of its continuous improvement strategy, this qualityaccredited, AS9100 rev D (Aviation, Space & Defence) and ISO 9001 company has introduced the Okuma Connect Plan, connected to 18 CNC machines to monitor the production process, efficiency and performance of all the machines in real time with immediate visual information on centralised screens. The Okuma Connect Plan is a system to increase process efficiency, collecting machine tool data and presenting it in a veryeasy-to-understand format to optimise machine operations. This A1 algorithm tool is not just for Okuma machines but any brand of machine tool or equipment. The Okuma Connect Plan data collection system features a simple visual aid, consisting of: Red – machine is down; Yellow – machine is idle; and Green – machine is running. It learns how you use your machine tool information to predict the ever-elusive yellow machine status. It utilises the system variables, parameters, machine specs and other tool information to automatically determine why a machine is sitting idle. Once corrected, it will spot that and similar scenarios during operations in the future.
Australian Precision Technologies (APT) has introduced the Okuma Connect Plan connected to 18 CNC machines at its factory in Berwick.
“This modern-day tool, Okuma Connect Plan, provides a hightech solution for customers with technological advantages with the ability to connect to different machines, showing which machine is running, review schedules and fully optimise production,” said Mark Richards, Okuma Australia Branch Manager for Victoria and Tasmania. “It provides the operational history of every machine, their exact productivity, and optimises maintenance schedules. Okuma’s Connect Plan is a system that provides analytics for improved utilisation by connecting machine tools and visual control of factory operation results and machining records with up to 30 machines per licence.” Okuma Connect Plan is promoted with three key advantages such as Connect, Visualise and Improve; planned machine historical data; preventative maintenance scheduling and analyse, all providing exact productivity of the factory. APT Managing Director Richard Weinzierl commented: “Okuma’s Connect Plan is APT’s way of measuring the efficiency of our production processes and provides my company with actionable data to measure machine performance. Okuma Connect Plan is recording in real time machine productivity. From the easy-to-read data, Connect visually records spindle uptime/downtime in an easyto-read format. Machine utilisation can quickly be increased when we know what to look for and a system such as this for measuring data so we can adjust processes. “With this information also available on my smart iPhone and other devices, I have become almost addicted as I can view what is happening in real time – anytime and anywhere in the world. Importantly our machine operators are watching and monitoring the colour-coded centralised screen all the time, reviewing their output in parts per month to maximise efficiency.” APT is currently celebrating its 30th anniversary and this private family business, which started from small beginnings, is today employing 30 highly skilled operators and four apprentices with some of the most advanced precision plant and machinery in operation. “State and Federal Government support for manufacturing has helped the company enormously, enabling us to invest in the latest precision machines to produce internationally competitive components and assemblies, an important factor as we see more
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Australian Precision Technologies (APT) Managing Director Richard Weinzierl (second from right) with members of the APT team.
onshoring of products occurring for Australian manufacturers,” commented Weinzierl. “This has been a critical factor in the development of the company, which five years ago participated in a key Centre for Defence seminar providing guidelines and strategies on what we needed to do for the future, resulting today in more than 80% of our company’s production in defence contracts.” As an expert in its field, APT was inducted into the Victorian Manufacturing Hall of Fame in 2014, the company was a finalist in the Defence Industry Awards in 2019 and was awarded Casey Business of the Year in 2021. Central to APT’s continuous improvement development is its care for its people and the strong culture of involvement, resulting in staff engagement in excess of 85%, with values set and acted on by the company including Vision, Mission, Quality, Teamwork and Honesty. “Okuma is leading the way in the Smart Factory development in manufacturing with up-to-the-minute modern day tools such as Okuma Connect Plan,” said Okuma Australia’s Managing Director Dean McCarroll. “We are currently in the process of installing Okuma Connect Plan in a number of other companies and we look forward to watching APT and others continue to grow and expand production with the introduction of further efficiencies with the benefit of the Okuma Connect Plan.” www.okumaaustralia.com.au www.aptengineering.com
QUALITY & INSPECTION
Production measurement technology – Meeting the key requirements Modern measuring instruments ensure components are of a high quality, but to be effective there are a number of key requirements that they must meet. The purpose of production measurement technology is to ensure component and process quality. The measuring instruments must fulfill a range of requirements. If modern production facilities also aim for integrated production strategies according to Industry 4.0, they already lay the foundation for self-controlling production through their choice of measuring equipment. Production measurement technology can manifest itself in various ways. Typically, optical and/or tactile measuring systems are used in the production line, set up in a connected measuring room, or outsourced to an external measurement service provider. Whatever the particular set-up, its task is to verify the dimensional accuracy of components and ensure they are of the required quality. In addition, production measurement technology often reduces set-up times. Bruker Alicona is one of the leading suppliers in the field of optical co-ordinate measuring technology and roughness measurement. The optical measurement solutions are successfully used in a wide range of industries to optimise manufacturing processes. The manufacturer provides the following tips on what is important when choosing the right measuring system.
Measuring instrument capability The measuring instrument must be capable of completing the measurement task adequately. To make sure that this is the case, it is necessary to verify the instrument’s measuring capability and accuracy. This is usually determined based on predefined Cg and Cgk values. Other important factors in the assessment of measurement quality include high repeatability of measurement results, traceability to national and international calibration standards, compliance with global ISO standards, and low measurement uncertainties.
Long-term stability The long-term stability of a measuring instrument is crucial for ensuring high process reliability at all times. When a component is measured at different points in time over a longer period, results must be consistent, even when environmental conditions such as temperature, vibrations or illumination vary.
Usability Since different machines are used in a production, the operator and/or measuring technician often has to operate several different machines. Therefore, the simple, intuitive operability of the measuring system is indispensable for ongoing operation. Singlebutton solutions and automated measuring procedures ensure constant measurements without user influence.
The optical µCMM coordinate measurement machine from Bruker Alicona is the first purely optical co-ordinate measuring machine. Users can measure dimensions, position shape and roughness also in production.
The Bruker Alicona Cobot consists of a collaborative six-axis robot and a high-resolution optical 3D measuring sensor. Shown here is the system installed at MTU Aero Engines, where it is used for the automatic measurement of turbine blades.
Cost efficiency Investing in a measuring instrument has to pay off. Quick returns on investment (RoI), low maintenance costs, and consumablesfree operation make a measuring system cost-efficient. The device should also receive regular software updates and come with other services to ensure flexibility and quick adaptation to new or adjusted production requirements.
Speed Measurement and set-up times are directly related to each other. Short set-up times demand high measurement speeds and repeatable, traceable measurement results. The faster a measurement result is available, the faster personnel can react and reconfigure machines. Therefore, measurement speed is a key factor in reducing downtime and ensuring fast response and process adjustment times.
Flexibility Flexible production requires flexible measuring instruments. It is becoming more common to produce small lots of different components, resulting in a difficult task for production measurement technology. Different component shapes, types, and sizes, often made of various materials and composites, must be measured fast and reliably. Measurement technology must be able to adapt to production and the varying components, geometries, and materials. One important requirement for this is quick and easy access to the component details that need to be measured.
Future-proof technology Modern production strategies are increasingly based on integrated production concepts. In Industry 4.0, production systems, machines, and measuring devices connect and communicate with each other. In this production concept, also referred to as SmartManufacturing, measuring instruments are integrated directly into production and are able to intervene in it. Measuring sensors recognise faulty components and automatically feed this information into the production loop. Production then automatically adapts to the new information and corrects the error. To ensure long-term implementation of self-controlling production, the measuring devices employed must fulfill various requirements. Among these are fully automatic measurements, high-precision sensors suitable for production environments, and interfaces for easy connection and integration into existing production systems. www.metoptix.com.au
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Specifying a tool like never before In 2018, PricewaterhouseCoopers (PwC) reported that manufacturers would turn increasingly to eCommerce to improve their processes — following examples set by Amazon, Tesla and Uber. Jonas Ljungdahl of Sandvik Coromant explains how one leading hydraulics manufacturer designed and acquired a tool in just ten days, with Sandvik Coromant’s own eCommerce platform. PwC’s ideas were presented to global steel industry representatives at the 2018 Surface Inspection Summit (SIS) in Aachen, Germany. Their ideas were widely seen as outlandish at the time, including predictions that: original equipment manufacturers (OEMs) would centralise their sales online, like Amazon; would increasingly support customers with design and development, like Tesla; and would form digital networks, much like Uber. The predictions raised eyebrows at the time. However, if anything, manufacturers have since moved beyond eCommerce and adopted customer engagement (CE) and customer experience (CX) as main principles behind their online investments. As confirmed in PwC’s later Retail Outlook 2020 report: companies are competing on CE; and most of the competition now takes place online. Manufacturers have embraced multichannel commerce models that bring several customer routes — online web pages, product catalogues and sales teams — into a unified, single ecosystem that offers the best possible experience and freedom of choice. After all, it boils down to time, costs and acquiring the right tool for the best end result. So, why not go online? Another advantage is that customers can today access an entire manufacturing and process planning system, with just a few clicks of a mouse. Sandvik Coromant has been using computerised software for process planning and production since the 1980s. We call this complete computer aided process planning (CAPP), a parametric process planning system that commences when we wish to manufacture a product. When we refer to process planning, we mean selecting the right process order, the right machine and operation, and so on. We can calculate the time-per-piece and any other operating instructions. Most of our production units around the world are equipped with this software, and, what’s more, they are linked together. So, any product that can be described by parameters can use the CAPP system — all by automation. The possibilities for customising tools were extensive. So, we realised, why not share these capabilities with our customers? The result was that Sandvik Coromant developed its own Tailor Made software platform.
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Manufacturers have embraced multi-channel commerce models to offer customers more freedom of choice.
With a few clicks The customised tooling aspect is important because there has previously been a fear among manufacturers that online platforms make it difficult to treat customers as individuals. In other words, these platforms won’t provide the solution to their unique problem. Also, with any custom tooling solution, manufacturers are wary of high costs and long lead times. The opposite is true with Sandvik Coromant’s Tailor Made platform. Customers can go online, enter their tool requirements and receive two dimensional (2D) and three dimensional (3D) computer aided design (CAD) files of the component, plus the price and lead times. Customers are not just browsing or buying existing off-the-shelf products — as you would typically find on Amazon. Instead, they are interactively developing solutions for their own manufacturing needs. Customers can log in the Tailor Made portal on Sandvik Coromant’s website, customise their own tools — let’s say a drill bit — and specify crucial factors like geometry, diameter and more. Users can even resubmit their order to refine the tool, receiving updated models and drawings.
When the design is finished, the customer receives an immediate quote for prices and delivery times and can place an order with just another click. And, when a customer uses the software, they are actually accessing Sandvik Coromant’s CAPP system. So far, so good. But there is one obstacle with the Tailor Made online software, which is overcoming a lack of awareness among manufacturers. The vast majority aren’t aware that they have the opportunity to tailor tools online. For Sandvik Coromant, a challenge is encouraging customers to make the conscious decision to log in and explore this application.
Two becomes one One customer that uses Tailor Made is Kawasaki Precision Machinery, the hydraulic technology specialist, which also happened to be the first company to use the platform. The customer creates world-class pumps, motors and valves that are used across the maritime industry and other sectors. It has been a Sandvik Coromant customer for more than 20 years and uses Sandvik Coromant tools for drilling, milling, turning and boring.
CUTTING TOOLS
The new benchmark in production metrology. By Alicona. That´ s metrology! In this instance, Kawasaki Precision Machinery sought to speed up one of its drilling processes at its factory in Plymouth, UK. It wanted a better way to drill holes for the bolts in one of its cast-iron Staffa motor cases. Kawasaki was using two separate drill bits — one for the hole itself and one for the countersink — because the standardised-solution step drill wasn’t suitable for both jobs. So, it turned to Sandvik Coromant and Tailor Made. Within just a few minutes, Kawasaki Precision Machinery was able to log on and enter its customised parameters into the platform. It used its own CAD software to make the necessary tweaks before placing the order, even printing a 3D prototype of the tool. The result is a customised drill that reduced the cycle time normally taken to source a new tool by more than 10%. In fact, the total lead time from design to implementation of the new drill bit was only around five weeks. Significantly, the customer’s entire manufacturing process can now be achieved with just one tool, rather than two. A productivity analysis has also found that the new tool has produced instant results. The cycle time for each motor case has been reduced by two-and-a-half minutes, which translates into saving £4 ($7.50) per component. Given that Kawasaki produces 42 of its Staffa motor cases every day, these advantages add up. What’s more, Kawasaki was able to reduce its machining time by 30% with its tool designed through Sandvik Coromant’s Tailor Made platform. This is an excellent example of how CE and CX can support customers with design and development in ways that contribute towards tangible overall equipment effectiveness (OEE) results.
Reduced lead times It’s incredible to think that a customer can go on the internet, design a bespoke tool and receive related CAD and 3D designs of the tool, and for this to be ready for manufacturer. Moreover, there are the advantages of short lead times. For Kawasaki, it could normally take two weeks for the design team to create the right specifications and come back with a design and quotation. However, with tailor made approval processes, this could also be removed. A process that could take two-to-three months was greatly reduced. You can create a unique instance of a tool that has never existed before, that is ready for manufacturing, and receive it in just 10 days.
µCMM is the first purely optical 3D coordinate measuring machine. As a user, you measure dimension, position, shape as well as roughness of complex components and tight tolerances with only one sensor. Length measurement deviation: E=(0.8+L/600) µm.
www.alicona.com
With Sandvik Coromant’s Tailor Made software platform, customers can go online and specify customised tool parameters, as shown here with the CoroDrill 460.
These reduced lead times are a major advantage for manufacturers. I recall one Sandvik Coromant customer was amazed that he could key in the parameters and get his customised tool delivered like any other stock item. The tool arrived with the customer’s own designated article code printed on the side. Going forward, Sandvik Coromant predicts growing demand for customised tools. We would also like to extend Tailor Made to other parts of our offering. We have a really strong tooling recommendations engine on our website, and plan to use this to meet growing demand for customised tools. Overall, Sandvik Coromant’s Tailor Made platform gives the customer more control — and proves that PwC’s predictions back in 2018 weren’t so outlandish after all.
Available in Australia @Met Optix, Web: www.metoptix.com.au Phone: 1300 363 409
Jonas Ljungdahl is Marketing Development Manager at Sandvik Coromant. www.sandvik.coromant.com www.kawasakihydraulics.com
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Multi-axis roughing extends tool life and speeds production success For decades, Seco has encouraged customers to optimise chip thickness, feeds and speeds, and heat dissipation during the machining process. The increasing sophistication of the technologies that support machining applications has helped make it easier for shops to pursue these approaches consistently. When CAD/CAM programming still involved manual creation of every line of code, the complex process limited machining strategies considerably. CAD/CAM systems couldn’t produce corners or automate complex moves, and no programmer had time to write thousands of lines of code to produce the small stepovers involved in dynamic milling. Now, the CAD/CAM universe has caught up with the message that Seco has been communicating for many years: programming must consider all aspects of the tool and the workpiece to formulate an approach that optimises both. Today’s CAD/CAM systems can implement the full range of these strategies, achieving the capabilities that Seco always builds into its tools and making it easy to automate an optimised approach to every workpiece. One of the most important of those CAD/ CAM developments gives shops the ability to control table movement so they can produce precise rounded surfaces. This multi-axis version of dynamic milling – also known as optimised roughing or adaptive milling – helps shops use Seco tools more efficiently. With this approach, not only can shops extend tool life, but they can do a better job of predicting it in advance. The strategy provides better control of cutting speeds, feeds and depth, as well as chip thickness. It also enables shops to reduce machining and programming time while they run tools evenly throughout a machining process.
