NZ Manufacturer July 2015 by Media Hawkes Bay Limited

July 2015

www.nzmanufacturer.co.nz

EDITORIAL Outsourced work coming back from China.

VIEW 31 REAR The evolution of the NZ

SOUTHMACH 2015 PREVIEW

Steel Industry.

AutoMATE 7-Axis robotic machining cell – On show at SouthMACH 2015 The largest Nachi robot ever sold in New Zealand will be on show at SouthMACH later this month - in the form of a 7-axis robotic machining centre from NZ based robotic machinery builder AutoMATE™. Design Energy Limited, owners of the AutoMATE™ brand and NZ distributor for Nachi Robotics, have developed a robot machining centre based on the newly released Nachi SRA210 six axis robot. This particular system, for customer Cutting Innovations in Auckland, is equipped with a 7.5kW 24,000rpm HSK tool-change spindle, rotary table and PowerMILL CAM

software. The result is a system offering a machining envelope of 2.5m x 2.5m x 2.5m with +/-0.25mm accuracy. Mike Shatford, Director of Design Energy explains: “AutoMATE™ machining centres are highly adaptable, with robot and fixturing options available to suit a wide variety of machining requirements. The high level engineering used to develop each system structural loading of each machine is carefully analysed using FEA analysis. Providing high levels of rigidity and stiffness are key to successfully carrying out machining operations using a multi-axis robot.”

The team at Design Energy are already considering producing further machining cells of various

configurations and would be keen to hear from interested parties. Contact:info@designenergy.co.nz

Business returning from China benefits local manufacturers Nationwide FIFA infrastructure build welcome challenge for Kiwi IT firm It’s no easy task to deliver IT services for an international event on the scale of the FIFA U-20 World Cup New Zealand 2015, but it was a task that local company Origin was confident it could achieve to the highest international standards. The Auckland-headquartered company won the 22-day tournament tender over one of the biggest IT companies in New Zealand thanks to their “innovative approach, focus on customer experience, and technical excellence”, says Origin CEO Michael Russell. With the contract calling for planning and project management;

delivery and installation services; IT communications, cabling, wifi, power, backup, hardware and wireless supply; and onsite support services at stadiums as well as remote helpdesk support for all technology services, it was a “huge and quite unique” project, says Origin project manager Matt Sellar. “While these are all services Origin already offers, many of our processes had to be adapted,” says Sellar. “Also, because specifics were still being worked through between FIFA and the LOC (Local Organising Committee), we quoted the project based on the best information we had at the time, but as

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Specialist high tech manufacturers are benefiting from a steady stream of local businesses bringing their outsourced work back from Asia, to New Zealand. Wiring loom manufacturer Fero is one of several businesses that are gaining custom from local companies that have found it harder than originally anticipated to get their componentry manufactured in China. Sam Fulton, Sales and Marketing Director for high tech wiring loom manufacturer Fero, says many returnees had not taken into account the true cost of doing business in China: “It is easy to be beguiled by what on the surface appears to be a low price, but buying at the cheapest price always comes at a cost”.

costs by compromising the quality of the raw materials in their product. For example, copper wire costs are reduced by using recycled copper, which does not perform to specified standards. This can result in quality problems and high mitigation costs once the component is in use. “It’s a very different way of doing business to New Zealand, so it is easy for local manufacturers to get stung. That is why it is important to shift one’s thinking from unit-based to taking into account the overall cost of doing

continued on page 10

“You get what you pay for in China so if the price too good to be true, then it is. Many Chinese manufacturers reduce Sam Fulton, Sales and Marketing Director, Fero.

METALS NZ CONFERENCE STEEL INNOVATIONS CONFERENCE METALS INDUSTRY EXHIBITION

METALS INDUSTRY ASSOCIATIONS’ MEETINGS NETWORKING EVENING INDUSTRY AWARDS GALA DINNER VISIT WWW.METALSWEEK.CO.NZ / EMAIL EVENTS@METALS.ORG.NZ

NZ Manufacturer July 2015

CONTENTS DEPARTMENTS 4 EDITORIAL

Larry Wiechern

Outsourced work coming back from Asia.

Is the Manager of the Maintenance and Reliability Centre, Manukau Institute of Technology.

5 EXPORT NEWS

Exporting to India and the Middle East. Dean Viljoen, CEO of Colour Communications Inc.

MANUFACTURING TECHNOLOGY

ADVISORS

PowerFlex 527 AC optimised in Studio 5000 software. PowerMILL webinar now online. Craig Carlyle

3D sand printing ‘steels’ show at GIFA. NZ demographic trends leading to manufacturing skills. 3D printed hovercraft used Inventor 2013.

10 ANALYSIS

Business returning from China benefits local manufacturers.

Catherine Beard

Defining Hi-Tech Manufacturing – Does it Matter?

12 SOUTHMACH 2015 PREVIEW

Leussink Engineering new Faro distributor.

Is Director of Maintenance Transformations Ltd, an executive member of the Maintenance Engineering Societyand the Event Director of the NationalMaintenance Engineering Conference.

Is Executive Director of Export NZ and Manufacturing, divisions of Business NZ, NewZealand’s largest business advocacy group, representing businesses of all sizes.

Jerico Walker Sheetmetal install Ermaksan 220T- 7 Axis Pressbrake.

19 DEVELOPMENTS

GMP Dairy to develop Chinese market further. Brian Willoughby

New emission targets achievable.

20 WORKSHOP TOOLS

EIS partner with mega company in safety systems. Safer driving with engineering know-how.

Is Senior Vice President of the NZ Manufacturers and Exporters Association and Managing Director of Contex Engineers and Plinius Audio.

The wave of future energy. HyAccess extended consumables available for more systems.

Lewis Woodward

Is Managing Director of Connection Technologies Ltd, Wellington and is passionate about industry supporting NZ based companies, which in turn builds local expertise and knowledge, and provides education and employment for future generations.

22 FOOD MANUFACTURING

US market offers huge potential for NZ wines.

FUTURE OF MANUFACTURNG\ 24 THE Where to for IoT? The Future of Productivity and Growth in Manufacturing Industries. Top 10 emerging technologies of 2015.

MAINTENANCE Engineers require de-icing at Waikato network evening. Maintenance supervisors can boost productivity?

29 ANALYSIS 30 DEVELOPMENTS

Become a market leader –part one.

Low-tech manufacturing, the new champion of innovation.

31 REAR VIEW

The Evolution of the NZ Steel Industry.

Dr Wolfgang Scholz

Is HERA Director and a Fellow of the Institute of Professional Engineers NZ.

30 Bruce Goldsworthy

An advocate for NZ manufacturing for 40 years, he was Chief Executive of the Auckland Manufacturers Association for seven years He has been Manager of EMA’s Advocacy and Manufacturing Services, and lately manager for Export New Zealand in the north.

NZ Manufacturer July 2015

EDITORIAL Outsourced work coming back from Asia

PUBLISHER

Media Hawke’s Bay Ltd,1/121 Russell Street North, Hastings, New Zealand 4122.

MANAGING EDITOR

“It is easy to be beguiled by what on the surface appears to be a low price, but buying at the cheapest price always comes at a cost”.

all the innovation and growth that is created in other parts of the sector, just because they do not fit a specific definition.

Holly Green, Kevin Mckillop, Dieter Adam, Katalin Csikasz, Stephen Broadbent, Troy Coyle

“You get what you pay for in China so if the price too good to be true, then it is”.

By the way, high-tech manufacturers are defined as those who spend more than 8% of revenue on R & D.

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Although its manufacturing is still cheap by New Zealand standards, rising labour and other costs are seeing China become more expensive to do business with. Its manufacturers are off-setting these costs through economies of scale. As a result, minimum run sizes are increasing beyond the reach of many New Zealand manufacturers

As we know, the current dairy business climate is both challenging and promising, because regulations on infant formula are still very sticky and unclear. There is some good news…

Doug Green T: +64 6 870 9029 E: publisher@xtra.co.nz

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Vol.6 No. 6 July 2015 Copyright: NZ Manufacturer is copyright and may not be reproduced in whole or in part without the written permission of the publisher. Neither editorial opinions expressed, nor facts stated in the advertisements, are necessarily agreed to by the editor or publisher of NZ Manufacturer and, whilst all efforts are made to ensure accuracy, no responsibility will be taken by the publishers for inaccurate information, or for any consequences of reliance on this information. NZ Manufacturer welcomes your contributions which may not necessarily be used because of the philosophy of the publication.

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For every $1 of value added in manufacturing, $1.4 of additional value is created elsewhere in the economy, and every job in manufacturing generates between two and three jobs in the rest of the economy. Money brought in by both high-tech manufacturers and those in the sub sectors. As far as categorising hi-tech manufacturers. Dieter Adam, Chief Executive of the New Zealand Manufacturers and Exporters Association, believes there are many businesses that should be considered high-tech due to their complex and innovative processes and products, but are not captured by the current definition. Hi-tech manufacturing is considered the way to go for growth and innovation in the country. However there is considerable high value-added activity happening across the spectrum of manufacturing businesses.

Evergrande Group’s investment into GMP Dairy Limited’s business has given the company more opportunities. GMP Dairy is currently working on four to six new productions mainly in their adult milk powder range. The key markets for the products lay in Japan, Singapore, Russia, Korea, Hong Kong, Taiwan, and China. The Middle East and South East Asia are seen growth markets. GMP has put together a new team to focus on research and development for consumers in these countries. And finally, all the best for exhibitors at SouthMACH 2015. The show with its keynote speakers and manufacturing expertise on display promises to be a real display case for South Island manufacturers and businesses to visit as they re evaluate their company’s direction and ‘push’ into enhancing their manufacturing expertise and efficiencies.

Dieter Adam believes that focussing only on what is defined as high-tech can lead to missing or undervaluing

Doug Green ASIA

MANUFACTURING NEWS

www.nzmanufacturer.co.nz

NZ Manufacturer July 2015

When everything seems to be going against you, remember that the airplane takes off against the wind, not with it.

EXPORT NEWS

- Henry Ford

Exporting to India and the Middle East The Middle East and India present many attractive opportunities for exporters, but you would do well to hear about these regions in detail before attempting to enter their markets. Dean Viljoen, CEO of Color Communications Inc., has agreed to share his experience with us. India: pace yourself When we see India on a map, we tend to underestimate how truly immense the country is. Therefore, it is vital to target only one or two cities to begin with. Once you have, select the companies you wish to do business with. One of your best assets will be New Zealand Trade and Enterprise, who can help you with market research, set you up with a number of credible contacts, and accompany you to initial meetings. You can also contact the India New Zealand Business Council, which can help introduce your company to Indian business owners. Dean’s main piece of advice with India is to take your time. “You can’t think that you are going to walk into India on Monday morning, and go home on Friday with an order. It took us over eight visits to a single customer to finally get our first order. So, financially, you have to plan ahead.” Dean estimates the cost of implementing a foothold

Commercial & industrial growth

in India to anything between $30,000 and $40,000 a year.

Make the most of your time while waiting for your first order by ensuring you have the capacity to deliver. Make the most of your time while waiting for your first order by ensuring you have the capacity to deliver. “From a manufacturing point of view, any order you’re going to get is probably going to be five or six times bigger than the biggest order you’ve ever done. Make sure you are ready for it.” It is important to decide up front which currency you would like to operate in, as many Indian companies are very good at playing the currency exchange game. “The sweetness of a potentially massive order can be very tempting, and you can easily be manipulated into accepting very strange quoting and payment terms.” Therefore, it is crucial to always stick to the currency you have established from the beginning.

Finally, remember to cultivate business (and personal) connections with your customers. “Legal contracts are fine in principle. But ask yourself: how easy will it be to enforce that contract if something should go wrong?” Dean advises to rather spend time building a face-to-face relationship: “In India, this is worth more than any words on a contract.” Middle East: documentation maze Initially, dealing with the Middle East may seem much easier than India. The catch comes later, once you realise that each of the dozen Middle Eastern countries has their own documentation requirements. Documentation is critical, as it can hold up both delivery and payment. It is therefore important to make sure you have the capacity to monitor and track shipments efficiently. “The way we usually proceed is: we prepare all the documents and email them to the customer, then wait for a response to say the documentation is correct. At this point only do we ship, and then we courier the original documents to the customer. And even then, we’ve had situations where a black and white original invoice was not acceptable – it had to be colour!” Dealing with documentation is difficult enough, so you do not need a shipping

Employment growth

company that makes things harder for you. Dean’s advice: use a reputable company, preferably one that does both sea and air freight, and especially one that has offices in your destination port (as opposed to using an agent). “When something goes wrong, you need somebody on the other side to answer questions directly. You don’t want to be talking to a third party and complicate things even further.” Billing is also a complicated matter in the Middle East, due to the heavy taxation laws in place between each country. This means that, if you are dealing with a large company located in several States, ordering may be centralised, but payment will come from each individual country. The best solution here is to prepare one global quote for the company, then get purchase orders from each country. Seeing how difficult business with the Middle East can get in terms of documentation, monitoring and invoicing, it is important that you take a moment to scrutinise the way your company works. Dean believes this is a good exercise, even if you do not end up with a large exporting turnover. “When we were preparing to export

continued on page 29

Economic output

Crime rate East Tamaki is the largest industrial precinct in Auckland with 2000 businesses and a growth rate higher than the regional average. getba.org.nz

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Greater East Tamaki Business Association Inc.