Multi-axis milling strategies Five-axis adaptive milling helps reduce the heat build-up that results when a tool engages fully with workpiece material but the CAD/CAM program does not use the right types of tool paths to match the milling strategy. With new adaptive milling strategies, shops can take advantage of the connection between cutter engagement and diameter on the one hand and cutting speeds and feeds on the other. For example, when 2% of the cutter engages with the workpiece, cutting speed can increase by up to 80%, and when Ae rates reach 2% of cutter diameter, feed rates can climb by 50%. With new developments in CAD/CAM software, shops can leverage these relationships in ways that Seco always has understood but the technology could not accomplish.
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To showcase simultaneous five-axis roughing in NX CAM with tools optimised for use in aluminum, Seco recently assisted its partner IDEAL GRP to produce a thinwalled demonstration part. Similar to components often produced for use in aerospace or general engineering, this type of part typically becomes a short-run job that shops cannot create cost effectively through casting or forging. The menudriven, point-and-click automated solution from IDEAL GRP can reduce machining time by up to 60%, using large depths of cut and small radial stepovers to maintain constant chip thickness and material removal rate with minimised vibration and heat. The operation automatically finds the largest open region within the cut area and uses one of several cut patterns to produce short tool paths. Arc-shaped cutting movements extend the full width of the cut region with a small lift between cuts. The process also works smoothly over a free-form surface. Constant tool engagement maintains optimal cutting conditions and increases material removal rate. Although this is a roughing strategy, it yields better tool life – and produces results that come closer to finished shapes, with fewer operations and setups. Aluminum provides an extremely high level of heat conductivity, so much of the heat generated from machining processes – up to 95% – dissipates through chips. This limits the need for coolant in this type of roughing application and offers environmental benefits as a result. Shops gravitate toward coolant use because it does a great job of maintaining consistent workpiece temperature, clearing away chips and keeping the machine itself clean. However, coolant also causes hundreds of little temperature fluctuations during every minute of machining, and this triggers the development of small cracks that shorten tool life. The application in the
IDEAL GRP demonstration used a harder aluminium that did not need coolant to avoid the tool-clogging chips that can form with very soft aluminium alloys.
Solid and indexable SECO tools excel in aluminium In this collaboration with IDEAL GRP, Seco used four tools, three of which were run without coolant. The machining process was begun with a Seco 97-series end mill, designed for face, side and copy milling. This initial roughing pass used very steep ramping angles that ran as high as 15°, combined with a 10%-20% radial stepover. Next, Seco ran an 8mm JH40 highperformance end mill to create pocketed areas. With two flutes, this end mill produces thicker chips. In this application, Seco used a 10%-20% radial stepover to avoid metal pickup on the tool. The same tool also performed spiral cutting to rough out large pocket areas and finish the profiles of pocket walls. The last two processes began with a 16mm JS534 ball nose end mill that finished the top surfaces of the part. Finally, a JS509 chamfer mill with 0.8mm tip engraved the IDEAL GRP and Seco logos into the part, using coolant to avoid clogging the tool. Throughout the demonstration, Seco showcased a match between tooling and material, with solid and indexable tools specifically made for use with aluminium. Shops can adapt Seco technologies to match not only the parts they create but the machine tools they use. Seco gives customers the flexibility to use a high-feed milling cutter in a fast machine or other options in a bigger, slower machine. Thus, shops can find multiple ways to accomplish the same task. With a broad cutting tool portfolio, Seco offers proven, successful selections for every need. www.secotools.com
CUTTING TOOLS
Have you considered the benefits of bar peeling? Bar peeling is a specialist application that requires relatively high feed rates and small depth of cut applied to round bars and thick-walled tubes. Operations include the removal of surface layers of oxides, rolled contaminants and cracks caused by hot forging or rolling. This is mostly done in carbon steel, alloy steel for heat treating, tool steel, stainless steel and heat-resistant alloys. The advantages of peeling in comparison with turning are higher productivity, less consumption of inserts, excellent roughness quality and high dimensional accuracy. Bar peeling inserts are generally mounted in two ways, either using a screw through the centre hole of the indexable insert or via a top clamp mechanism. Using a screw through the insert distributes the forces in axial and radial directions at the same time, leaving more room for chip evacuation. Clamping from the top significantly reduces the time to flip the insert and is more userfriendly. This is because it only takes a few turns of the clamping screw to loosen it, allowing for faster indexing of the cutting edge. Dormer Pramet provides a range of cutting tools specifically for bar peeling applications. Its inserts, within the Pramet brand, are designed and manufactured to meet the most demanding machining processes. The range includes standard and special tools that ensure high efficiency, optimal surface quality and reliability in a range of peeling operations. Dormer Pramet’s state-of-the-art production methods for cemented carbide grades and MT-CVD and PVD coating layers, reduce edge wear and increase the tool life. Bar peeling indexable inserts have different cutting-edge geometries to create chips with the required shape necessary for a smooth removal from the inside of the cutting head. This is one of the most important factors affecting the efficiency of the bar machining process. The wide variety of materials to be machined encourages
tool manufacturers to continuously improve both tool geometries and carbide grades. In a recent addition to the bar peeling inserts, Dormer Pramet now displays on the tool, not only the geometry of the insert (PM), but also the variant of support facet on flank surfaces (S01, S02 or S03) and of course the grade. This helps the customer to recognise the difference between inserts with the same size and geometry, but a different edge preparation. Also, accurate holding cassettes have a significant impact on the machining process. There are many manufacturers of machine tools for bar peeling around the world. Most of these use different holders in their cutting heads which are equipped with proprietary cassettes for the inserts. Dormer Pramet can make custom-made cassettes using the highest quality tool steels that will match the machine tool specifics. Pockets on these holders are designed to utilise standard inserts, while spare parts are also now available within the assortment. Production of special indexable tooling to meet the specific needs of customers is also possible. To showcase the wide range of tools for bar peeling, Dormer Pramet has produced a new catalog which outlines the wide range of indexable inserts and cassettes that are used on machine tools of different manufacturers. The publication includes a technical section, which features detailed information about the geometry of cutting tools, materials, calculation of machining parameters, recommended initial cutting speeds and a troubleshooting guide to help respond to the most common problems during machining. www.dormerpramet.com
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Iscar – To hold effectively While it may be rare to hear news of significant changes or developments in the world of toolholding, this shouldn’t be taken as evidence that new innovations are not taking place. Toolholders were designed for mounting cutting tools reliably. They also facilitate the torque transmission from a machine spindle to a rotating tool. It has been a long time since we have heard of any significant changes in toolholding, which may suggest we are behind in innovation. Indeed, wellestablished tool clamping principles, the need for wide interchangeability and unification, and normalised designs of machine tool adaptations have resulted in well-defined standards, which specify detailed toolholder parameters. However, this doesn’t mean that new innovations and development is over. Time puts new demands on machining, which has transformed to new requirements for machine tools, and, consequently, to cutting tools and toolholders – both elements of a chain that enables recognition of machine tool capabilities possible when a machining part of a surface. The toolholder relates to the most “conservative” link of the chain and has undergone fewer revolutionary changes for the noted reasons. Nevertheless, the spirit of the time and modern trends in metal cutting has not surpassed. Obviously, the Industry 4.0 philosophy has had a serious impact on toolholding. Smart manufacturing of tomorrow demands intelligent toolholders to exchange data in the formed Internet of Things (IoT). This will lead to creating new information capabilities of toolholders by adding more and more electronic units. Even today, built-in chips provide various data about a toolholder that communicates with machine tools, industrial robots, storage devices, and more. Adding a new data function is no doubt an extremely important direction in toolholding development. However, it does not cancel the common way of an improved mechanical design, which may look a little bit prosaic when compared to the enthusiastic data intelligence of smart tooling. However, it should be noted that a traditional development component that relates to toolholders as mechanical systems to advance, is very far from coming to a dead-end. Recent improvements in toolholder designs are distinctly seen in the following areas: •
Heat-shrink chucks. High-speed machining (HSM) methods have brought tool balancing requirements to new heights. In HSM, the dynamic characteristics of a tool cannot be separated from a toolholder, and a particular focus must be given to
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Combining exchangeable heads and toolholders in modular assemblies simplifies tool customisation.
the assembly on the tool and the toolholder. Hence, minimising the unbalance of such an assembly is one of the challenges tool developers face. They have tried to guarantee the required balance parameters at the design stage before production. This engineered balance design cannot replace “physical” balancing of a real assembly, but it substantially diminishes the mass unbalance of a future product and makes “physical” balancing much easier. Axisymmetric heat-shrink chucks optimally meet the requirements of a balanced toolholder for HSM already in the design stage. This explains why the advance of heatshrink chucks is of priority. •
Coolant supply. A pinpointed coolant supply through a tool body, when a coolant flow is directed to a cutting zone, significantly improves machining performance. The industry requires more advanced toolholders with inner supply options, especially for machining with high pressure cooling (HPC).
•
Modular quick-change tooling. A modular design principle considerably simplifies finding the optimal configuration of a tool assembly and diminishes requests for special tools.
•
Long-reach applications. Longreach machining applications,
which require high overhang of a tool assembly, feature poor stability. Increasing vibration strength of the assembly is one more trend of toolholder development. •
Polygonal taper connection. The ISO-standardised polygonal taper adaptation has proven itself and become common in multitasking machines and turning centers.
These are only a few of the high-profile directions for developing toolholders. The others are focused on a high-torque transmission, preventing tool pull-out because of the high axial component of the cutting force, increasing accuracy, more ergonomic solutions, etc. Therefore, the conclusion that there is seemingly a stagnation in the mechanical design of toolholders is incorrect. By way of example, let’s consider the newest releases of toolholding by Iscar over the past few years. Recently, Iscar expanded its family of heatshrink holders by adding new chucks with C8 polygon taper shank. The chucks offer several bore sizes from 6mm to 32mm. The introduced products feature coolant channels along the chuck bore to provide effective coolant supply to the cutting edge of a clamped tool. Due to increasing popularity of the polygon taper adaptation, Iscar has developed a new tool family for external and internal
CUTTING TOOLS ER collets with cooling jets.
A heat-shrink chuck with polygonal taper shank features internal coolant supply capability.
turning and threading applications. A modular concept of the family enables various tool assemblies using a wide range of cutting heads with indexable inserts that are mounted on toolholders with polygon taper shanks by serration-face connection. What else can be new in ER spring collets? Tool manufacturers have developed a rich variety of precise collets that offer coolant supply capability. For example, Iscar’s new updated ER rubber sealed collets with an extremely narrow collapse range ensure better clamping force, maintain high runout accuracy of 0.005mm, and facilitate four cooling jets. Iscar’s integral collets, tools with a tapered shank for direct mounting in ER chucks, are accurate and rigid tools, and are considered toolholders themselves: the front of the collet has its own adaptation for mounting
cutting heads with indexable inserts or are fully made from cemented carbides. Hydraulic chucks ensure high gripping torque that is vital for heavy-duty machining. During the last few years, Iscar extended its product range of hydraulic chucks, and they are now available with BT-MAS, DIN 69871, and HSK shanks. In addition to a high-torque transmission and fast toolchange capabilities, the hydraulic chucks are characterised by excellent vibration damping properties and high accuracy. Iscar developed a system of quickchange assembled tools specifically for turning aluminium wheels. A tool assembly comprises of a cutting head and a holder. The head is mounted on the holder by use of a dovetail connection. The dovetail mechanism assures full-face contact between the holder and the head with very
Quick-change tooling for turning aluminium wheels.
high clamping forces and can resist tough cutting conditions when turning the wheels. The holders are produced with VDI40, VDI50 or round shanks. We can see that progress in toolholding is far from exhausting the resources of advanced designing. Although highquality toolholders have reached the right level of performance to meet the needs of today’s manufacturers, the smart factory of tomorrow demands an even higher level. Intelligent design, in combination with progressive technology, continues to play a key role in toolholding improvement. www.iscar.com
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Recycled beverage carton walls for Aussie buildings Australian builders will be able to replace plywood, particle board and plaster board with low-carbon, environmentally sustainable construction boards made from packaging waste such as used beverage cartons and coffee cups. saveBOARD Australia last year received a $1.74m grant from the Federal and New South Wales Government towards setting up a $5m facility that will turn packaging waste into high-performance building material. The project is funded by the Federal Government’s Recycling Modernisation Fund and the NSW Government’s Waste Less, Recycle More initiative. The Australian and NSW Governments and the companies behind the project expect the facility will create confidence in a new market for recycled construction materials, similar to roads made from recycled glass, and enable more packaging to become 100% recyclable, in line with national packaging targets. The Australian Packaging Covenant Organisation (APCO) said it marked a fantastic step forward for beverage cartons and for the brands and consumers that use this important type of packaging. “It is great to see this level of collaboration across the entire supply chain, addressing post-consumer materials by putting in place effective local end-market solutions,” said Brooke Donnelly, APCO CEO. “This is a prime example of the collective impact model in practice which will help establish a manufacturing capacity in Australia. Led by industry with the support of government, APCO will continue to support this type of collaboration as we work to transition to a circular economy for packaging and meet the 2025 National Packaging Targets.” The project is the first collaboration between Tetra Pak and SIG Combibloc in Australia under the umbrella of the Global Recycling Alliance for Beverage Cartons and the Environment (GRACE) and is a joint initiative with saveBOARD and its supporters Freightways and Closed Loop. According to saveBOARD co-founder and Chief Executive Officer Paul Charteris, making high-performance lowcarbon building materials using 100% recycled materials from everyday waste will be a game-changer that will transform the construction industry in Australia. “It will enhance the construction industry’s drive towards more sustainable construction practices,”said Charteris. The first Australian saveBOARD plant will reprocess liquid paperboard beverage containers, including both aluminium-lined aseptic packages and non aluminium-lined containers collected through the container deposit scheme and coffee cups collected through the ‘Simply Cups’ recycling program. It will also source material from document recycling company Shred-X. Together with supplementary material from industrial processes, these items will be used to manufacture high-performance lowcarbon building products to substitute plaster board, particle board, and oriented strand board (OSB) that can be used for interior and exterior applications. The saveBOARD process uses heat and compression to bond materials, eliminating the need for glues or other chemical additives, to produce a clean product with zero volatile organic compounds (VOCs), suitable for use in homes and commercial buildings. Tetra Pak Oceania Managing Director Andrew Pooch said the solution demonstrates Tetra Pak’s commitment and contribution to a low-carbon economy: “It is more than just an investment for us. It is the right thing to do – to help limit waste to landfill and support a technology that improves local waste collection and recycling infrastructure. Cartons are the most sustainable packaging option for beverages in Australia. With a bespoke whole carton recycling solution, we are excited to contribute to a robust circular economy in Australia.”
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SIG Combibloc Australia & New Zealand General Manager Adam Lipscomb said his company is delighted to support this first full recycling solution for beverage cartons on Australian soil: “Ensuring beverage cartons are recycled at scale in markets we operate in is of utmost importance to SIG. This project is a key milestone towards achieving full onshore recycling capability for beverage cartons in Australia, and we look forward to seeing it come to fruition as soon as possible. SIG is united with its partners in working to ensure beverage cartons remain the premier sustainable choice for food and beverage packaging in Australia and we are committed to ensuring every carton we produce is recycled.” Closed Loop Managing Director Rob Pascoe said saveBOARD products will be the lowest-carbon footprint interior and exterior board products on the market: “saveBOARD promises a better, greener, more affordable solution that can lead us towards a more sustainable future. It’s the perfect example of the circular economy in action.” www.saveboard.nz saveBOARD CEO Paul Charteris with waste material and product samples.
CONSTRUCTION & INFRASTRUCTURE
How Monitum future-proofed its business with Ind.4.0 Geospatial data is a critical component of every construction project, reducing risk and improving efficiencies. But gathering this data is often costly and labour-intensive, something that Lee Hellen, MD of leading Australian automated monitoring business, Monitum, knows firsthand. When working on a complex, high-risk surveying project in 2012, Hellen imagined the difference an affordable solution that automatically monitored displacement could make to industry. “As our sector advanced, we recognised the need to harness the Internet of Things (IoT), cloud computing and artificial intelligence to provide precise and accurate insights to manage risks around buildings and structures,” he said. And in 2019, Monitum, in partnership with Queensland University of Technology (QUT), embarked on a $4.5m collaborative research project to bring such a product to market. The three-year project, supported by $875,000 in funding from the Innovative Manufacturing Cooperative Research Centre (IMCRC), has developed a cost-effective IoT solution using low-medium-end Global Navigation Satellite System (GNSS) sensors and low-power wide-area networks (LPWAN). According to Hellen, Monitum’s Australian-made product will make precise GNSS positioning accessible and affordable, with many applications across industries such as infrastructure, transport and mining. “We’ve created a fully-integrated smart device that is supported by a cloud processing and data analytics service. Together, they enable millimetre-precise deformation data to be obtained automatically, remotely and in near real-time,” he said. Central to delivering such an innovative outcome was the expertled research provided by QUT’s project team, headed up by Professor Yanming Feng. Hellen said that working closely with QUT researchers in GNSS, networks, data science and geotechnical engineering provided Monitum with greater capacity, depth of thought and understanding and the ability to conduct cutting-edge geospatial research. The collaborative wins are demonstrated in the optimal manufacturing and data infrastructure design of the sensor and the adoption of state-of-the-art analytical techniques, including machine learning, to develop the monitoring service. Professor Feng said collaborating with Monitum had been a unique experience in applying QUT’s expertise, bolstered by mutual trust and the ability to communicate openly. “Because of our respectful working relationship, QUT and Monitum were able to effectively manage the inherent risks and multifaceted challenges posed by undertaking research,” he said. “Collaborating with smaller businesses like Monitum can increase efficiency within research and development (R&D) projects because you’re able to work directly with key stakeholders. In this instance, we were able to work together as one team, and the project outcome is a testament to the importance of this effective integration.” Raymond Johnson, Manager, Industry Engagement (Science and Engineering) at QUT, added that having strong ties to businesses like Monitum supported the development of new technologies and improved university-industry collaboration. “Throughout the collaboration, Monitum gave the QUT team the freedom to apply their knowledge and expertise as they saw fit to deliver mutually beneficial outcomes,” he said. “One of the major project outcomes for QUT is that the successful research findings have strengthened the university’s credibility within the geospatial sector. QUT now has a persuasive case study in geospatial science to demonstrate its capability, allowing the university to undertake more diversified research in IoT and positioning technologies.”
As part of the project, Monitum engaged Brisbane-based electronics designer and manufacturer, Intellidesign, to apply the research findings to the design and production of the monitoring device. Commenting on the project, Matt Bromwich, Intellidesign’s CEO, said that collaborating with Monitum had been a rewarding process. “Monitum approached us with a well-proofed concept. By applying our mutual understanding of the market and technical requirements, we’ve collectively transformed Monitum’s concept into an innovative product ready for mass production,” he said. Hellen also identified IMCRC’s business model as key to supporting the fruitful research project, as it incentivised university-industry collaboration and drove co-investment. “By championing the project and being a hands-on advisor, IMCRC helped to formalise our idea, keep us committed to the innovation, and ensure we were able to reach mutually beneficial outcomes,” he said. “This enabled us to guarantee our supply chain and offer consumers an Australian-made product in a market that’s currently dominated by overseas competitors. “The project is an exemplar of how a small business with fantastic ideas, passion and drive can partner with university to transform its offering and create significant opportunities for Australia’s manufacturing sector. “And by embracing Industry 4.0 technologies, we’ve been able to future-proof our business,” Hellen concluded. Monitum will launch its new technology under the name of ‘Kurloo’ in 2022. www.monitum.com.au
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Innovative building materials help moderate temperature year-round A team from UNSW Sydney has developed new intelligent building materials that can help keep the temperature in check throughout the seasons. The innovative design adjusts the optical properties used in conventional heat mitigation materials (coatings for buildings) to change the amount of heat they reflect and emit depending on the temperature in the air. The new materials were designed by Scientia Professor Mat Santamouris, Anita Lawrence Chair in High Performance Architecture at the School of Built Environment, UNSW Arts, Design & Architecture. He says the new materials could be used worldwide in buildings to help better protect them from the elements. “This is a smart, intelligent building material that understands the urban temperature, and it is modulated according to the weather conditions,” Professor Santamouris says. “So it is ideal for cities that have issues with overheating in summer, but also have heating requirements during winter.” Professor Santamouris specialises in developing heat mitigation technologies and strategies that decrease urban temperatures in cities worldwide. Extreme urban heat is the most documented climate change phenomenon, affecting more than 450 cities worldwide. Higher urban temperatures significantly increase energy consumption needs and adverse impacts on health, including heatrelated morbidity and mortality. His team recently tested the new generation of materials in Kolkata, India, in an international collaboration with colleagues from the University of Calcutta India, Public University of Navarra Spain and the University of Tsukuba Japan. The study is the latest in their ARC Discovery Project, Fluorescent Daytime Radiative Cooling for Urban Heat Mitigation, which aims to develop cooling technologies to mitigate urban overheating and reduce cooling energy demands in buildings.
Thermal comfort through the seasons While many conventional cooling materials help mitigate urban overheating during warmer periods, they’re not necessarily suitable for cities that have winter heating requirements. Furthermore, because the materials reflect light, they can generate glare, and can only be used in specific locations. “Traditional super-cool materials work by having very high reflectivity and emissivity, making them ideal for cities that only require heat mitigation,” Professor Santamouris says. “However, they can cause overcooling in cities that also need heating during cooler periods. They also can’t be used in low-level streets or vertical façades because of the glare, so they can only really be used on roofs of high-rise buildings – not in walls or pavements.” Professor Santamouris’ team added new layers to the conventional super-cooling materials to help modify their solar reflectance and emissivity during colder periods without compromising the cooling efficiency. The first layer is composed of a ‘phase change’ material, which uses transitional metal oxides to modulate the reflectivity and emissivity during the seasons. A second fluorescent layer then increases the cooling capacity of the material. “We have integrated a new layer into the materials which changes the reflectivity and emissivity as a function of the ambient temperature,” Professor Santamouris says. “We have also decreased the reflectivity of the materials to decrease glare by integrating [another] new layer that increases heat losses through fluorescence.” Fluorescent materials absorb solar radiation but immediately reemit it as fluorescent radiation at a lower wavelength. Because the material can emit more than it absorbs, it compensates for the
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reflectivity loss, and can be used without causing glare. The result is a material that, during the summer, has a surface temperature below the ambient temperature, providing cooling to the building, and then much above the average temperature during winter, providing heating. “In the recent study, we were not only able to overcome the overcooling issue, but we were able to decrease the peak summer ambient temperature up to five degrees and increase the peak winter temperature by 1.5 degrees.”
Levels of application Because the new materials rely less on reflectivity to reduce heat, they can also be used on any level of a building. “It’s an intelligent material that is adaptable to any climate, can be used at a low level, and can be of any colour, and does not create any glare,” Professor Santamouris says. “It is also durable, nontoxic, and will be affordable when produced at scale.” Professor Santamouris says the team will continue to test the materials in new locations around the world with a view to making the materials commercially available. “This technology has the potential to be used in all cities worldwide, which would reduce energy costs and help combat the impacts of climate change.” www.unsw.edu.au
CONSTRUCTION & INFRASTRUCTURE
Rocking the foundations of the building industry A generation ago, the waffle pod foundation forever changed the way homes are constructed. Now a new, sustainable product manufactured in Australia is creating the latest step change in foundation design, according to Jim Prior, General Manager of Biax. Biax represents a clever rethinking of the waffle pod, replacing unsightly, hard-to-manage, environmentally-damaging polystyrene blocks with a compact, lightweight and sustainably produced product. Broad adoption of Biax could help the construction industry eliminate 25,000 tonnes of styrene from the building market each year. While other brands have attempted to completely redesign the waffle pod to achieve better environmental outcomes, Biax retains the best elements of the waffle pod design, but replaces the bulky styrene blocks with compact, recycled plastic pods. The Biax brand was last year acquired by Holloway Group, an Australian business that produces and distributes a number of innovative and sustainable products, in addition to offering custom moulding through its A Plus Plastics business. Prior says Holloway Group was the perfect acquisition partner for Biax. “Holloway Group was already manufacturing the product,” he explains. “Through this acquisition we have been able to remove one of the layers between manufacturer and purchaser, which will help bring costs down, but more than that, the acquisition will allow Holloway Group to leverage its manufacturing capability and national footprint to bring scale to the Biax operation. The product has already been installed in over 800 slabs nationally, but we anticipate a rapid acceleration in demand that we are excited to meet. We know that about 80,000 residential waffle pods are poured each year, so there is a huge opportunity to be met and Holloway Group is positioned to keep up with fast-growing demand.” To help achieve scale and meet market demand, Holloway Group is looking to build a distribution network of reseller partners in key locations. “This product is set to become the gold standard, so we want to develop a robust sales channel that includes businesses already selling into the markets we want to access,” says Prior. “This includes trade and hardware operations and we’re also keen to engage with businesses that sell adjacent products, like those who sell steel reinforcement for slabs. According to Prior it has taken time for industry to recognise the need to move on from foam. “The waffle pod foundation system serves its purpose well, providing a very reliable, proven, cost- effective base for building residential dwellings,” he says. “But every builder and concreter knows that the polystyrene pods are a problem. They take up a huge amount of space on sites that are only getting smaller, they’re unsightly and they inevitably end up creating a mess throughout neighbourhoods when they break up with the slightest wind, resulting in pieces spreading to nearby properties or into waterways.” In addition to its sustainability credentials, the stackable Biax product takes up far less precious space on site – in fact, about 80% less than the space required for foam. Finding an alternative is something the industry has been working on for a long time, but according to Prior the products weren’t right, and the timing wasn’t right.
“It’s understandably difficult for engineers and builders to move away from a system they know is fundamentally reliable,” he says. “While it clearly has flaws, when an engineer specifies a foam-filled waffle pod, they know it’s going to perform as expected and comply with all the relevant building codes. The trouble with some of the earlier products that tried to replace foam was that they threw the baby out with the bathwater, relying on an entirely different foundation design. “Biax retains everything that is good about the waffle pod slab, but replaces the foam with a product that is made of recycled and recyclable material. It’s stackable, so it’s easier to transport and store on site, and it’s priced comparably. Rather than simply replicating the same sizes as waffle pods, the Biax sizes are specifically calculated to also offer heightened engineering outcomes.” Prior notes that the building industry is under increasing pressure to adopt sustainable practices, and Biax can help achieve measurable improvements. “Social licence to operate is becoming more of a focus area for builders, who face mounting scrutiny over their commitment to sustainability. There will come a point, probably soon, where environmentally unsustainable components like polystyrene will simply become unacceptable.” www.biax.com.au
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COMPANY FOCUS
Taking on the world with its innovative welding technology World-wide distributors and ongoing global deals for K-TIG’s automated welding systems, as well as a severe shortage of welders across the globe, is helping the Adelaide high tech welding manufacturer succeed on all fronts. By Carole Goldsmith. ASX-listed, Adelaide high-tech welding manufacturer K-TIG, is accelerating its global expansion, exporting its state-ofthe-art welding technology system worldwide, with distributors across 20 countries. Among these are the USA, the UK, Korea, Malaysia New Zealand, Singapore, India, Belgium, Norway and France. K-TIG is the developer and manufacturer of a patented, high productivity welding technology known as Keyhole TIG. This February, it landed new distribution deals in Europe with Turkey’s pipeline equipment supplier BMC Marine Muhendislik Limited and with Spanish/Portuguese manufacturer MetaWelding. K-TIG’s latest Asian distributor is Jacom Vietnam Ltd, which has clients in key industries suited to K-TIG’s capability across oil and gas, aviation, ship building and steel fabrication sectors. The company’s three new distributor appointments across Europe and Asia reflect a push to expand third party sales channels to complement the hi-tech welder’s direct sales force. A key focus of this strategy is the appointment of welding integration distributors who represent proficient fabrication technologies and services. K-TIG’s Managing Director, Adrian Smith says specialist automation integrators are essential in incorporating K-TIG’s unique technology into a turnkey welding solution across industries: “Our newly formed distributorships with these three companies present an exciting opportunity for us to continue to grow sales around the world.” There is a severe shortage of trained welders in Australia and globally, primarily due to COVID lockdowns and reduced
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welding training opportunities, advises Smith: “This is leading to a world-wide trend of manufacturers investing in high-tech welding automation, as they can’t get the required trained welding workforce.” Fortune Business Insights, August 2021, Welding market share and COVID impact analysis, 2021-2028 forecast, re-enforces Smith’s comments. It reports that the global welding workforce shortage is a major factor behind the high adoption of robotic welding across major industries. The global welding market is projected to grow from $20.99bn in 2021 to $28.66bn in 2028 at a Compound Annual Growth Rate (CAGR) of 4.6% in forecast period, 2021-2028. The latest welding workforce data enforced by the American Welding Society reveals that 314,000 new welding professionals are projected to be required in the US alone by 2024, with 78.500 on average, welding jobs to be filled annually in the US, from 2021 to 2024. K-TIG is expanding rapidly in the US market with automated welding solutions to alleviate this welding professional’s shortage. Last November K-TIG announced a Tier One distributorship with US Precision Welding Automation Systems company MITUSA, to supply integrated K-TIG products across the USA and into Mexico. Smith says specialist automation integrators were essential in incorporating K-TIG’s unique technology into a turnkey welding automation solution across many industries. “Our newly formed distributorship with MITUSA is an exciting growth opportunity enabling us to increase sales across the United States and extend into Mexico. MITUSA is a highly regarded
K-TIG – Innovative welding
welding automation company specialising in automated can seamers, offering both technical and logistical expertise for customers in North America,” Smith says.