NZ Manufacturer July 2015

MANUFACTURING TECHNOLOGY

For all things difficult to acquire, the intelligent man works with perseverance. - Lao Tzu

continued from page 1

Nationwide Fifa infrastructure build welcome challenge for Kiwi IT firm it progressed the amount of changes and variations were immense.” Coping with changes to the initial planning proved to be one of the key challenges for Origin, according to Sellar. “We soon realised our usual variation process was too slow. Ordinarily we may get a few variations and hardware has already been procured, but during this project we ended up with over 100 separate hardware orders totalling well over 3000 pieces - each of which had to be tracked, reported, configured if required, and delivered to a tight schedule.” The company quickly implemented some new systems to deal with the orders, using a quick email system and Onenote notebooks to confirm the variations, and collaborating on spreadsheets via a Sharepoint project site to avoid multiple copies circulating. “We also leaned on our suppliers to facilitate a build area in their warehouse where we sent our configuration engineers, which saved double freighting costs, and logistically made sense with the quantity of equipment,” explains Sellar. Adapting quickly was a key to success for the team, says Sellar, along with thoughtful recruitment and planning to work within the tight timeframes of the project. Spread across seven

cities in the space of just 22 days, the Origin team had only two weeks in each stadium prior to kick-off to install and setup everything required for full operation. That included the installation of an estimated 3000 metres of cable, and installation and management of 45,000 square inches of additional screens for press and conference areas. However, Sellar says Origin was careful to select the right people for the demanding job. “We actively chose engineers who were experienced, technically proficient, and able to work under pressure unassisted,” he says. “We then ensured we trained people at the right times, with refreshers just prior to the onsite work.” “We also decided to sub-contract the South Island venues, which saved a lot of time and effort as compared to Origin flying engineers back and forth between the islands,” Sellar adds. Extensive planning ahead of the project also smoothed the process, with six months of research and consulting taking place just to win the tender. “Training was made easier as we had collected good site information, including photos and detailed network diagrams, during the design phase. The planning work up front definitely paid off during setup.”

In working with FIFA, the company was required to meet the global giant’s “exacting standards”, says Sellar. “FIFA protect their brand very seriously. We outfitted our staff with approved uniforms, and although the network setups at the venues were temporary, great care was taken to create tidy installs, to the point of having to do quite a bit of re-work.” Origin also supplied an 0800 support number, full 24/7 helpdesk, and email support, along with the onsite technicians, throughout the tournament. As testament to the quality of design and installation, the helpdesk volume was extremely low, with just single digit calls for a nationwide network with over 1000 users and 52 matches. Sellar says the tournament proves New Zealand is more than capable of hosting large-scale events. “The only New Zealand-specific issue was connectivity from here back to the FIFA offices in Zurich. As this is nearly halfway around the world, we couldn’t provide as much bandwidth as we would have liked for the FIFA team,” he explains. “Whilst New Zealand is making good strides in general Internet connectivity with the UFB rollout, international bandwidth is always a contention.” However, the overwhelmingly positive outcome showed such things can be overcome, and the success of the project has given Origin a boost of confidence for similar future opportunities. “Successfully delivering on this gives us the confidence and belief that it can repeated,” says Sellar. “Often times it is a mindset that can make all the difference, and this project gives the Origin team a lot we can draw upon.”

PowerFlex 527 AC drive optimised in Studio 5000 software The PowerFlex 527 drive is the first AC drive designed to work exclusively with a Logix-based programmable automation controller (PAC). The drive leverages the benefits of the controller capabilities and uses a single software package – Rockwell Software Studio 5000 Logix Designer – to help simplify machine development and operation. The PowerFlex 527 drive also offers a low-cost solution for machine applications – such as pumps, fans, and in-feed and out-feed conveyors – that need simple speed control for induction motors. The servo drive handles the more precise motor control operations involving speed, torque and position control. Premier Integration allows users to seamlessly integrate PowerFlex drives into a Rockwell Automation Integrated Architecture system, reducing the time and tools necessary to configure and program a system. The PowerFlex 527 drive introduces an added level of Premier Integration by using the defined, motion instruction sets within Studio 5000 software for machine control and motor synchronization. Once programmed, drive configuration files can be more easily transferred to a new machine without painstaking, line-by-line copying. Additionally, the Allen-Bradley Logix PAC family can automatically detect a replaced drive and download all configuration settings over EtherNet/IP, helping reduce downtime.

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NZ Manufacturer July 2015

Our greatest glory is not in never falling but in rising every time we fall - Confucius

MANUFACTURING TECHNOLOGY

Delcam webinar on PowerMILL Advanced Simulation & Verification now online Delcam has made available for download its recent webinar on the Advanced Simulation & Verification module in the 2015 R2 release of the companyâ&#x20AC;&#x2122;s PowerMILL programming software for five-axis and high-speed machining.

a clearance value and, when the machine tool comes within this value, it will turn yellow in colour to highlight a near miss. The clearance distance is shown in the display so that a decision can be made on whether to keep or change the toolpath.

To download the webinar, please go to www.delcam.com/software/powermill/ webinar/index.asp

Also demonstrated are a new PowerMILL dialogue that can be used to track and adjust the position of the machine tool, and the special toolbar to simulate and adjust the configuration and tool axis of a 3+2 machine or any equipment with incremental rotary axes.

The webinar demonstrates how PowerMILL can undertake complete verification of a project for machine-tool issues such as collisions, rather than having to undertake verification of each individual toolpath in turn. Comprehensive verification is shown, including how to ensure that the machine tool is capable of running the proposed strategy, as well as methods for checking for both machine-tool collisions and tooling collisions, during cutting moves and all leads and links, including machine-tool movements as tool changes are executed. PowerMILL generates a detailed list of any problems found for the complete project so that these can be fixed on a case-by-case basis. As well as highlighting potential collisions, warnings can also be flagged for near misses. The user can specify

tool. This allows quick and easy updates to existing toolpaths with the new parameters. Warnings appear automatically in the event of machine-tool collisions or axis-limit violations. In addition, a new workplane that is aligned to the new axis and orientation can be created for subsequent programming operations. The webinar also showed how another new plug-in for PowerMILL can provide

a graph of the linear and rotary axes of the machine during the simulation. Analysis of this graph allows users to locate any potential problems, such as sudden changes in direction or axis reversals that can adversely affect the surface finish on the part. Adjusting the position of the part on the machine and running another simulation will often identify a solution to these problems.

The dialogue presents data on the position of the machine tool, together with the limits set for each axis. It includes a slider to jog the machine components into position during the simulation and displays a warning if any axis limit is exceeded. The toolbar can be used to edit the tool axis and the orientation of the machine

The Advanced Simulation & Verification module in Delcamâ&#x20AC;&#x2122;s PowerMILL provides comprehensive checks on machine-tool projects.

NZ Manufacturer July 2015

MANUFACTURING TECHNOLOGY

Nothing is impossible, the word itself says “I’m possible”! —Audrey Hepburn

3D sand printing ‘steels’ show at GIFA Callahan Innovation led a successful technology delegation to GIFA in Dusseldorf, Germany recently. GIFA is an international trade fair focusing on Casting and Foundry technologies, taking place every 4 years, this one being the lucky 13th. The objective of Callaghan’s mission was to help expose the New Zealand foundry & casting industry to new technologies, techniques and partners. The New Zealand casting industry has lost a large chunk of business over the years to offshore suppliers who compete on cost.