K-TIG is establishing an R&D facility within Adelaide’s Factory of the Future The company is expanding its Adelaide operations, announcing this February that K-TIG will build an R&D facility within BAE Systems Australia’s Factory of the Future, where it will demonstrate and further evolve the application of its robotic welding capabilities. “The aim of having the R&D facility within the Factory of the Future at the Tonsley Innovation District, was to prove that K-TIG’s technology can not only expand Australia’s shipbuilding capability but it has vast industrial applications,” says Smith. “The Factory of the Future is under
097 development by BAE Systems and Flinders University and will connect businesses and sectors, which are of growing importance to the national economy.” When asked what the K-TIG system is, Smith explains: “Our Keyhole TIG technology which is also a type of Gas Tungsten Arc Welding (GTAW), consists of a welding torch with power supply and water-cooling system combined with our electronic controller that connects with various forms of automation.” “Our system welds thicker materials faster and at a higher quality than other welding methods. This technological edge results in dramatic productivity increases and can give our customers a distinct advantage over their competitors.” K-TIG technology reduces multi-hour conventional TIG welds to just minutes, while providing the sort after cleanliness of TIG/GTAW. It finishes to a quality standard, which meets the most demanding requirements of the nuclear, aerospace and defence industries, advises Smith. In addition to the speed advantages over TIG/GTAW, the K-TIG technology reduces power and gas consumption by up to 95% and dramatically reduces labour costs. “The K-TIG system sells for around $100,000, which includes commissioning it, building it into a client’s automation system and training employees on its use,” advises Smith. “It can be integrated with most types of welding automation components, including positioners, rotators, headstock, tail stock, turning rolls, column & boom manipulators, longitudinal steamers, buggies, carriages and robots.” The welding torch and system was six years in development before its first commercial sale, advises Smith. It was invented by CSIRO scientists as a novel welding form in 2009. After being granted the intellectual property (IP) for the invention in 2010, the scientists worked on its commercialisation from 2010 to 2019, winning its first commercial sale to GE Welding in 2015.
With many system sales under its belt by 2019, they sold the business to investors in 2019 and K-TIG Limited was born, after its listing on the ASX in October 2019. The company has been capturing the Australian and global welding automation market ever since. “K-TIG’s keyhole welding process is the culmination of 10 years of intense research. This research developed the physics that underpinned the K-TIG process, a high speed, single pass, full penetration welding technology that reduces the need for wire,” says Smith. Trained with Degrees in both Science and Electrical/Electronics Engineering and an MBA, all from Adelaide University, Smith also has an extensive career path in manufacturing senior management and skills training. He came on board at K-TIG, just over two years ago as Executive Director and then as MD since November 2020. The global business employs 28 people including 19 in Adelaide, a team of four in the UK and five in the USA. Its automated welding system is used across many industries and Smith provides some examples of its diversity: “We’re used a lot in the oil and gas industry in the production of the tanks and vessels, pressure vessels and in transport industries for tankers, and welding piping. “Primus Pipe and Tube in Florida use our technology to weld its pipes and tubes. A UK-based company, Darchem uses K-TIG to create nuclear waste containers. When they decommission a nuclear waste site, they put all the waste material into these large containers, which are around three cubic metres in size. Our technology is used in the container’s production. “Melbourne-based company Fuelcraft successfully integrated our K-TIG system on a new project with the Australian Government, to supply diesel storage tanks used in Antarctica, given the harsh conditions the vessels would face. Many Australian SMEs can advance their capacity and capabilities by installing our welding system, especially with the shortage of welders in Australia and globally,” Smith advises proudly.
K-TIG team: (L to R) Vanessa Mercurio, Adrian Smith, Jayne Osborne, Bill Kelly and Ben Mitchell with K-TIG’s advanced welding system and containment vessel made from stainless steel.
Future plans Expanding its workforce and facilities is on the horizon for K-TIG’s future plans with additional employees scheduled for the USA, Europe, Asia and the Middle East. “We can ship our welding systems around the world and these global personnel can provide additional tech support, training and sales at the client’s workplace.” On 9 February this year, K-TIG announced to the ASX, that it had signed a formal agreement with the UK Nuclear Advanced Manufacturing Research Centre (Nuclear AMRC) to develop a turnkey robotic welding cell. This may be used for the production of nuclear storage containers, each holding 3 m³ of intermediate level waste (ILW). Up to 17,000 stainless-steel containers are needed for the decommissioning of the UK Sellafield nuclear site, as part of a GBP £1.5bn procurement plan currently scheduled to commence in FY 2023/24. K-TIG will maintain all Intellectual Property and commercialisation rights to the robotic welding cell developed, which can be adapted and rolled out across the globe. “This agreement takes our nuclear strategy from planning to execution. It will provide us with the foundation to enter into a fabrication joint venture or acquire an appropriate business,” advises Smith. “We are now moving towards realising long- term revenue from the nuclear sector by offering a world-leading nuclear storage solution and creating value for our shareholders. “Our collaboration with the Nuclear AMRC is a generational leap in technology for the fabrication industry. The project aims to show the nuclear industry and the wider fabrication sector, the benefits of an Industry 4.0 approach. It will showcase how K-TIG’s technology combats the challenges of labour market shortages and volatile metal market prices.” Smith is certainly positive, as K-TIG offers a bright future for its employees, clients, distributors and investors alike. https://www.k-tig.com
Adrian Smith, Managing Director, with K-TIG’s advanced welding system
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Assistive tech company eyes off growth opportunities at Tonsley A leading assistive technology company, helping those with degenerative conditions like motor neurone disease (MND) retain their voice, will set up a new state-of-the-art headquarters at Tonsley Innovation District. Link Assistive, which supplies sensory, interactive, and assistive devices including world-first eye tracking technology in iPads, will move into a custom-built premises later this year, in a major expansion of its Adelaide operations. Its new headquarters will include space to reconfigure and service a range of assistive technology products for the Australian market, a warehouse to store its growing suite of devices, and a cutting-edge sensory play space where children and their carers can trial and test equipment. Link Assistive Managing Director Bas Tijdhof said the move to Tonsley would allow the company to significantly upscale, with plans to expand its workforce by almost 40% in the next year: “Having a larger space for Adelaide-based clients to go to experience the technology and have access to our highly skilled team who can work with families and carers and show them the highest quality technology, is an exciting new chapter for us. “We have an amazing team, and we want to be able to further attract great staff with the move to Tonsley. For an innovative business such as ours there is so much opportunity to unlock partnerships at Tonsley, particularly with the small and medium tech businesses and medical businesses that we might be able to work with.” Link Assistive is one of just two companies in Australia delivering eye gaze technology devices, which allow non-verbal people, or those with severe physical challenges such as cerebral palsy, Rett syndrome or spinal injury, to control their environment solely through eye movement. The precision technology means users can simply move their gaze to open an app on-screen or trace out words via a standard QWERTY keyboard that can then be converted to speech. In practical terms, the lightweight, durable devices aid independent completion of everyday tasks such as turning on the TV, while providing critical communication during a medical emergency. They also help users maintain emotional connections such as the ability to read a child a bedtime story.
Link Assistive will be the latest business to set up headquarters in the Tonsley Innovation District in Adelaide.
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“Your eyes become a replacement for your mouse and keyboard,” Tijdhof said. “It really is lifechanging. Just like you use a mobile phone, they can text, make a restaurant reservation and do online banking. And on another screen, they can be drafting an email or reading a newspaper. It’s their leisure, their education and their interaction.” Vincent Rigter, Renewal SA Project Director for Tonsley Innovation District, said having a multifaceted business like Link Assistive join the Tonsley district would further add to its flourishing ecosystem of innovation. “Link Assistive is at the leading edge of utilising globally-sourced technology to provide tangible benefits to those living with a disability,” Rigter said. “They are supplier, product designer and technology trainer all mixed into one, so by moving to Tonsley they will have the space to unlock their service delivery potential. “Tonsley’s health, medtech and assistive technology sector is rapidly growing, and we see business thriving, from PPE to X-Ray manufacturing. Link Assistive will bring new expertise in this space and we are excited for the opportunities it presents as they leverage their ideas and capabilities off other tech companies and research entities co-located within the precinct.” Tijdhof said that, as a NDIS-verified provider, Link Assistive was keen to build upon its connection with Autism SA – which has also chosen Tonsley as its headquarters – having designed and installed a sensory room at its Elizabeth office in the past. Autism SA’s speech pathology team also trial Link Assistive’s communication equipment with their clients regularly. Tijdhof added that he also saw natural, future partnerships with Flinders University’s Medical Device Partnering Programme and the Tonsley-based Global Centre for Modern Ageing, with many of Link Assistive’s products including ceiling, flooring and table interactive multisensory projection systems having practical and potentially life-changing advantages to older users.
SOUTH AUSTRALIA
STATE SPOTLIGHT Adelaide-based assistive tech company Link Assistive specialises in eye gaze technology for non-verbal people.
“To source parts more and more locally, that’s the long-term strategy,” Tijdhof said. “At the moment, if something needs to be fixed or repaired, we have to send it to manufacturers overseas. Tonsley will give us the space to increasingly do work ourselves, decreasing turnaround times to get products back to clients and get a better understanding of the manufacturing process. “We now have quite a big say in the hardware and software, and we are heavily involved in development with our clinical team continuously feeding back data. I am very proud of what we are doing.”
Established in 2008, Link Assistive currently employs nine staff in Adelaide and a further four interstate, including a series of speech pathologists and occupational therapists. It supplies its technologies all over Australia, as well as exporting products to New Zealand and Singapore. It’s hoped its bigger footprint at Tonsley will not only allow for larger-scale importation of assistive technology from Europe, the US and the UK, but also to provide scope for future SA-based manufacturing.
Currently working out of a house at Pasadena, Link Assistive staff will move into a 600sqm space, prominently located next to Siemens within the Tonsley precinct. Link Assistive will be the second and final tenant in the building after perfume robot manufacturer Accurate Dosing Systems announced it was joining the precinct in November. Link Assistive is one of a growing number of businesses including Ziptrak, Nice Australia and Western Air that have chosen to relocate their operations to Tonsley over the past 12 months to take advantage of the world-class expertise in high-value manufacturing on site. www.linkassistive.com
Fleet Space Technologies’ factory plan cleared for launch The Australian space industry is set to soar to new heights with Fleet Space Technologies winning state and federal government backing to build its new Hyper Factory in Adelaide. The Federal Government on 3 March announced $20m in grant funding support for Fleet Space’s Australian Space Manufacturing Hub – to be located at the recently announced Australian Space Park at Adelaide Airport – under the Collaboration Stream of the $1.3bn Modern Manufacturing Initiative. The South Australian Government is also contributing $20m towards the $66m project, which is expected to create 221 local jobs, as well as more than 1,000 others indirectly.
Fleet Space Technologies co-founders Matt Pearson and Flavia Tata Nardini.
Fleet Space is Australia’s leading space company. The company has designed, built and launched the country’s only commercial satellites and has six satellites already in orbit as it works towards a mission towards building a constellation of 140 small satellites in Low Earth Orbit. Fleet Space plans to build a satellite Hyper Factory in Australian Space Park in Adelaide, and develop new 3D printed small satellites. The Federal and State funding will supplement industry investment into the Australian Space Park by Fleet Space Technologies, AT Space, Alauda and Q-CTRL. The purpose-built facility will drive collaboration between Australia’s local space manufacturers to build innovative satellites and rockets. It will make South Australia the largest manufacturer of satellites in Australia. From the Hyper Factory, the Fleet Space’s Alpha smallsat constellation will be designed, engineered and manufactured. Working with a range of partners, Fleet Space Technologies will help local companies in neighbouring industries like defence, communications and precision engineering enter the space supply chain and harness local robotics and automation expertise. Fleet Space is currently enjoying a period of rapid growth and global expansion. In February it announced that it had established
its first international HQ in Houston, Texas. The choice of Houston as an anchor location places Fleet Space at the heart of the world’s leading government space agency NASA, following collaboration between Fleet and NASA on the Artemis manned missions to the moon planned for 2024. “The technology we have developed has the potential to provide worldwide connectivity to multiple industries,” said Flavia Tata Nardini, CEO and Co-Founderof Fleet Space. “This is reflected in our global ambition and commitment to the United States as the first phase of our international expansion. We have built strong links in the US through our work with NASA’s Artemis Mission and we look forward on building on these foundations in the world’s fastest growing space market.” www.fleetspace.com
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Transforming SA into a powerhouse in plant protein manufacturing South Australia is set to be home of the largest pulse protein ingredient manufacturing capability in Australia, thanks to a $113m funding package from the Federal Government that will deliver thousands of new jobs for the state and supercharge Australia’s place in the global plant-based food value chain. The Federal Government has announced support for a project led by Australian Plant Proteins (APP) under the Collaboration Stream of the $1.3bn Modern Manufacturing Initiative to transform local production of pulse protein ingredients and help meet the growing global demand. APP owns Australia’s only commercial-scale pulse protein extraction facility. This project will quadruple production in South Australia, to produce 25,000 tonnes of pulse protein yearly. Partnering together with one of Australia’s largest family-owned food producers, Thomas Foods International and the Australian Milling Group, more than $378m will be invested in the construction of three plant protein manufacturing facilities supplying domestic and international markets. South Australia produces over a quarter of all Australian pulses and this project gives Australia the opportunity to value-add by up to eight times the value of the product. That value will be captured here in Australia for Australians benefit. Locally based plant protein ingredient and food manufacturing will create a new high valueadded domestic supply option for pulse growers which will in turn have downstream benefits to local communities. The South Australian Government has also contributed $65m to the $378m project. Minister for Finance and Senator for South Australia Simon Birmingham said this investment was a win for jobs, a win for SA’s pulse farmers and it would take our state’s manufacturing capabilities to a whole new level. “This investment by Government along with the private sector will put SA ahead of the pack in the manufacturing of products for the high-growth domestic and booming global plant-based foods market,” Birmingham said. “It is a major step forward in transforming South Australia into a plant-based protein manufacturing and export powerhouse. “It will not only generate thousands of local jobs but has the potential to generate billions in export dollars for our state. Demand for plant-based foods is booming globally. Just as SA leads Australia in renewable energy generation this investment will put us at the forefront of capitalising on this environmental trend too.” Minister for Industry, Energy and Emissions Reduction Angus Taylor said projects such as this would help spur further private investment to help our manufactures scale up. “Manufacturing is strong in this country and we want to see it become even stronger,” said Taylor. “Australian made food products with Australian produced and manufactured ingredients will give our food manufacturers a significant advantage in this rapidly expanding global market. “These investments are about increasing the productivity growth and job creation that we know collaboration can deliver. We also know that for every manufacturing job we create, at least another three are generated in other industries thanks the multiplier effect that our investments have on the broader economy.” Premier Steven Marshall said the announcement would create a large-scale plant-based food & beverage value chain for South Australia and unlocks an entirely new export industry for the state, and the nation. “South Australia is already world-renowned for our premium food and produce and we now have a first mover opportunity to capitalise on the emerging global demand for plant protein-based food,”
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Marshall said. “You need a strong economy to be able to invest in hospitals, schools and roads and you can trust my Government to build a stronger future for all South Australians. “Under the State Liberal Government, we have the fastest growing economy in the nation, allowing us to invest in hospitals, schools and public services which have driven us to be independently recognised as the most liveable place in the nation, and third most liveable in the world. Today’s announcement is all about creating more jobs, opening the door for more South Australian exports and making sure we create a stronger future for our kids and grandkids.” The project is expected to create up to 1345 construction jobs and 384 new direct manufacturing jobs by 2024 and eventually support more than 8,500 new full-time positions in the supply chain and economy by 2034. It is also expected to generate up to $4bn in exports by 2032, including to the US, south-east Asia and Europe. www.approteins.com.au
Real Business Real People Real Members Apart from any financial benefit what other reason is there to be a member of AMTIL? The world is getting smaller and globalisation provides an abundance of opportunities and threats. AMTIL provides us with tools and support to stay connected and collaborate with businesses who are driven to harness the opportunities and counteract the threats together, and retain a strong manufacturing footprint here in Australia. Erika Hughes, Integra Systems
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
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Three ways manufacturing CFOs can achieve ROI from ERP systems Gone are the days in manufacturing where the chief financial officer (CFO) was predominantly responsible for the back-office or accounting function. In today’s dynamic world, the CFO is a strategic navigator, responsible for steering the business through uncharted waters and mapping a direction for the future. A big part of this role is the enablement of digital delivery models. By Jaco Maritz, COO at SYSPRO. 2. Measuring the success of diversification of business models
According to the 2021 SYSPRO CFO 4.0 survey, 57% of manufacturing CFOs agree that proficiency and knowledge to create an effective plan to operationalise and transition the business into a digitalised and automated manufacturer is the most critical factor globally. The “CFO 4.0” will need to understand emerging technologies and the impact that digital transformation will have on the business.
The pandemic pressured businesses into thinking ‘out of the box’ to thrive. According to the SYSPRO CFO 4.0 study, moving forward, 65% of businesses stated that they will look at diversifying businesses to drive profit and improved revenues, 29% plan to innovate with a new product line, and 39% plan to invest in e-commerce as a new route to market. While these strategies sound good on paper, the CFO expects to see the ROI from such costly investments. There is no guarantee that introducing a new product to the market or investing in a new e-commerce platform will bring in tangible ROI.
The role of the CFO 4.0 is also not only about supporting the business to make the right technology investments. The CFO plays a critical part in building measurable shortterm and long-term plans that address the ongoing supply chain disruptions impacting efficiencies and revenue growth. Here enterprise resource planning (ERP) is often regarded the digital backbone in that journey. As a single source of data, ERP provides full visibility into the full operations of the business. With data insights, the CFO can plan and make the right investments for the greater good of the business. ERP also allows the CFO to measure the impact of those plans to determine what is working, and what is not working and make the necessary adjustments. Here are three ways the CFO can garner return on investment (ROI) from their ERP system.
1. Enabling agile sourcing and procurement The manufacturing CFO has the difficult job of balancing expenditure with the operational need for agile and responsive sourcing and procurement. With ongoing supply chain disruptions, many businesses have struggled to collaborate with their supplier base in real-time and many were left with no choice but to revisit strategies on the sourcing of raw materials, subassemblies and finished products.
and deductions. ERP also mitigates purchasing risks, improves governance and maintains negotiated agreements, while enabling the purchase of products and services at the best value-to-price ratio. One of SYSPRO’s Australian customers is AF Gason, which designs and manufactures world-class broadacre farm machinery as well as industrial and woodheating products. The company’s Industrial Services Division provides technical solutions for commercial and industrial applications across multiple sectors. AF Gason distributes and supports all its products via an extensive dealer network across Australia and New Zealand.
On top of that, many manufacturing businesses have still relied on manual, paper-based systems to complete monthend tasks, which further impacts on sourcing and procurement processes.
AF Gason uses SYSPRO as its enterprise system across the entire length of its supply chain to provide a single source of the truth. The SYSPRO ERP system records everything on the manufacturing side of the business from shopfloor recording to shopfloor data, job management, traceability, procurement and inventory management. It also covers all finance functions such as sales processing and invoicing, payables, receivables and cash management.
ERP can also assist with improved sourcing and procurement by fostering improved supplier collaboration, ensuring demand accuracy and even the ability to manage global pricing requirements, while minimising the costs and effort associated with the administration of trade promotions
“We’ve had 100% improvement in our results over the past couple of years,” says Leon Nash, CFO at AF Gason. “And a great deal is related to being able to use the information out of SYSPRO to give us better decision-making capability in the business.”
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Here ERP can help by providing measurable data around areas such as Material Requirements Planning to purchase orders, inventory management, inventory control and lot serial tracking. It can also provide further success factors such as the ability to communicate effectively with staff and allocate accountability. Besides having clear objectives at the start of a pivot, the CFO should also have a clear understanding of the business case and focus efforts in the areas of the business with the greatest pain points to manage spend and ultimately generate revenue.
Proactively managing business risks When asked about top business risks for 2022, unsurprisingly, 40% of the CFOs within the SYSPRO study highlighted the management of rising inventory costs as a top concern, while 35% pointed to the management of local and global supply chains. As CFOs take up more strategic roles within the business, the reduction of these risks is key, along with the critical need to budget for capital expenditure and to forecast the requisite cash requirements. Ultimately, ERP is an essential tool as the manufacturing CFO role makes a shift. As the saying goes, the whole is greater than the sum if its parts, and ERP can at least give the CFO a heads-up around what to plan for and how to pivot in a time of continued volatility. www.syspro.com
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Scheduling and supplier management in a changing world The implementation of specialist software can integrate all key business data, meaning your sales team no longer need to bother the schedulers or planners when a new order comes in. Joe Wrightman, Managing Director at ECI Software Solutions, discusses the streamlining of your scheduling processes and the performance gains this can bring. All schedulers or planners who are reliant on disjointed spreadsheets or manual processes will be well aware of the daily challenges this brings. Interruptions and constant questioning around order lead time and capacity are often accepted as the norm, but it doesn’t need to be this way. Combine this with the supplier issues that the industry is currently facing and the process of scheduling, planning and effectively managing orders becomes a near impossible task. Whether you’ve outgrown a legacy system or you’re finally saying goodbye to manual processes, there’s a number of benefits specialist technology, such as an enterprise resource planning (ERP) system, can bring. Since the announcement of the $1.5bn Modern Manufacturing Strategy back in October 2020, the Government has been supporting Australian manufacturers to scale up, innovate and access new markets. As Angus Taylor MP, Minister for Industry, Energy and Emissions Reduction, wrote: “Manufacturing is transforming rapidly around the globe and Australia is no exception”. New technologies are being deployed and more innovative methods of production being trialled, helping to improve overall service delivery. No matter the size or nature of your manufacturing business, the decision to implement new technology should not be taken lightly and it’s important to conduct a thorough analysis of what’s working, the processes that need to be improved and your wider business aims.
Integrating every department Even when managing complex projects that include multiple phases, manufacturers need to be able to give customers accurate cost estimates. Keeping costs low and cycles short, and – of course – delivering the product on time need to be a top priority. Those reliant on disparate systems will struggle to streamline this process, finding themselves constantly chasing a paper-trail or having to speak to other departments to source key information. The implementation of a specialist ERP, designed to provide a single source of truth, can integrate all key business data, meaning that your sales team no longer need to bother the schedulers or planners
when a new order comes in. Once a piece of information is entered into an ERP system, it’s stored on the central system and can be accessed by any department that might need it. Not only does this increase data accuracy and minimise the chance of duplication, it will help the entire business run more smoothly.
Improved visibility With full visibility, sales representatives can effectively calculate the number of days it will take to fulfil a certain order, instantly adding any new orders into the ever-evolving planning schedule. Should a customer then call to amend the order or ask for an update, this information can immediately be processed on relayed. In such a competitive marketplace, this will help improve customer satisfaction and enable future growth. Customer and project data can also be entered as soon as the order is placed. This data can then progress through all phases of the project. Eliminating the need for this data to be re-entered at each stage will not only save you time and speed up the process, it will also reduce the chance of error.
Performance gains It seems obvious, but not hitting promised delivery dates can damage a business’s reputation and undermine your efforts in producing quality materials. It all comes down to managing expectations. Solutions such as ECI M1 can enhance scheduling functionality by helping you stay ahead
“No matter the size or nature of your manufacturing business, the decision to implement new technology should not be taken lightly and it’s important to conduct a thorough analysis of what’s working, the processes that need to be improved and your wider business aims.” of any changes in your scheduling and the impact these changes might have on delivery dates. Of course, delays are sometimes unavoidable – especially given the ongoing global supply chain crisis. The earlier you can communicate any delays to a customer, the better. With enhanced analytics, you can also provide a reliable estimate of the new end date and manage their expectations accordingly. An ERP will significantly reduce the administrative burden associated with processing orders, helping to keep jobs on time. By only having to enter information once and not having to transfer pieces of paper physically between departments, hours of administration will be saved in the early stages of the job. Similarly, the ability to analyse production standards at each stage will help managers identify bottlenecks and inefficiencies. In order to successfully navigate the challenges manufacturers are currently facing, and ensure profitability long-term, your scheduling and planning department needs to be running as efficiently as possible. At ECI, we are seeing an increasing number of manufacturers considering specialist software, such as ERP systems, to help navigate these challenges, drive performance improvements and increase overall revenue. www.ecisolutions.com
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Managing pricing complexity in uncertain times Uncertain global conditions and supply chain shortages are creating significant challenges for Australian businesses. Articifial intelligence (AI) can help businesses manage while also meeting business objectives. By Haley Glasgow. In 2022, wildly fluctuating material availability and exchange rates are making it impossible for Australian businesses to do the basics – price their products correctly – putting strain on operations or customer relations as they either absorb the costs or pass them on to the buyer. While this situation is unlikely to ease soon, government and industry are nonetheless looking towards economic recovery. For example, in February the Federal Government announced that it’s investing $2.2m into research in the manufacturing sector. This is a step in the right direction. But in the meantime, manufacturers need to address market volatility to mitigate the risk of further business closures. Margins are eroding, and the legacy way of doing things is no longer fast enough to stay competitive. Today’s manufacturers need to fast-track e-commerce channels to overcome competition from imports and online sources. Leveraging technologies such as artificial intelligence to inform pricing strategies is one way to help achieve that. Let’s take a look at how AI can inform and accelerate the sales cycle while providing customers with the customised and efficient sales process that they demand.
Adapting a dynamic pricing strategy The digital economy has evolved much faster than predicted. B2B buyer expectations have shifted, non-traditional competitors have entered the market, and costs are constantly fluctuating. B2B businesses need better visibility into market dynamics so that they can react quickly, in real time, and at scale to protect margin. Manual methods no longer suffice when it comes to setting and updating pricing, as they struggle to keep pace with the volume and logistic complexities associated with the manufacturing sector. Instead, manufacturers need to adopt a digital mindset and embrace AI-based price optimisation and management. Pricing fast and smart is crucial to a company’s success in business. By implementing a dynamic pricing strategy, B2B companies can set flexible prices for products or services that incorporate realtime market conditions, capacity, input costs and competitive perspectives. It also offers price consistency and greater accuracy, giving sales teams the confidence to execute sales without the fear of making mistakes, or remove the guesswork out of negotiations (e.g. underselling); one of the largest sources of profit leakage. Dynamic pricing isn’t just for big business either. It doesn’t require undertaking an overly costly or complex digital transformation project that lasts for years. While there is no one-size-fits all approach to adopting dynamic pricing, smart price optimisation and management software, businesses can pinpoint sources of revenue and margin changes using real-time data and personalisation.
Driving maximum value for customers With the shift to digital and self-serve channels, B2B buyers demand an efficient online experience and quick quote response rate. According to Gartner, 96% of customers who had a higheffort experience reported being disloyal, compared to only 9% of customers with low-effort experience. Many are also seeking personalised recommendations to obtain more value from manufacturers. According to Hanover research, more than half (53%) of respondents said they would pay as much as 5% more for personalised recommendations – a staggering premium for purchasing teams who are usually incentivised to find the deepest discounts. The way manufacturers price a product has a knock-on effect to the customer experience. This is especially true in the current market where supply chain shortages are heavily impacting pricing and material availability.
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Configuring pricing using traditional methods in response to market disruption can cause pricing to fluctuate dramatically without cause, resulting in confusion or alienating customers. By leveraging dynamic pricing, manufacturers can predict how the market might fluctuate over the course of a year, and set prices accordingly to account for those fluctuations and provide consistency. For example, a leading dairy manufacturer based in New Zealand was faced with widespread supply chain disruption and increased market volatility as a result of the COVID-19 pandemic. Due to having a dynamic pricing solution, the manufacturer was able to better set contract prices for their buyers while managing risk and keeping margins intact. By transforming its end-to-end buying and selling processes, the manufacturer can proactively pursue sales and margin opportunities. This is an important aspect to alleviate long-term pressure caused by the COVID-19 pandemic.
Looking ahead As supply chain disruption and exchange rate fluctuations continue, manufacturers need to look for every opportunity to maintain a competitive edge and protect against the next market event. The pandemic perpetuated this need, but now it’s inflation and next it could be deflation – there will always be factors impacting the markets, and in turn, pricing and margins. For manufacturers feeling the squeeze, dynamic pricing can relive pressure. Now is the time to embrace innovative tools like AI-driven dynamic pricing, to help manage pricing complexity and improve the buying experience for customers. Haley Glasgow is Head of Strategic Consulting & Alliances – APAC at PROS. www.pros.com
SOFTWARE
The intelligent edge to win in industrial AI More and more businesses are adopting artificial intelligence in their processes, but with this shift come significant challenges. By Adi Pendyala and Lawrence Ng “Innovation distinguishes between a leader and a follower,” pronounced Steve Jobs. In 2019, Accenture conducted a global survey with 1,500 C-level executives across 16 industries, titled ‘Scaling to new heights of competitiveness’. The majority of top managers strongly agreed that leveraging artificial intelligence (AI) is necessary to achieve their growth objectives, while acknowledging that scaling AI at the enterprise level is a real challenge. Scaling AI means that diverse teams, departments and individuals across the enterprise realise the value of AI and utilise it in their work processes to achieve efficiency and business advantages. The volume and rate of data accumulation, especially for capitalintensive industries, increases exponentially, as more devices become internet-enabled each year. This generates rising demand for data storage and computing resources. According to Flexera’s 2021 State of the Cloud report, the COVID-19 pandemic has accelerated cloud plans and spend, with more organisations leveraging public cloud services, private ones, or hybrid models. But many enterprises are still not running their applications in the cloud and face challenges relating to response latency; data security; data management; cyber regulatory compliance; implementation costs; retaining employee knowledge; as well as inference at the edge. The first critical decision is how to transfer data and the cost of doing so. Response latency is seen as a constraint or an obstacle. For any business, it is important to consider whether the benefit of achieving lower latencies is greater than the cost of acquiring the necessary network bandwidth. Another challenge is the increased cyberattack surface. More businesses are shifting confidential information to the cloud, and data breaches targeting cloud-based infrastructures increased by 50% from 2019 compared to 2018, according to Verizon. Moving data out of the plant increases the number of potential cyberattack vectors. Data breaches can be caused by a simple misconfiguration or internal insider threats, and can be hard to avoid when part of the IT infrastructure is outsourced to a third-party business. Ensuring data security in this dynamic environment is crucial. Digital sovereignty – the level of control over the data, hardware, and software that a company relies on to operate – is another challenge. Operational sovereignty provides customers with assurances that those working for a cloud provider cannot compromise a customer’s workload. Software sovereignty ensures that the customer can control the availability of its workloads and run them without being dependent on or locked into a single cloud provider. Moreover, data sovereignty provides customers with a mechanism to prevent the cloud provider from accessing their data, designating access only for specific purposes. The real challenge for organisations is trusting those managing their cloud services, especially when sensitive data could circulate in the hands of multiple third-party businesses. Cyber-regulatory compliance has its own complexity; making sure that compliance programs evolve with cloud deployment, infrastructure, environments, and applications, and that various cloud services and applications are configured securely. Data movement from the plant to the cloud service, especially when it is owned and operated by a third-party business, may violate regulatory compliances. Organisations that have a multi-cloud strategy can benefit from what is called Cloud Security Posture Management (CSPM) as it becomes difficult to ensure that various cloud services and applications are securely configured.