A national body, CTNZ (Casting Technology NZ), brings the industry together working as a collective and was a first port of call in pulling this mission together. Businesses that joined us were: A&G Price, Fraser, CWF Hamilton, Cast Components, IXOM, Precision Foundry (formally Masport), Progressive Castings, Metcast, Pyrotek and The Casting Shop. Top of the list of must-sees was the additive manufacturing space. New 3D printing equipment removes a whole step by printing sand direct to form the sandbox ready for pouring. Two major players in this space are German companies Voxeljet and ExOne – both of which had machines on display. What became apparent was that for prototyping and low-run complex profiles, this technology is on the cusp of disrupting major sections of the industry. A spare 1 million Euros will see one of these big boys in your foundry capable of 2 cubic metre

New Zealand demographic trends leading to manufacturing skills The aging of New Zealand’s manufacturing workforce, a decline in school leavers, and a shortage of skilled people continue to challenge manufacturers to find new ways to bridge their skill gaps. “We talk to manufacturers across New Zealand every week,” says Andy Bunny, National Manager General Manufacturing at manufacturing industry training organisation Competenz. “They’re all telling us the same thing: it’s hard to attract and retain skilled people.” The manufacturing workforce is aging. In 2006, 55% of the general manufacturing workforce was aged 40 and over. In 2014 that figure was 64%. The trend is similar in specialised manufacturing industries too, like plastics processing and wood manufacturing. “These are big numbers,” says Andy. “And they bring with them big challenges. These older people have built up skills during their careers. Who’s going to replace those skills when they retire? Who’s going to mentor younger people? And, if you’re a small manufacturing business, who are you going to sell your company to, so you can enjoy a comfortable retirement?” www.nzmanufacturer.co.nz

He warns employers not to rely on school leavers to plug the gaps. “The number of young people leaving school is volatile: it’s fallen strongly since 2004 and that fall’s going to continue for a few years yet. And employers across New Zealand are competing for these people.” Bringing in skilled immigrants can help, but it introduces new challenges like language and a lack of familiarity with New Zealand practices. Poaching another company’s employees is self-defeating. “It becomes a vicious circle.” The solution? According to Andy, the manufacturing sector needs to look at this issue at an industry level and invest in technical and business skills for the long term. “Training is a sustainable way to lift productivity, quality and safety. It has lots of spin-off benefits too, like increasing your employees’ confidence and loyalty. “The government subsidises workplace training to keep the costs manageable. They do this because they recognise that New Zealand industries – including manufacturing – benefit from having a skilled workforce. And those benefits are long-term and lasting.”

moulds, and could aid the return of large, complex work to New Zealand. What is uber-exciting about this technology is the design freedom it creates as complex tooling doesn’t come into the equation. It completely rewrites design for manufacture where the primary design consideration can now be design for function. Another observation from the delegation was the focus on teaching the craft of casting to the younger generation. German polytechnics teach hands-on foundry techniques, something that could very well be lost after our current generation of foundry-men retire. ABB and KUKA robotics were everywhere at the show with the heavy, dangerous, and dirty work being done by very fast and accurate robots. This included loading cores and sandboxes, cutting off gates and runners or loading castings into CNC machines for finishing.

Also exciting was the use of dry ice to clean metal surfaces. Traditionally abrasive media are used to grind surfaces, which can cause damage. Now solid CO2 can be accelerated at very high speeds to sublimate on impact and lift contaminates. As well as attending the show, Callaghan Innovation organised a meeting with VDMA (the industrial association covering the German engineering sector), and a visit to the impressive GROHE (tapware) factory. The group also got to see firsthand examples of world leading automation, LEAN and quality focused casting and manufacturing. We already know that two of the companies who joined us at the show discovered technologies that they will implement. If there was a quote from the delegation that has stuck with me it’s “the black art is being taken out of casting”. For that alone, the trip was a great success. Source: Callaghan Innovation.

NZ Manufacturer July 2015

Believe you can and you’re halfway there. —Theodore Roosevelt

3D printed HoverCraft Hovercraft’s which are also known as air-cushion vehicles or AVC can travel on over land, water, mud or ice and other surfaces. Unlike all the other vehicles we know, a Hovercraft does not touch the ground to get the lift, it uses blowers to produce a large volume of air below the hull that is slightly above atmospheric pressure. The thus generated air cushion makes the vehicle levitate in air making the journey smoother than any other vehicle.

It uses blowers to produce a large volume of air below the hull. Surprisingly the first ever reference of such vehicle was done in 1716 by a Swedish scientist Emanuel Swedenborg and the air cushion design which is symbolic to these vehicles was patented by a British shipbuilder John Isaac Thornycroft in the year 1870.

an Open Source 3D Printed Hovercraft. He designed all the parts of the hovercraft himself using the Autodesk’s Inventor 2013 software and has uploaded the same on Thingiverse. This allows anyone with a 3D printed to download the STL and create their own motorized hovercraft design. The current model of the 3D printed Hovercraft is the 3rd iteration and probably the most versatile model. In the earlier version of the Hovercraft Mr. Bürstner, experienced issues like the inability to control them outside of turning around their own axis, the inability to carry weight. The other major issue he faced was that the Vehicle was unable to recover from damages to the propeller caused by small pebbles. This was solved by adding a rubber base which could be a cycle tube attached to the base.

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Jan Bürstner, printed the HoverCraft using a MakerbotReplicator printer with 15% infill on his two-shelled parts at a speed of 75 mm/s.

If you look up on the internet you will find a lot of DIY hovercraft projects which can be made with little to no experience and believe me it’s an extremely fascinating vehicle to make.

According to him all the parts of the design takes around three days to print and use two motors while a single thrust motor helps control the direction of the craft. 2800 mAhLipo batteries are used to power the motor that runs the propeller to make the air cushion and the thrust.

Jan Bürstner is a Hovercraft enthusiast and was working on one such DIY project when he got inspired to make

The HoverCraft can also be fitted with LED lights as well as a small action camera to capture the ride.

AUCKLAND

CHRISTCHURCH

Fluke 3000 FC Series Wireless DC Clamps improve productivity New high current and 4-20 mA dc current clamps speed troubleshooting through collaboration, regardless of location Now added are two new dc current clamps to the Fluke Connect system of wireless test tools: the Fluke a3003 FC Wireless DC Current Clamp and the a3004 FC Wireless DC 4-20 mA Current Clamp. Both fully-functional current clamps can wirelessly send measurements to Fluke Connect enabled master units as well as the Fluke Connect mobile app so

users can view measurements from multiple devices simultaneously, review equipment history, and share measurements with other team members for faster troubleshooting. The a3003 FC Wireless DC Current Clamp measures up to 2000 A dc making it ideal for very high dc current measurements typically found in utility and dc machine controller applications. It features a large jaw size (64 mm) for clamping around and measuring on large, high current conductors. The a3004 FC Wireless DC 4-20mA Current Clamp measures 4 to 20 mA signals without breaking the loop so process control technicians can make accurate measurements without interrupting the workflow. It features a detachable clamp with extension cable for measurements in tight locations. www.nzmanufacturer.co.nz

NZ Manufacturer July 2015

Some people make things happen, some watch things happen, while others wonder what has happened.

ANALYSIS

- Proverb

continued from page 1

Business returning from China benefits local manufacturers business,” says Mr Fulton. Although its manufacturing is still cheap by New Zealand standards, rising labour and other costs are seeing China become more expensive to do business with. Its manufacturers are off-setting these costs through economies of scale. As a result, minimum run sizes are increasing beyond the reach of many New Zealand manufacturers.

“It is easy to be beguiled by what on the surface appears to be a low price, but buying at the cheapest price always comes at a cost”. “Even large manufacturers by New Zealand standards can be shocked to find that an order they consider huge by local standards is only a fraction of the Chinese manufacturer’s minimum,” he says. Sourcing resource materials in China is also harder than most Kiwi businesses anticipate because Chinese regulations make it surprisingly difficult to access many manufacturing materials from within that country. “Export and manufacturing licence constraints mean Chinese manufacturers are often unable to source raw materials that are readily available in other parts of the world. This causes problems for New Zealand businesses that specify product materials that their Chinese manufacturer is not able to purchase, even though the material may be made literally down the road. The New Zealand business then has to go to the hassle and expense of specifying and validating alternative parts,” says Mr Fulton. Fero, which manufactures in New Zealand and also outsources to China,

gets around this issue by importing the required resources itself, then re-exporting to its manufacturers in China. Mr Fulton says the company has set up a dual New Zealand / China manufacturing option so that it can deliver what its customers need – no matter what the timeframe, quantity or specification. The company makes wiring looms for local technology manufacturers, ranging from automotive and marine lighting, to air conditioning units, air quality sensors and aeronautical units. It is the most experienced of a small handful of wire solutions providers to integrate Chinese supply with local manufacturing, thus providing a stronger supply chain and a more comprehensive service. “We have been doing business in China for the past 12 years and have learnt what works. Rather than using an agent, we have Chinese employees here in New Zealand, who are invaluable for helping us to manage the relationship with manufacturers in China. This business model means that Fero can use its Chinese partners for its New Zealand manufacturer customers who need high volume, high labour input looms and harnesses. Alternatively, Fero can manufacture at its Auckland facilities – often at a very competitive price, and a cheaper overall cost, than could be done in China. Where possible it has automated its operations, enabling it to keep labour costs down.

“Long lead times and distance mean that specification changes to Chinese-manufactured goods can take many months to flow through the supply chain. This makes it difficult for the manufacturer to respond quickly to their own customers’ needs.”

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Mr Fulton says that although there remain many advantages to getting goods manufactured in China, it is vital to do a lot of due diligence and spend a lot of time building relationships and understanding Chinese business culture before embarking on a business arrangement.

Mr Fulton says providing a local manufacturing option is proving to be increasingly popular with New Zealand manufacturers because it enables them to be more responsive and turn changes around far faster.

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For example, if an appliance manufacturer wants to change a function such as adding a button to turn off the timer alarm, then the wiring loom will need to be updated. It can take five or six months from the time that change is notified, until the new stock arrives in New Zealand and then subsequently replaces the old stock ahead of it in the supply chain.

“It’s a high-risk game and there are no shortcuts. Many New Zealand companies are finding out the hard way just how difficult it is to resolve issues from the other side of the world, and how hard it is to prevent intellectual property and other rip-offs. This presents a lot of opportunities for Fero and other local businesses because we manage the difficulties and navigate the minefields of doing business with China, enabling our customers to benefit from the best of both worlds. “Anyone trying to do this themselves without prior experience is essentially playing Russian roulette with their business.”

Not all doom and

Grant Thornton International’s latest Business Report reveals the scale of technology’s influence on business with the majority of firms surveyed now planning to automate operations and practices. With capital costs low as labour costs rise, the findings pose fundamental questions about the extent to which machines will eventually replace humans. As businesses consider whether to invest in staff or machines, for many the latter is becoming a more cost effective option. Globally, over half (56%) of

firms surveyed told Grant Thornton they are either already automating business practices or may do over the next 12 months. By industry, 43% of manufacturing firms said they expect this to eventually replace at least 5% of their workforce. Cleantech was in second place on 39%, followed by the technology and food & beverage sectors on 35%. At the other end of the spectrum, just 9% of hospitality, education and healthcare firms expect 5% or more of workers to be replaced. However, Michael Worth, Partner, Business Transformation at Grant Thornton New Zealand says, “While there will be job losses as technology transforms both the private and public sectors, technology will also enhance the skills and capabilities of humans. Our findings suggest that workers will be able to take on new roles and

NZ Manufacturer July 2015

I can’t change the direction of the wind, but I can adjust my sails to always reach my destination.

ANALYSIS

—Jimmy Dean

Defining High-Tech Manufacturing- Does it Matter? By Dieter Adam, Chief Executive, New Zealand Manufacturers and Exporters Association I recently spent time in Wellington, meeting members and officials from the Ministry of Business, Innovation and Employment (MBIE) and Callaghan Innovation. It was interesting to discuss MBIE’s recent Sector Reports, and to see how government defines and views manufacturing, in particular high-tech manufacturing. There are still misconceptions on what manufacturing is, and what should be considered high or medium-technology manufacturing. High-tech manufacturing is often touted by government as an important source of growth and innovation for our country. But it does not capture all the high value-added activity happening across manufacturing businesses, and focusing only on what is defined as high-tech can lead to missing and undervaluing all the innovation and growth that is created in other parts of the sector, just because they do not fit a specific definition. The definition used for high-tech manufacturing in the Sector Reports covers those manufacturers who spend greater than 8% of revenue on research and development (R&D). By this definition, the high tech sub-sectors of manufacturing are: pharmaceuticals, aircraft manufacturing, professional and

scientific equipment manufacturing and computer and electronic manufacturing. Medium-tech manufacturing is defined by R&D expenditure of between 2% and 8% of revenues, and sub-sectors listed as medium tech are: Chemical manufacturing, transport equipment manufacturing and machinery and equipment manufacturing. It is important to note that these definitions have been created by the OECD and are used so to allow international comparison. One issue is that any definition based on R&D expenditure relies on such expenditure being captured reliably by the accounting practices used by the companies in question. We know that this is often not the case, as doing so introduces additional complexity in accounting methods without any immediate benefit to the firm. Moreover, accepted definitions of ‘R&D expenditure’ in accounting fall well short of capturing all the innovation investment made in business process and business model / market innovation by many companies. Thus the definition of high-tech manufacturing used by government does not fit the reality of manufacturing in New Zealand well –

there are many businesses that should be considered high-tech due to their complex and innovative processes and products, but are not captured as such by the current definition. This focus on a narrow definition of high tech can often lead us to the wrong conclusions - a lot of the most effective innovation happens in the manufacturing sub sectors currently defined as medium-tech, with some of the biggest positive flow on effects to the rest of our economy. Flow on benefits to the rest of our economy must be a key consideration for what we value as important, helping us make the most efficient use of resources to create wealth. Manufacturing generally does this very well: for every $1 of value added in manufacturing, $1.4 of additional value is created elsewhere in the economy, and every job in manufacturing generates between two and three jobs in the rest of the economy.

will not only make it easier for companies to apply for government innovation grants, but more importantly, undertaking innovation in a more systemic and planned way can both keep track of and make the most of R&D expenditure helping to improve the effectiveness of a businesses innovation efforts. We can’t improve what we don’t measure, and separately capturing both the cost of and the return on specific innovation activities is one of the paths to a more profitable business.