The next concern is around the cost of cloud-centric implementations. According to the International Data Services (IDC) report, annual public cloud spending will hit $500bn by 2023. There is a growing awareness of the long-term cost implications of the cloud, and several companies are taking the dramatic step of repatriating parts of their workloads or adopting a hybrid approach to alleviate the costs. This shift is driven by an incredibly powerful value proposition – infrastructure available immediately, at exactly the scale needed by the business – driving efficiencies both in operations and economics for enterprises.
Adi Pendyala
Lawrence Ng
A critical challenge is to retain experienced employees’ knowledge as a key strategic resource before they retire or after a merger or acquisition occurs. One of the solutions is to automate workflows and processes at the edge. Utilising such automation, along with incorporating AI and machine learning (ML) techniques, can track and store the critical knowhow of key employees, and retain, improve, and share the knowledge with new recruits. Finally, instead of streaming process data from the plant edge into the cloud for running inference models, the application (including the trained model) could be shipped to an edge execution environment. Actionable responses and insights could be quickly communicated to the human stakeholders. This mechanism would reduce costs in terms of time, network bandwidth, storage capacity, loss of independence, security and privacy caused by centralised cloud storage and computing. In the current state of Internet of Things (IoT) devices, edge computing reflects as intelligently collecting, aggregating and analysing IoT data via cloud services deployed close to IoT devices (i.e. at the edge) based on the business needs of the application. The future of edge computing is complementary to cloud capabilities. The cloud will not be replaced by the edge. The duality of these two paradigms promotes an infrastructure risk distribution between the offshore facility (manufacture) and its data centre. This will provide uninterrupted real-time actionable responses on the edge. The cloud will execute less critical tasks such as model training, retraining, and sustainment as well as monitoring. This hybrid combination will optimise uptimes while minimising the risk of unseen issues. To achieve this intelligent edge vision, it is necessary to leverage today’s edge computing technology in an optimal and scalable way to deliver high-value intellectual property (IP) in an intelligent edge solution. For example, the Aspen AIoT Hub provides access to data at scale, whether in the enterprise, the plant, or the edge, providing comprehensive AI pipeline workflows to embed AI in Aspen Models for both engineers and data scientists. Indeed, change is mission-critical. As the famous quote goes: “If you always do what you always did, you will always get what you always got.” Adi Pendyala is a Senior Director and Lawrence Ng is VicePresident – APJ at Aspen Technology. www.aspentech.com
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Harnessing the value of data: calculating KPIs According to a 2021 report by Fictiv, 91% of manufacturers have increased digital transformation investments over the past year. Companies are more aware of the data their facilities produce — but do they know how to use it? Johan Jonzon, CMO and co-founder of Crosser, explores how manufacturers can calculate key performance indicators (KPIs) using edge analytics to make the most of their data. The message is clear: to be successful in a turbulent market, manufacturers must digitalise. However, collecting data alone isn’t enough. To gain true value from digitalisation, manufacturers must analyse the data collected. They can do this by calculating KPIs, which are measurable metrics that help businesses focus on what’s important. KPIs can track and analyse equipment performance to identify inefficiencies and improve future process runs.
Overall equipment effectiveness Arguably the most fundamental KPI to calculate, and therefore the best place to begin, is overall equipment effectiveness (OEE), which measures an asset’s level of productivity. Some KPIs can be a single measurement, but OEE is actually a combination of multiple measurements. It’s essentially three KPIs in one: availability (A), performance (P) and quality (Q). A × P × Q = OEE Availability reflects how long a machine operates out of the total available time. For instance, a machine may have been expected to run continuously for eight hours per day, but in fact only operated for one hour. Thus availability would be one divided by eight, with the result being 0.125. Availability = Run time ÷ Planned production time Now we have how long the machine performed for, we can work out how well it performed while it was active — the performance part of the OEE equation. A machine’s performance is measured by the number of units it produced within a given time against the optimal number of units it should be able to produce. Performance = Number of units produced ÷ Optimal number of units The final part of the OEE equation, quality, measures the machine’s yield, which is the ratio of products produced that can actually be used without requiring rework or being scrapped. Quality = Adequate products ÷ Total products
Enter edge analytics While calculating equations for KPIs such as OEE may seem straightforward, applying them to the plethora of data generated by machines can be a complicated process. Edge analytics serves as a powerful tool to both collect and analyse data from all pieces of equipment and generate KPIs in real time. Calculating KPIs at the edge allows rapid results, as the analysis is performed close to the source of the data. The real-time KPI values generated at the edge can be used to trigger quick action when anomalous behavior is detected. This helps manufacturers to rapidly overcome areas of inefficiency, such as a faulty machine, to ensure productivity is constantly optimised. Alternatively, the data can be sent to on-premise or cloud systems for direct visualisation and/or storage for trend analysis. It’s important to select an edge analytics platform that is low code to make creating data flows for calculating KPIs as straightforward as possible. For instance, the Crosser low code edge analytics platform has a selection of pre-built modules that can be arranged using a simple drag and drop function — removing the need for
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complex code. Within the Crosser Flow Studio there are also a library of pre-designed data flows (templates) called FlowApps. These FlowApps enable even faster implementation of analytics and KPIs like OEE and others. The platform was designed with simplicity in mind, and its intuitive nature empowers employees across the organisation to be able to work on the platform, without the need for extensive coding experience.
An intuitive system The prebuilt modules can easily be arranged to gather information from data, providing a shortcut to working out KPIs. For instance, a scheduler module can be used to outline when KPI measurements should be active, such as by defining shift hours. The module will generate a ‘start’ message at the beginning of the active period and a ‘stop’ message at the end of it. A message counter module, as the name implies, can count messages received within a given time period. The module can count the total number of messages delivered over the time period, and also how many messages were received for each value of a specified property. For instance, for calculating the quality part of the OEE equation, the module can record how many messages were received reporting an adequate or faulty part. These values could also be used to calculate other KPIs, such as scrap rate. In contrast, a time counter module measures the time a machine has spent in different states by looking at a specific signal such as ‘machine stopped’ or ‘machine running’, measured over a time period. At the end of the time period, the recorded signals are used to calculate the relative time spent in each state. The COVID-19 pandemic has highlighted the importance of productive and flexible processes, causing manufacturers to increase investment in digitalisation. However, to truly transform processes, manufacturers must extract value from the data being collected by calculating KPIs. A low code edge analytics platform can simplify applying many different equations to a whirlwind of data, providing a shortcut to ultimate efficiency and adaptability. www.crosser.io
WORKHOLDING
New Lang Modular Plates offer improved ergonomics and quicker installation Lang Technik’s Quick-Point zero-point clamping system has established itself as the benchmark for direct clamping of workpieces and fixtures offering improved productivity and maximum flexibility. As an interface between the machine table and clamping device, Quick-Point is characterised by an enormous range of variations and high repeatability. The system provides a solution for just about every application and can be used universally in vertical, horizontal and five-axis machining centres. Quick-Point clamping studs connect the zero-point system and Lang workholding devices. They can be also mounted directly to a workpiece in order to clamp it directly without a workholding device. With an actuation torque of 30 Nm (60 Nm for four-fold grid plates) holding forces of up to 6,000kg can be achieved. Due to a very small number of wear-free parts the system is reliable and virtually maintenance free. One of the key benefits of Lang’s QuickPoint zero-point clamping system is that it allows for a one-time installation. Once the base plate is mounted and aligned to the machine tool table and the zero point is defined, workpieces and fixtures can be built quickly and accurately. “The zero-point system provides a huge boost to productivity, reducing typical changeover times from 1-2 hours to just several minutes,” says Matthew Williams, General Manager of Dimac Tooling, Lang Technik’s agents for Australia and New Zealand. Now Lang Technik has added another dose of productivity with its latest development: Quick-Point Modular Plates. Previous plates operated on a combination of an Allen key and Hex nuts, so the operator needed different tools. The previous system also had a screw for each individual vice. The new Modular system features a single screw for the plate enabling the operator to lock down multiple vices at a time. The new system also uses just a single hex nut – further speeding up the installation process.
“You no longer have to awkwardly lean over to locate the back screw or rotate the plate to clamp to reach the other side,” Williams adds. “The Modular system takes a large step forward in terms of ergonomics and speed coupled with high repeatability.” Over the years the Lang Technik has been responsible for numerous workholding innovations that reduce costly changeover time, reduce operator workload and maximise productivity. “These new products reinforce Lang Technik’s reputation as the worldwide leader in design and development of workholding solutions for almost any clamping requirement from raw material to the finished workpiece,” Williams concludes. “Because all Lang products come from the one place, they are perfectly matched and interfacing problems with other systems do not exist. The modular building system and the multitude of combinations and capabilities are the reason that their workholding systems can be used in almost any machining centre.” www.dimac.com.au
Under pressure – Power clamping spindles from JAKOB The MSP and MSPD power clamping spindles from JAKOB offer the ability to clamp the largest and heaviest workpieces with ease. Workpieces up to approximately 50cm are usually mechanically and manually clamped with three- or four-jaw chucks, or automatically by pneumatic or hydraulic equipment. If, however, the workpieces to be machined are larger, then planar disks are used, which can also hold much larger parts safely on site with jaw boxes and tensioning spindles. As a user, you have the choice between seven standard thread sizes from TR 50 to TR 200, with which, due to the proven principle of force multiplication by means of wedge clamping systems, clamping forces of up to 500kN can be achieved. In addition, selflocking is achieved in each tensioning position as well as a high degree of stiffness. The power clamping spindles are equipped with an internal switchover to switch between external and internal clamping. The MSP / MSPD power clamping spindles from JAKOB Antriebstechnik offer very high clamping forces, a large clamping range and easy operation and assembly. This ensures maximum operational safety. In order to guarantee this permanently, JAKOB recommends (depending on the frequency of the clamping cycles) a regular inspection of the spindles once or twice a year. JAKOB’s force measuring systems, such as the hydraulic, autarkic force transducer HMD, are particularly simple. The intelligent clamping
claw FMS even allows a constant clamping force control during the machining of the workpieces. The determined data can be transmitted wirelessly directly to a handheld display device or PC. If the clamping forces deviate from the stated nominal values by approximately 25% to 30%, an overhaul is recommended. Maintenance can be carried out directly by JAKOB. Alternatively, JAKOB also offers training courses to certify participants as operating or maintenance personnel. This means that installation and maintenance can be carried out in the company;s own operation in the future. www.jakob-gruppe.de
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What Victoria’s new environment protection law means for OHS The new Victorian Environment Protection Act enacted last July, has changed how Victoria regulates pollution, waste and contamination from businesses. The Australian Institute of Health & Safety explains. Victoria’s new Environment Protection Act 2017, which came into force on July 2021, is the biggest change in environment protection legislation since the original Environment Protection Act 1970, according to health & safety, environment and emergency management consultancy Greencap. The new Act has enhanced powers to prevent risks to the environment and human health, with a change of focus from responding to pollution (or “cleaning up after a spill”) to preventing the pollution in the first place, said Jean Meaklim, Senior Principal Consultant with Greencap. “It is based on similar principles to the Occupational Health & Safety (OHS) Act, where a person or business has to assess their business activities for risks to health and the environment, put in place safeguards to prevent or manage the risks before they happen, and provide training and supervision to staff to work with the safeguards to protect health and the environment,” said Meaklim, who presented on Victoria’s new environment protection legislation together with Peter Oxnam, Greencap principal consultant – environment, as part of an Australian Institute of Health & Safety (AIHS) webinar held in February. General Environmental Duty: Criminally enforceable The General Environmental Duty (GED) is a centrepiece of the new laws and Meaklim said it applies to all Victorians. “If you conduct activities that pose a risk to human health and the environment, you must understand those risks, and you must also take reasonably practicable steps to eliminate or minimise them,” said Meaklim. “In an Australian first, the GED is criminally enforceable.” The GED is similar to the duty under the Victorian Occupational Health & Safety Act 2004 Section 21, where employers have a duty to provide and maintain a working environment that is safe and without risks to health, whereas the GED requires risk assessment, mitigation and training to maintain workplaces that are safe to health and the environment. “The Environment Protection Authority (EPA) said they will support businesses that have taken reasonable steps to understand and meet their obligations under the Act. They will also support businesses that must make major changes to their compliance obligations,” said Meaklim. However, for those who haven’t attempted to understand or follow the new laws, Meaklim said the EPA will act to ensure obligations are met. “The EPA can now issue stronger sanctions and penalties to hold environmental polluters to account,” she said. Another new concept is the ‘state of knowledge’, which Meaklim says is all the information businesses should reasonably know about managing your business’ risks, including an understanding of risks your business may pose to human health and the environment, and steps you should take to eliminate or reduce those risks. This includes information from the EPA; other relevant government departments (such as WorkSafe), business and industry associations, and independent organisations like Standards Australia and universities. “The state of knowledge can change over time, as different ways of working develop, and new risks emerge,” said Meaklim. “There are
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also changes to some of the licensing provisions, with some new businesses now requiring a license or registration.”