We encourage our members, however, to move to a more systematic view and treatment of innovation in their business. Currently we still see a fair bit of intuitive and owner-driven innovation.

While politicians like to mention innovation, high-tech manufacturing and growth in our economy in the same breath because it sounds sexy and intuitively right, the reality is just a little bit more complex, as is often the case.

As businesses grow, and to help them to grow, analysing, documenting and accounting for innovation activity separate from the production process

Having said that, moving from intuitive to systematic innovation is something you can do to create more wealth in and from your business.

gloom on the job front as businesses embrace automation responsibilities created by increased use of technology”. Globally, 54% of automating firms expect to redeploy workers in other areas, with 28% stating that workers will be trained to operate new machinery. Even in manufacturing, 44% plan to redeploy rather than remove staff. This is particularly the case in New Zealand – executives surveyed said that their people would either be deployed to other areas (44%) or trained to use new technologies (28%). And when asked their principal motivations for considering automation, 39% of New Zealand respondents identified freeing up staff for higher value add tasks. Steve Perkins, global leader for technology at Grant Thornton said, “The roles reserved for humans could look very different years from now. Some will feel the effects more sharply. Driverless cars could render taxi drivers unnecessary, while Yahoo Finance

recently announced its newsroom would be going fully automated, removing the need for human journalists. The taxi drivers and journalists of today could be the quality control analysts or machine servicing staff of the future. Automation in the first industrial revolution made us stronger, automation the second made us faster, and in the third we will have tremendously greater insights. The possibilities are enormous. “History has proven that workforces are resilient and adaptable but the rise of intelligent machines, analytics and a ubiquitous ‘internet of things’ pose significant opportunities and challenges. No sector or profession is immune. Increased dialogue between governments, businesses and education institutions will help us better understand where gaps in the labour market will exist, to ensure we have a pipeline of people being educated and trained to fill those roles.” www.nzmanufacturer.co.nz

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NZ Manufacturer July 2015

22 - 23 JULY 2015 Horncastle Arena, Christchurch

100+ EXHIBITORS

Largest South Island Manufacturing, Engineering and Technology Trade Show Talk with global experts, get up close and hands-on with the latest tools, products, technology and services. Take advantage of exclusive show-only deals, up-skill and stay current with a wide range of free to attend seminars. Network with fellow professionals to get great ideas and solutions to industry challenges.

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NZ Manufacturer July 2015

SOUTHMACH 2015 PREVIEW

Do or do not. There is no try. —Yoda

Leussink Engineering, Appearing on Stand 112 at SouthMACH 2015, is the new Faro metrology distributor for New Zealand advanced, state-of the-art Faro Arm ever produced. With the Edge ScanArm, the addition of the Faro Laser Line Probe to the Faro Arm adds unparalleled noncontact 3D scanning capabilities for detailed measurement of surface form, making the ScanArm the perfect combination of a contact and non-contact portable CMM. Faro Laser Tracker – Vantage.

Australian engineering design and refurbishment specialist Leussink Engineering has added Faro Metrology technologies equipment to their portfolio of engineering capabilities & distribution within New Zealand. The latest Faro Edge ScanArm is a portable coordinate measuring machine (CMM) that allows manufacturers easy verification of product quality by performing 3D inspections, tool certifications, CAD comparison, dimensional analysis, reverse engineering, and more. The all-new FARO Edge is the most

and Vantage Laser Tracker include: • Accurately performs measurements within many refurbishment applications. • Operates in real time • Particularly effective in measuring alignment and providing proper trending and distortions

• Allows complex geometry, surfaces and feature positions to be compared to nominal data without any need to relocate the part to a fixed inspection tool • Provides full volumetric accuracy tests and verifies dimensional integrity and repeatability.

The Faro Laser Tracker is an extremely accurate, portable coordinate measuring machine that enables you to build products, optimize processes, and deliver solutions by measuring quickly, simply and precisely. Customers around the world trust the Faro Laser Tracker to solve their everyday measurement challenges as well as their most complex problems that simply weren’t previously possible. Companies are saving millions of dollars by completing jobs faster, reducing downtime, eliminating costly scrap, and getting accurate, consistent, and reportable measurement data. Key features of Faro Edge ScanArm

Faro Edge ScanArm + LLP Scanner.

Visit Stand 151South Mach15 and See the Expanding Future of Unmanned Aerial Services Global Aerial Platforms Ltd (‘GAP’) is a New Zealand based developer and manufacturer of unmanned aerial vehicles (UAV) for a range of commercial, scientific, environmental and community purposes. All GAP UAVs deploy GPS satellite connectivity for the purpose of navigation and can be equipped with embedded stabilised cameras for the relay of thermal, multispectral and high definition imagery Engineering, materials, communications and imaging technology has positioned GAP at the forefront of a fast changing industry. GAP’s UAV models range from” ■ ■ ■

Our ■ ■ ■ ■ ■

The 1.9m delta wing ‘Kuaka’ UAV is designed as a fast response multi-purpose short-range vehicle with a flight time of 40-50 minutes. Launched by catapult, the Kuaka cruises at 50 knots and can land on land or water. The 3.5m quad UAV ‘Hummingbird’ is designed as a robust work platform for multiple tasks in the urban landscape and horticultural fields including environmental monitoring and prevention systems. (Under development). The 7.5m + dual fuselage‘Global Ranger‘ UAV is a fast response specialty vehicle with a stable platform to accommodate payloads, This version will cruise at high altitude on flights of long duration.

exciting range of UAVs is designed for multi-uses: Search and Rescue operations (seafront, ocean maritime and alpine rescue) National border surveillance Maritime support (fisheries, ports) Vessel monitoring (including yacht racing, anti-piracy) Livestock monitoring

■ ■ ■ ■ ■

Emergency services Horticultural atmospheric analysis, crop monitoring and frost protection Highways, bridges and traffic surveillance Inspection and Maintenance of major installations Disaster management

VISIT US ON STAND 151 AT SOUTH MACH15 AT CBA ARENA CHRISTCHURCH JULY 22-23 2015 OR CONTACT US ON 64 27 265 5557 www.skygap.co.nz www.nzmanufacturer.co.nz

NZ Manufacturer July 2015

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Work spares us from three evils: boredom, vice, and need. – Voltaire

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NZ Manufacturer July 2015

Life is 10% what happens to me and 90% of how I react to it. —Charles Swindoll

SOUTHMACH 2015 PREVIEW

Jericho Walker Sheetmetal install Ermaksan 220T - 7 Axis Pressbrake Established sheetmetal and fabrication engineers Jericho Walker Sheetmetal have installed the latest Ermaksan Speedbend Pro 220T 7 Axis CNC Pressbrake. This advanced Pressbrake is equipped with the latest Delem DA66T touchscreen pressbrake control that provides fast and efficient programming and quick job setup.

Although this is a large pressbrake machine it is very fast in operation with servo amplifier systems on all axis. This servo drive system is superior in speed and positioning accuracy to conventional AC induction motors with variable speed AC drives that are common on lower cost or older NC and CNC machines.

Business owner Robert Jackson says “the Ermaksan is a strong, accurate, and fast pressbrake that fits our requirements for Jobbing work and also high production rate accurate folding”.

Ermaksan has an excellent reputation for durable and strong machine tools with over 100 machines installed in New Zealand and full technical support and spare parts backup NZ wide from their NZ agent, Revolution Precision Machinery. As part of the Jericho Walker Sheetmetal production expansion CADCAM software from European software developer ALMA will be installed and supported by Revolution Precision Machinery. This software automates the combined process of sheetmetal profiling, punching, folding, and job quoting and will increase the productivity available

from their new and existing Laser, Turret punch, and Pressbrake cnc machines. The software will increase productivity because job setup, progress, and information storage can be determined offline before the work starts. Job costing and quoting are also done by the Alma CADCAM software from the information entered by the programmer. Machinetool operation and job progress-pricing can be determined directly from the drawing files that are commonly sent as part of the pricing and quoting process for a sheetmetal and fabrication business. Revolution Precision Machinery engineers have the skills and experience to provide full technical support for the Ermaksan range of machinetools. The technical support offered is

backed up by the manufacturers own service centre that provides a quick and detailed fault fining information and spare parts. For more information on the Ermaksan range of CNC machinetools contact Phil Robinson or Quentin Rowe, sales engineers for Revolution Precision Machinery (RPMcnc) Email: sales@rpmcnc.co.nz Phone: CHCH 960 0892 AKL2650380 Web: www.rpmcnc.co.nz

NZ Manufacturer July 2015

EVERYONE WHO GOES TO WORK COMES HOME HEALTHY AND SAFE WorkSafe and ACC will be at SouthMACH, in Christchurch – 22-23 July 2015. We’ll help you improve your health and safety performance and reduce harm in your work place. Come and see us at Stand 29 and pick up your copy of best practice guidelines for the Safe use of Machinery and Safety Toolkit. SouthMACH, Horncastle Arena, Hall 1, Stand 29.

worksafe.govt.nz

See us at at Stand #116ach the Southm , Exhibition 22-23 July

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NZ Manufacturer July 2015

Don’t judge each day by the harvest you reap but by the seeds that you plant. —Robert Louis Stevenson

DEVELOPMENTS

New emission targets achievable GMP Dairy to develop Chinese New emission trading targets are a the majority of market further electricity realistic goal for New Zealand business, our says the Employers and Manufacturers Association (EMA). However, it warns that New Zealand must continue to show willing to play its part in initiatives designed to combat climate change to maintain the goodwill of its trading partners. EMA CEO Kim Campbell says climate change and green technology issues were a major focus at a recent OECD meeting he attended in Paris and climate change issues are a major focus for many of our trading partners. “Climate change and emissions are a significant concern for our trade partners and if they don’t see us taking steps on these issues they will begin to question trade links with our businesses. It is also critical that whatever steps New Zealand takes, that we also retain our business competitiveness,” says Mr Campbell. “The new target presents an achievable goal for New Zealand while remaining a challenge given the balance of our economy. Around 50% of our emissions (mainly methane) are from the agriculture sector and another 22% from the transport sector. With

generation already coming from renewables the quick gains available to many developed countries, made by switching from coal to alternative renewable generation sources, aren’t available to us in New Zealand.” The new targets have been set at 30% reductions on 2005 emission levels by 2030 or an 11% reduction on 1990 levels with the previous target being just 5% reductions on 1990 emission levels. “New Zealand is leading the international research project to reduce methane emissions from farm animals and the results are proving encouraging, while electric vehicle technology is playing a faster than expected role in transport options. Focusing on green technologies is also an area where New Zealand lags when compared to many of our trade partners, especially when it is an area that can help deal to our emission targets,” he says.

The current dairy business climate is both challenging and promising, because regulations on infant formula are still very sticky and unclear. However, Evergrande Group’s investment into GMP Dairy Limited’s business has given the company more opportunities. Evergrande Dairy chairman Mr Xu Wen has mentioned before the group, which had turnover this year of 131.5 billion Chinese Yuan and has 475 billion Chinese Yuan in assets, was attracted to invest in New Zealand because of its strong reputation for food safety. Evergrande has a large team in China to provide innovative marketing and distributing strategies, which has given GMP Dairy Limited more confidence in developing the China market further. On the 12th of June, 2015, GMP introduced their premium infant formula brand, Opobaby, at the Aotea Centre, Auckland Town Hall. Economic Development Minister Hon Steven Joyce, MP Jami-Lee Ross, Economic and Commercial Counsellor of the Chinese Embassy in NZ Mr Zhang Fan, along with Evergrande Dairy Chairman Mr Xu Wen officially

launched Cowala Superpremium Opobaby Infant Formula. Evergrande Group is a massive Chinese conglomerate, which started out in real estate and has diversified into a range of other businesses including fast moving consumer goods. In October, Evergrande launched its infant formula brand Cowala in China where it made its first appearance in a Chinese Super League football match when the successful Guangzhou Evergrande team, part-owned by Alibaba boss Jack Ma, wore Cowala baby formula-branded shirts. The team officially launched the new Opobaby brand in China after a match late last month.

• The regulator, WorkSafe New Zealand, provides guidance and standards for many industries on its website: http://www.business.govt. nz/worksafe/information-guidance/ guidance-by-industry • Board members may be interested in the Ministry of Business, Innovation and Employment / Institute of Directors guidelines at: www.iod. org.nz/Governance-Resources/ Publications/Health-and-safety

Visit http:// worksafesolutions. co.nz for more information about how to improve health and safety. Next time: The officer’s duty of monitoring information health and safety.

From left to right: MP Jami-Lee Ross, Evergrande Dairy Chairman Mr Xu Wen, Economic Development Minister Hon Steven Joyce, Economic and Commercial Counsellor of the Chinese Embassy in NZ Mr Zhang Fan and Korea Trade Commission Business Manager Ms Kim Kelly.

Health and Safety Article three:

Make sure resources and processes are available to manage operational risks

This series on the new health and safety laws looks at the duties of boards, business owners and managers (officers) and what they are expected to know and to do when the new act and regulations come into effect later this year. There will be an increased focus on high risk industries such as the manufacturing sector so this article looks at how to prepare for the new obligations. The duty to make sure resources and processes are available is relative to the size and nature of the business and the risks associated with work in the operation. Health and safety resources include having current and effective policies, procedures, guidelines, standards, training, auditing and control systems that are appropriate to the risk and hazards. If your organisation is not big enough for a dedicated health and

safety role, make sure managers’ and employees’ responsibilities are clear. The last article focused on risk and hazard identification. Starting with the greatest risks (i.e. those with the potential to cause the most harm) can help you to prioritise effort and resource allocation. Government websites provide a lot of useful information, so spend time familiarising yourself with it. Also speak with other similar businesses and sharing knowledge, information and insights. Industry associations such as the Employers and Manufacturers Association are running courses and seminars to help members get up to speed with the new health and safety requirements. Did you know? Other useful information sources include: • The Best Practice Guidelines for the Safe Use of Machinery gives duty holders advice on safe machinery use and includes helpful checklists in the appendices at the back. View it here: http://www.business.govt. nz/worksafe/information-guidance/ all-guidance-items/safe-use-of-machinery

about

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NZ Manufacturer July 2015

WORKSHOP TOOLS

If you hear a voice within you say “you cannot paint,” then by all means paint and that voice will be silenced.