Reviewing business activities There are a number of implications for OHS professionals to be aware of, depending on the type and scale of the industry they work in. However, Meaklim said all industry sectors should review their business activities and identify any that may impact the environment. For example, chemical use or storage, air emissions or waste management should ensure these activities are managed to prevent or minimise risks to health and the environment, and companies should document risk assessment and mitigation actions so that there is evidence, should it be required. “Consulting EPA industry guidance is a great starting point for a business seeking assistance in managing their environmental risks,” said Meaklim. The webinar focused on: • • • • • • • • • • •
The General Environmental Duty (new Overarching duty that applies to all) Other Duties Identifying, assessing & managing environmental risks Pollution incidents Noise, vibration, sediment control, erosion and dust Other impacts of pollution and waste Contaminated land Waste framework Waste classification – Industrial Waste Waste: contaminated soils Requirements for staff training and continuous monitoring The Environment Protection Amendment Act 2017 (the Act) focusses on prevention. The general environmental duty (GED) is central to the new Act and applies to all Victorians. You must reduce the risk of any activities which may harm the environment or human health through pollution or waste. The Act makes sure the public can access more environmental information. This means EPA can help you better understand the state of the environment and how regulatory decisions are made. The Act contains a greater range of penalties. It allows for review of decisions and encourages broader participation in decision-making. Courts will be able to order offenders to repay profits resulting from prior illegal activity. They can also order offenders to take part in a community project. www.epa.vic.gov.au
The Australian Institute of Health & Safety is the national association representing the health and safety profession. It works to build the capability of the profession and to provide health and safety people a voice on policy, legislation, regulation and standards. For more information on Victoria’s new Environment Protection Act 2017, please call (03) 8336 1995 or email communications@aihs.org.au www.aihs.org.au
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Seven important safety actions SMEs should implement before returning to travel Businesses are starting to plan their travel for 2022, however as the pandemic continues and new variants emerge, travel will remain a complex, yet doable business activity. Tom Walley explains. Despite promising vaccination rates, the threat of the pandemic remains. Therefore pre-planning and risk assessment to prioritise traveller safety and minimise disruptions must be a greater priority for businesses before resuming travel. These comments come amid the recent release of the international ISO 31030 Travel Risk Management standard which was developed to offer guidance to organisations on how to manage risks as a result of undertaking travel. Travel management companies such as Corporate Traveller have worked with businesses over the last 18 months on risk mitigation strategies to ensure they can continue travelling. The new Standard formalises these strategies and ensures businesses can implement them independently and easily, providing the protection needed in the event of COVID infection or other health and safety issues during travel. Organisations would be wise to review the new Standard, as it provides a foundation for them to reduce potential health, safety and security risks during every step of the travel journey. Certification is also beneficial to businesses and their employees as it can increase employee confidence to return to travel.
Seven must-have safety protocols 1. Establish pre-travel authorisations. Organisations would be wise to establish pre-approvals and booking procedures to provide better visibility over travel. This can include developing a mandatory booking process that clearly outlines the booking channels that can be used for all forms of travel, transport, and accommodation, as well as the senior leaders tasked with approving travel. It would also stipulate the approval process required to book travel outside official channels. A centralised system is recommended, such as a platform developed specifically for the organisation. 2. Conduct a travel risk assessment prior to planning and booking travel. This allows businesses to identify, analyse, and evaluate security threats and health and safety hazards that could occur during travel. Such assessments can be conducted on a company’s behalf or businesses can perform them independently. Business would first assess potential risks and likelihood of them occurring. These could range from personnel risk, including injury or illness, legal risk, financial risk, and data risk, including breaches in data and confidentiality. To analyse such risks, organisations can seek expert advice or source information from local government agencies and embassies, along with location-specific crime statistics. 3. Assess and approve accommodation and transportation based on health, safety, and security risks. Organisations need to consider these when determining approved accommodation for travellers. The Standard outlines how organisations can assess accommodation options. The same applies to transportation. 4. Source relevant, reliable, and up-to-date information and advice for travelling employees. Organisations that travel
regularly can consider onboarding a travel management company, which is equipped with innovative technology and expert teams that can source and provide information to businesses and travellers in real-time. They can also change itineraries before and during travel based on changing circumstances and increased risk to ensure travellers remain safe. 5. Perform pre-and-post-travel checks on all travelling employees. Pre-travel checks can assess whether an employee is medically fit to travel. Checks should consider pre-existing health conditions and ensure procedures such as testing, vaccinations and quarantine are adhered to prior to travel. Post-travel checks are also important. 6. Track travellers for peace of mind. The Standard outlines three methods organisations can consider to track travellers: itinerary based, expenses based, or technology based. However, tracking travellers should only be used to ensure their safety and give businesses peace of mind, particularly when travelling to a high-risk location. Itinerary-based tracking relates to the collation of booking information, from transportation to accommodation, to identify where travellers will be, and when, throughout their journey. This method keeps organisations informed and allows travellers to check-in with managers at agreed points in the journey for added peace of mind, while still maintaining privacy. Organisations could use a system that tracks an employee’s expenses, which can indicate where the traveller has been as well as ensure travel budgets are adhered to. Technology-based tracking involves using a device or specific app on the employee’s phone which can monitor and record movements, allowing organisations to view their precise location. 7. Evaluate the travel program through employee surveys. Businesses can conduct employee surveys to identify any gaps and areas of improvement needed in their travel program. The surveys assess all areas of the travel program, including the support and information provided before and during travel, the booking process, and the overall travel experience. The survey could ask for specific feedback, particularly regarding health and safety, to ensure travel remains seamless and safe for all employees.” Tom Walley is the General Manager at Corporate Traveller, Australia’s biggest travel management company for SMEs and a division of Flight Centre Travel Group. Established in 1993 as Flight Centre Travel Group’s first corporate brand, Corporate Traveller has offered its personalised service, expert tailored advice, dedicated travel consultants, and advanced booking technology to more than 6500 Australian business customers. Offering an all-in-one innovative booking platform with the support of a personal travel consultant, Corporate Traveller makes travel simpler, faster, and easier for businesses. www.corporatetraveller.com.au
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It all depends on the written contract David McLaughlin explains the importance of using the correct Contract terms when hiring employees or contractors, and that the correct type of Contract is in place. Australian businesses can engage labour either as direct employees or through contracting arrangements. Two recent decisions handed down by the High Court of Australia have confirmed the importance of using the correct contractual terms when hiring employees or engaging contractors. The decisions, both handed down by the High Court on 9 February 2022, confirm the previous decision delivered by the Court in the Workpac v Rossato [2021] HCA 23 (Rossato) decision last year. The decisions in all three cases give precedence to the terms of the written contract to determine the nature of the relationship between the parties. This article will provide an overview of the cases and what employers should consider when engaging labour. In the Rossato case mentioned above, the Court was concerned with determining whether an established employment relationship was permanent employment or casual employment. The two other decisions which followed, ZG Operations Australia Pty Ltd v Jamsek [2022] HCA 2 (Jamsek) and CFMMEU v Personnel Contracting Pty Ltd [2022] HCA 1 (Personnel Contracting), dealt with the question of whether individual workers were employees or independent contractors. In the case of Jamsek, two drivers were originally employees of the business. In 1986, in a decision instigated by the employer, the drivers ceased to be employees and established partnerships with their respective spouses. Each partnership then entered into a written contract to provide a truck and driver to perform delivery work for the previous employer. The decision handed down by the Full Court of the Federal Court held that they were employees based on the "substance and reality" of the relationship. However, the High Court held that was wrong and cited its own previous decision in Personnel Contracting, referring to the following points: •
While there may be cases where the rights and duties of the parties are not found exclusively within a written contract, this was not such a case.
•
Where the terms or the parties' relationship are comprehensively committed to a written contract, there is no reason why the legal rights and obligations so established should not be decisive of the character of the relationship.
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The employment relationship with which the common law is concerned must be a legal relationship. It is not a social or psychological concept like friendship. There is nothing artificial about limiting the consideration of legal relationships to legal concepts such as rights and duties.
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There is nothing of concern to the law that would require treating the relationship between the parties as affected by circumstances, facts, or occurrences that otherwise have no bearing upon legal rights.
Ultimately in the Jamsek case, the Court determined on the wording of the contracts that the partnerships were contracted parties with the principal business, and the individuals were not employees. Not all aspects of the decision were clear cut. The question of whether the individuals could fit within the expanded definition of "employee" for the purposes of the superannuation guarantee legislation was referred back to the Federal Court as it had not been determined by the Full Court in its decision. The High Court
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considered the Australian Taxation Office should be given an opportunity to participate in such proceedings. In the case of Personnel Contracting, the High Court determined that, despite the individual being labelled as a contractor, the terms of the contract were such that the individual was an employee. It was determined that the written contract gave the company the right to control the individual's work tasks and execute them. The individual was a labourer and Personnel Consulting was a labourhire firm that provided labourers to building companies. While the contract designated the individual to be a contractor, the Court noted the following points: •
Uncertainty if a relationship is one of employment may sometimes be unavoidable. It is the task of the courts to promote certainty with respect to a relationship of such fundamental importance, especially where both parties have taken legitimate steps to avoid uncertainty in their relationship.
•
The parties' legitimate freedom to agree upon the rights and duties which constitute their relationship should not be misunderstood. It does not extend to attaching a "label" to describe their relationship, which is inconsistent with the rights and duties otherwise set forth.
Lessons for employers As highlighted by these decisions, it is absolute that a written contract between an employer and employee, or principal and contractor is fundamental to establishing the nature of the relationship between both parties. It is clear that the label given to the relationship by the parties will not be the only factor to determine the relationship if other aspects of the written contract contradict that label. Finally, it is essential to remember that the Fair Work Act prohibits sham contracting (not alleged in either of these proceedings). An example of this would be if an employer suddenly and unexpectedly converts all production employees to be independent contractors. For employers, it is integral to consider the type of work that you require, how it can best be performed and ensure the business has the correct type of contract in place. Rigby Cooke's Workplace Relations team can assist businesses with reviewing current and future employment contracts or contractor agreements to ensure they align with business requirements. David McLaughlin Partner – Workplace Relations +61 3 9321 7838 dmclaughlin@rigbycooke.com.au www.rigbycooke.com.au
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Greater Insights – Better Business Jeremy Raniti and Samantha Zebrowski share their insights into what they consider are the five key pillars to a business’ survival and success as we slowly return to a semblance of normal life post-pandemic. As we see the landscape of Australia slowly returning to one which somewhat resembles life before the pandemic, we’ve been quickly reminded that natural disasters, financial uncertainties, and global politics are unpredictable but always have an impact on business. These ever-changing times, combined with the risks, fears and disruptions it brings is a constant reminder that as managers and business owners, we must be agile in our movements and at one with the core of our business. In this article, we apply our experiences from dealing with a vast array of clients to share our thoughts on what are undoubtedly the five key pillars to a business’ survival and success.
1. Prices are changing, fast. Raw materials, freight, insurance and even coffee. 2021 ended, and 2022 started with a similar discussion amongst all Australians: prices are changing, fast. The disruptions to a business’ supply chain, the ‘out-of-action/isolating’ workforce, and the everchanging landscape of doing business have added to inflation at an unexpected pace. It has now become imperative to have a great awareness of the cost required to do business and make informed decisions based on this information. This is not only possible by having the information readily available to you, but also having the right people in the room to interpret the data, crunch the numbers and provide sound financial and business advice.
2. Reporting - Daily feed Routine is everything. By the time we arrive at work, we’ve checked the news, listened to the radio, and if we’re in the mood for it, read a couple of emails. Thanks to the advances of cloud accounting, reporting has become easier, quicker and more relevant than ever. It is therefore a logical extension of this, that purposeful reporting be part of all business’ daily routine. Purposeful reporting is just that, built for the purposes of its user to provided purposeful results. It is also the result of business owner and advisor working in tandem to understand what is important and what it all means.
3. Cash is important We’ve all become familiar with the term ‘cash is king’, but what businesses often overlook is the assessment of how much available cash is required to keep the lights on, the doors open, and staff employed. It is an exercise worth its weight in gold, and one that requires business owners, managers, and their advisors to sit down and work out what are their non-negotiable fixed costs. From here, the plan should be to formulate a strategy to determine what the ‘rainy day’ cash balance should be, and how to build up this cash reserve in a predetermined time frame. This ‘rainy day’ cash reserve will serve as a first stop lifeline in the event an unforeseen incident brings everything to a standstill.
4. People are just as important In our ever-changing environment, our people are often one of our only constants. With talks of the great resignation, it is more important than ever to listen to our people. However, it’s more than that. Do we take on board their ideas? Are we sharing success stories and celebrating their achievements? Hopefully we’ve implemented a strategy to help reduce leave liabilities, keep up with work demand and encouraged our people to enjoy some time away from the workplace. It is also important to review employment contracts against the awards/EBA/market and regularly provide feedback to enable continuous learning. We have found that when we take care of our people, they will take care of our business.
5. Tax, the worst surprise Tax is a daunting word. A word that too many business owners don’t fully understand, appreciate, or plan for, and as accountants, we can understand exactly why. The ATO and SROs have increased their activity in all facets of tax. There are the regular updates to existing tax legislation, regular reporting of new taxes on the horizon, and the annual Federal Government Budget announcements which at times take months and sometimes years to enact. In addition to federal taxes, business owners are having to navigate their way through state taxes including Payroll Tax and Land Tax. To effectively manage these taxes, whilst also being confident your business is compliant with legislation, it is only right that as business owners, you are actively engaging with your advisors to gain greater insights as to the pipeline of financial obligations, taking advantage of proposed changes and ensuring compliance is being met on time. By doing this, you start the deliberate process of better understanding how it all works and remove the headache of the worst surprise. These five key pillars to a business’ survival and success largely revolve around the notion that with greater insights we will have better business outcomes. We appreciate that running a business whilst also becoming experts in these fields is a timely investment, highlighting the value of a strong relationship between Business Owners and Advisors. If you would like to know more about the impact these pillars could have on your business, please contact your local William Buck advisor for a complimentary consultation. Co-authored by Jeremy Raniti, Manager and Samantha Zebrowski, Senior Manager, from the Business Advisory Division at William Buck. William Buck is a leading firm of accountants and advisors. www.williambuck.com ph: 03 9824 8555
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Exhibitions and Events Back on Track It is great to see a number of trade shows back in action and the response from visitors has certainly shown they are ready to get back to some sense of normality, getting out of the business environment and visiting the events. We are very excited to be bringing to the industry the Australian Manufacturing Week in Sydney from 7-10 June. The exhibition floor is fully sold out, with 166 exhibitors ready to showcase their products and services. Pre-registration has opened and is ahead of where we expect numbers to be, so we are really looking forward to a great show. Since 2000, AMTIL has operated Austech alongside National Manufacturing Week and this newly branded show is the culmination of both of these events rolling in to one Mega show. We have not operated Austech in Sydney since 2012 so it is great to see so many machine tool suppliers supporting our return to Darling Harbour. You can register to attend by going to www.australianmanufacturingweek. com.au There are plenty of reasons to visit Australian Manufacturing week: •
Be a witness and a part of technological evolution.
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Be the first to experience innovative technologies, latest machinery.
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Meet and network with the innovators and trendsetting individuals who spearhead this technological revolution.
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Interact with peers and share ideas.
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Gain firsthand exposure to the companies who are at the forefront of technological excellence.
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See all the key industry brands all in one place at the same time
Admission is free to trade personnel. On a sad note we have lost the services of William Poole, with Will deciding to move on with a new career opportunity recently. I would like to publicly thank Will for his 10 years of service in the role of Editor. He did an outstanding job and has received many good wishes from our members that I am sure he values greatly. One door closes and another one opens. So please join me in welcoming Paul Hellard to the AMTIL team in the role as Editor. Paul is an experienced Editor with over 20 years in the field. His skills in researching, writing, editing and formatting will see him do well in this role. He has also had many years of experience both local and overseas in media technology which may well open doors for us in the digital space, which is a fast growing area for us. Paul started with us on 28th March. Please make sure you give him a good AMTIL welcome when you see him. Hopefully I will bump into a lot of my industry friends on the floor of Australian Manufacturing Week in June. See you then.
Shane Infanti, CEO AMTIL
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AMTIL HEADING INSIDE
Maximise Your Membership – Mark your diaries AMTIL has set the dates for the latest in its Maximise Your Membership series of social and networking events, which will take place around the country in July and August. Maximise Your Membership events will be held in New South Wales, Queensland, South Australia, Western Australia and Victoria. These events will offer an opportunity to learn about AMTIL’s latest activities and initiatives, as well as to make connections with colleagues from across the industry. Event details are as follows: New South Wales Tuesday 19 July; 6.00pm-9.00pm Verandah Bar and Restaurant 60 Castlereagh Street, Sydney Queensland Wednesday 20 July; 6.00pm-9.00pm Hyatt Regency Brisbane 72 Queen Street, Brisbane South Australia Tuesday 26 July; 6.00pm-9.00pm 2WK Bar 20 Peel Street, Adelaide Western Australia Wednesday 27 July; 6.00pm-9.00pm Santini Bar & Grill 133 Murray Street (#level 1) Perth Victoria Wednesday 3 August; 6.00pm-9.00pm The Boatbuilders Yard 23 South Wharf Promenade, Melbourne
All of these events are free to AMTIL members, with a $45 admission fee for non-members. Finger food and drinks will be served at all events. All attendees at any AMTIL events must be fully vaccinated against COVID-19. On arrival, please follow the directions of venue staff, check in using the COVID-19 app and present your vaccination status. Appropriate measures are being implemented at all AMTIL events to ensure
they are conducted safely. Moreover, AMTIL may be forced to make changes to scheduled events at short notice – anyone planning to attend should always register in advance and be on the lookout for updates from AMTIL. To book your place at any of AMTIL’s upcoming events, please visit the Events page on the AMTIL website. For more information, email events@amtil.com.au 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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Celebrating a decade of AMTIL membership The AMTIL team had great pleasure in presenting AMTIL 10-year membership plaques to several companies in Melbourne over the last week. 1
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1. The crew at DNA Engineering were pleased to accept their 10-year membership plaque inbetween jobs. 2. The small team from Hounslow Engineering accepted their plaque in Bayswater. 3. Richard and Sue Ladley, the husband-andwife team at Industrial Laser Pty Ltd. 4. Paul Hughes, MD & CEO of Integra Systems was happy to display his AMTIL 10-year membership plaque. 5. David Waddell from Waddell Engineering accepted the plaque. Their company has been turning out precision CNC dies for the brass forging industry for over 20 years.
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New Members AMTIL would like to welcome the following companies who have signed up as new members of our association.
3M AUSTRALIA
KSA TECH CONSULTING
MICROSCOPY AUSTRALIA
Dock 4, 137 McCredie Road GUILFORD NSW 2161
2 Refshauge Crescent MACGREGOR ACT 2615
University of Sydney SYDNEY NSW 2006
www.3m.com
www.onebusinesserp.com
https://micro.org.au
HOBSON ENGINEERING
MACHINERYPLUS
PRECISE BUSINESS SOLUTIONS
10 Clay Place EASTERN CREEK NSW 2766
2/15 Meares Way CANNING VALE WA 6155
1/116 Hobart Street MT HAWTHORN WA 6016
www.hobson.com.au
www.machineryplus.com.au
www.precisebusiness.com
INNOFOCUS PHOTONICS TECHNOLOGY
MFB PRODUCTS
585 Burwood Road HAWTHORN VIC 3122
105 Lewis Road WANTIRNA SOUTH VIC 3152
www.innofocus.com.au
www.mfb.com.au
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REAP THE BENEFITS OF AMTIL MEMBERSHIP Contact us to learn more www.amtil.com.au
AMTIL FOOTY TIPPING 2022
AMTIL INSIDE
AUTOMATE
AMTIL PRODUCT E-BLASTS
1800 465 348 www.romheld.com.au
GOAL1000!
Boom!…and just like that we have a new member to 1000 goal club. Lance 'Buddy' Franklin pumped through his 1000th goal on Friday night as the hoardes streamed onto the SCG – the scene took me back to yester-year when our national game was for the people and not for those who sit behind the glass – it's called progress me thinks? Welcome to all to AMTIL's Footy Tipping for season 2022, there are some familiar names and some newbies all kicking and scratching for the other notable 1000 ie $1000! It's been a steady start for the tipsters with two breaking away on 14 and a big group ready to pounce all separated on points. Football-wise, there are some surprises in the Top 8, coupled with flag favourite the 'Mighty Dees' letting everyone know they look like the team to beat for the flag – tthe wo other contenders, Doggies and Port are yet to open their accounts, but of course it's early days yet. Till next time… Sanchez 14 (29) 14 (63) 13 (16) 13 (36) 13 (38) 13 (38) 13 (38) 13 (38) 12 (16) 12 (24)
TARGETED CONTACTS
18.86% OPEN RATES
12.26% CLICK THRUS 0PEN II0T
STATISTICAL REPORTING Call Nicholas Raftopoulos to learn more on 0431 753 381 or email nic@amtil.com.au for all enquiries.
Still looking for a reason to integrate IIoT into your operations? Look no further than the cost efficiencies you can realise! Open IIoT has all the info you need to get started. Learn more by scanning the QR code
www.amtil.com.au
1510AMTIL
ROUND 2 1 Raff - (Parish Eng) 2 GHXST 3 Colesy! 4 Nick Sear 5 Saint Schmick 6 Julie Lovemore 7 Optimisticagain 8 Mab eng 9 murf56 10 Saints21-23
IT’S ALL IN THE NUMBERS 9OOO
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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 MACH UK, Birmingham 4-8 April 2022
HANNOVER MESSE Germany, Hannover 30 May-2 June 2022
MAKTEK EURASIA Turkey, Istanbul 26 September-1 October 2022
www.machexhibition.com
www.hannovermesse.de/en
www.maktekfuari.com/en
3D PRINT CONGRESS France, Lyon 5-7 April 2022
METEF Italy, Bologna 9-11 June 2022
STAINLESS STEEL WORLD The Netherlands, Maastricht 27-29 September 2022
www.3dprint-exhibition.com
www.metef.com
www.stainless-steel-world-event.com
TORNITURA Italy, Bergamo 7-9 April 2022
FABTECH CANADA Canada, Toronto 14–16 June 2022
MICRONORA France, Besancon 27-30 September 2022
www.tornitura.show
https://canada.fabtechexpo.com
www.micronora.com
CCMT CHINA China, Shanghai 11-15 April 2022
TUBE Germany, Dusseldorf 20-24 June 2022
ALUMINIUM Germany, Dusseldorf 27-29 September 2022
www.ccmtshow.com
www.tube.de
www.aluminium-exhibition.com
ATX WEST USA, Anaheim 12-14 April 2022
LASYS Germany, Stuttgart 21-23 June 2022
www.atxwest.com
www.messe-stuttgart.de/lasys
SAUDI FASTENER & MACHINE TOOLS EXPO Saudi Arabia, Riyadh 2-5 October 2022
FABTECH Mexico, Monterrey 3-5 May 2022
M-TECH Japan, Tokyo 22-24 June 2022
https://mexico.fabtechexpo.com
www.japan-mfg.jp
INTERTOOL Austria, Wels 10-13 May 2022
MANUFACTURING EXPO Thailand, Bangkok 22-25 June 2022
www.intertool.at
www.assemblytechexpo.com
PLASTIC JAPAN Japan, Osaka 11-13 May 2022
METALTECH Malaysia, Kuala Lumpur 22-25 June 2022
www.plas.jp/en
www.metaltech.com.my
METAL SHOW & TIB Romania, Bucharest 11-14 May 2022
SMART FACTORY South Korea, Seoul 24 June 2022
www.metalshow-tib.ro
www.smartfactorykorea.com
TOLEXPO France, Paris 17-20 May 2022
ALUMINIUM CHINA China, Shanghai 6-8 July 2022
www.global-industrie.com/en/tolexpo
www.aluminiumchina.com
INTERMACH/MTA ASIA Thailand, Bangkok 18-21 May 2022
MANUFACTURING SURABAYA Indonesia, Surabaya 13-16 July 2022
www.intermachshow.com
www.manufacturingsurabaya.com
TECH INDUSTRY 2022 Latvia, Riga 19-21 May 2022
EXPOMAC Brazil, Curitiba 16-19 August 2022
www.techindustry.lv
www.expomac.com.br
SIMTOS South Korea, Seoul 23-27 May 2022
MMMM India, New Delhi 25-27 August 2022
www.simtos.org
www.mmmm-expo.com
PM CHINA China, Shanghai 23-25 May 2022
IMTS USA, Chicago 12-17 September 2022
http://en.pmexchina.com
https://www.imts.com
AMT APR 2022
www.fabxsaudi.com/saudi-fastners
WELDING BRNO Czech Republic, Brno 4-7 October 2022 www.bvv.cz/welding
MOTEK Germany, Stuttgart 4-7 October 2022 www.motek-messe.de
BI-MU Italy, Milan 12-15 October 2022 www.bimu.it
IMT Taiwan 19-21 October 2022 www.imttaiwan.com
EUROBLECH 2022 Germany, Hanover 25-28 October 2022 www.euroblech.com
ATX Canada, Montreal 9-10 November 2022 www.admmontreal.com/en
TUBE INDIA India, Mumbai 23-25 November 2022 www.tube-india.com
METEC INDIA India, Maharashtra 23-25 November 2022 www.metec-india.com
INDUSTRY CALENDAR HEADING LOCAL AUSTRALIAN AUTOMOTIVE AFTERMARKET MELBOURNE, MCEC 7-9 APRIL 2022 The latest vehicle repair, servicing equipment, replacement parts, tools and accessories. www.autoaftermarketexpo.com.au
DESIGNBUILD MELBOURNE, MCEC 10-12 MAY 2022 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
AUSMEDTECH MELBOURNE CONVENTION CENTRE 24-26 MAY 2022 Held by AusBiotech, Australia’s premier medical technology conference - brings together the Australian and international devices and diagnostics sector. www.ausmedtech.com.au
WORKPLACE HEALTH & SAFETY SHOW MELBOURNE, MCEC 25-26 MAY 2022 Bringing together the world’s best practice in workplace health and safety
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 Products and sustainable solutions to collect, process and recycle waste efficiently. www.awre.com.au
MEGATRANS2022 MELBOURNE, MCEC 24-26 AUGUST 2022 Freight and logistics industry. Co-located with Australian Bulk Handling Expo 2022. Showcasing the latest in artificial Intelligence (AI), robotics, automated racking, telematics and route optimisation, warehouse automation, intelligent fleet systems. www.megatrans.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 Planned to be one of the largest manufacturing and technologu exhibitions of its type in the Southern Hemisphere, AMTIL is excited to be bringing this to the Australian manufacturing sector. AMW/ Austech will also run in its usual timeslot in Melbourne from 9-12 May 2023 at the Melbourne Convention and Exhibition Centre.
www.whsshow.com.au
FOODTECH GOLD COAST CONVENTION & EXHIBITION CENTRE 7-8 JULY 2022 The latest advancements in food and beverage manufacturing, plus a new conference stream and networking events. www.foodtechqld.com.au
www.amtil.com.au/Austech
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118
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 48
STILL CONVINCING AN ALLY PART 2
WW2: Laurence is still in the US meeting its top brass in order to change its perception that offering Lend Lease war materiel to Australia would be a waste. Steel shell cases are now under discussion. Warfare in the tropics is new to America, but not to Australia. Will America listen to the advice Australia offers based on our experience in the tropics? Laurence overcomes fierce resistance and prevails.
A
ustralia had the reputation in America of being young, eager and falling over itself to try anything. Lend-Lease (US) was concerned that we might lack the know-how to make full use of the equipment we asked for. And it was very difficult to change their minds. America was very new to the war and was almost completely without experience of the type of war she would be fighting in the tropics. We had been forced to learn the hard way, and some of our developments in machine-tool operations, which enabled us to get the maximum output from our existing equipment, were news to them. Most of their objections were based on misconceptions of Australia and the problems of war in the Pacific. Our request for machine-tools to increase output of shells and small-arms ammunition provided a typical example of their wrong thinking. One of the top Lend-Lease officials, a man named Carpenter told me flatly, "You're wasting your time and effort out there on a lot of things. You talk glibly about making all these shells and ammunition for a variety of guns, but we know you can't do it: you haven't got any copper. And without copper how can you make brass for the shell-cases?" ''But we have copper - plenty of it,'' I protested. ''In the early days of the war, when we could see a copper shortage coming, we brought in about three thousand tons. We've got more since, and now there's a very good stockpile of it.'' (It was through the wisdom of Sir Colin Fraser that we had stockpiled copper and as Director of Materials he had told me all about it.) Carpenter wouldn't buy that one. He sat there in disbelief. He obviously thought I was lying. Frantically I cabled Australia: "Please tell them we have plenty of copper." But I got very poor support from Australia, and I couldn't convince them on my own. I kept at it, though in later meetings, and there was a bit of a thaw in their attitude. Then they came up with an offer. "Look, Mr. Hartnett," Carpenter said. "We can't accept your facts about copper, but we'll let you have some equipment if you'll agree to make your ammunition cases out of steel. We've perfected excellent steel cases and we are very happy with them." Pointedly, he added: "They are a baby of Bill Knudsen, who, as you know, was
Inspecting anti-aircraft shell cases in a munitions factory at GHM Woodville Plant, South Australia, 1942.(State Library, SA)
president of Chevrolet in your time and a good manufacturing man.'' "Well, I'm not happy about steel cases not for warfare in the tropics," I told them. "In New Guinea we're fighting in a very humid climate. A film of rust grows on steel overnight. I know you can coat the steel with preventives, but you 'II probably get jammed shell-cases and all kinds of troubles. In that climate and terrain I think steel shell-cases would be useless." To hell with Bill Knudsen and his pet schemes! I wasn't going to let his GM connections throw me. Steel shells were out! The Americans thought otherwise. And so we were at a dead end. That evening in a Washington club, I met one of the most extraordinary characters I have come across: a debonair young Colonel in the British Army named Gosling. He was a Regular Army officer, the King's Gunner - one of those odd roles the British sometimes give to an expert. Gosling - he was known to everyone in Washington as "The Goose"- was in the U.S. on a liaison job. We started talking guns, and I mentioned the trouble I was having. He agreed with me that steel shell-cases would be useless in the tropics. There was to be a full dress meeting with Army Ordnance and
Lend-Lease the next day, and "The Goose" offered to go with me as technical adviser. He was a wonderful help. When the subject of steel shell-cases was brought up he said: ''If you gentlemen are so confident about steel ammunition why don't you give it a go yourself in the tropics?" "We've tested the shells here in the U.S. Fired thousands of rounds. There's no trouble with them," they said. "Fine," said The Goose , “but you try serving steel ammunition up to your troops. If those fellows in the tropics, say it's good, then we'll have another look. In the meantime, you can understand our reluctance to be the guinea-pigs.'' He said all this in high good humour, and he brought a good atmosphere to the discussion. The Americans agreed to have another look at the steel cases. Two days later we met again. They had checked my story about stocks of copper in Australia and found it was perfectly true. They appreciated our reluctance to try the steel shells in the tropics and they'd help us get most of the equipment we wanted for guns and brass shell-case production. I think the happy chance of meeting "The Goose" gave us success with that negotiation.
This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.
AMT APR 2022
To be continued…
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