EIS partner with mega company in safety systems Invercargill based multi-disciplined automation and electrical company EIS has become the first South Island based Omron safety systems integrator. EIS Operations Manager Johnny Mauchline said the certification is a great accolade for EIS, especially given the fact that there are only two other Omron safety integrators in the country, both based in Auckland. Omron, which employs approximately 35,000 people worldwide, has more than 80 years’ international experience of innovation in the electronics and automation industry. Mr Mauchline said partnering with such a company means EIS is now fully equipped to deliver affordable, quality and custom made automation Omron control systems and safety solutions to clients with manufacturing and industrial operations. He sees the certification as well-deserved recognition of the local company’s vast experience, capabilities and dedication to health and safety. “Every day we work with a range of machines across a broad spectrum of industry sectors. We are known for punching above our weight and being driven by health and safety. This certification is another great recognition of that driving factor and

the opportunity to offer clients the best combination of resources when required,” he said. Mr Mauchline believes the combination of EIS’ on-site inspection, risk assessment and automation systems design and installation expertise pairs well with Omron’s ability to specify the equipment and hardware needed to eliminate or mitigate any identified hazards and risk. “Ultimately it’s about working together to improve efficiencies, processes and output for our clients and ensuring their machines and processes are 100 percent safeguarded and compliant,” he said. Dunedin based Omron Senior Technical Sales Representative Peter Watkins said the certification further strengthens the longstanding partnership between EIS and the international Japanese mega company. “We are proud to have EIS partnering with us within the South Island. This is a relationship between two companies that are extremely experienced and innovative in automation and safety, not only in New Zealand but internationally as well. Together, we can help clients navigate the minefield that is safety legislation,” Mr Watkins said.

—Vincent Van Gogh

Safer driving with engineering know-how Visits to automotive manufacturing sites McLaren Formula 1, Volkswagen and Bentley are a regular occurrence for Leon Henderson at the moment. It’s all part of the job for the mechanical engineering graduate, who works as a research associate at Cambridge University in the UK. Leon hails from Whitianga where he attended Mercury Bay Area School. He graduated from the University of Waikato with a Bachelor of Engineering, Mechanical with Honours in 2009. He later moved to the UK to begin his PhD at Cambridge, finishing it in October 2013. Safer braking for HGVs Since 2013 he’s been a research associate at Cambridge, working in an automotive engineering capacity on a project funded by Volvo Trucks. The project involves the development of a new braking system that takes a fifth of the stopping distance off an HGV (heavy goods vehicle), enabling better driving control. Each wheel has a computer calculating how slippery the road is and how fast the vehicle is going, and adjusts the brakes accordingly. The BBC recently ran a story on the project, available online here, and he has been named as a co-author on the successful patent application describing the pneumatic valve used in the truck’s braking system.

and design projects, along with the work placements arranged by Waikato, gave me a really good foundation of knowledge for my PhD. “It also gave me a good combination of theoretical knowledge and hands-on engineering experience. The industry experience I gained was extremely helpful when it came to collaborating with industrial sponsors – which I’ve done a lot of here at Cambridge,” he says. Leon was inspired to study engineering after a visit to a University of Waikato Open Day and Science Summer School. “At the time, the engineering degree at Waikato was quite new. The facilities were nice and modern and the lecturers were engaging. I was also offered a couple of scholarships to attend – the Tearaway Scholarship (now the School Leaver Scholarship) and a Bachelor of Engineering Fees Scholarship, which made it even more attractive.” His next step looks like it will be a move to New Zealand. “I’m looking for an industry position in New Zealand where I can use some of the automotive engineering skills I’ve gained in Europe. Failing that, there are also possible job opportunities for me in Sweden with Volvo.”

Leon says the opportunities presented to him after his time at Waikato have made the move to the UK worthwhile. “Alongside presenting my research to Volvo Trucks, I’ve also worked at vehicle testing facilities where prototype vehicles from companies such as Aston Martin, Jaguar and Bentley are tested. I’ve also visited some pretty cool automotive facilities – like McLaren Formula 1’s research and development base, and production lines belonging to Volkswagen, Bentley and Hyundai – to name a few.” Skills gained at Waikato EIS Electrical Manager Daryl Cook (left) and Operations Manager Johnny Mauchline (right) review Omron equipment and hardware information after becoming the first South Island based Omron safety systems integrator. www.nzmanufacturer.co.nz

Leon says his undergraduate study at Waikato prepared him well for the challenges of a PhD. “My final year of research

Bachelor of Mechanical Engineering graduate Leon Henderson has been working on the development of safer braking systems for HGVs in the UK

NZ Manufacturer July 2015

Remember that not getting what you want is sometimes a wonderful stroke of luck. —Dalai Lama

WORKSHOP TOOLS

Speedglas welding helmet result of great technology The new Speedglas auto-darkening welding helmet series 9100XXi from 3M is built on 30 years of expertise and sets a new benchmark in welding helmet technology. The 3M Speedglas 9100XXi series is designed for professional welders who require optimum comfort, trusted protection and ultimate performance. The new top-of-the-line series features the largest Speedglas welding lens available. The Speedglas welding lens 9100XXi when combined with the peripheral Speedglas SideWindows gives welders the largest viewing area amongst auto-darkening welding

helmets currently available on the Australian & New Zealand market at the time of printing. The new “True-View” lens delivers a greater degree of definition and natural colour. Shades of blue and red as well as contours and edges are more visible due to improved welding lens optics. The new “Grab-and-Go” motion detector senses movement and instantly activates the welding lens to the welding setting that was last used. A “One-Touch” external button activates grind mode. Another quick push reactivates the auto-darkening welding settings.

The wave of future energy “It’s a big step but we are going to make it,” said Armin Howard, Business Development Manager at EHL Group which is based in New Plymouth. The big step he was referring to is EHL’s goal of developing a billion dollars’ worth of wave energy arrays over the next fifteen years.

energy device is currently installed off the Island of Oahu in Hawaii and within 24 – 30 months their full scale device will be installed also supplying energy to the grid.

“While that sounds a lot,” he said, “In context, that’s only 15 to 20 devices a year and our focus right now is on niche applications.”

The current development and testing has been funded by the companies involved with support from the US Department of Energy and an application has been made to Callaghan Innovation to support their R&D activities.

EHL along with their US joint Venture partner have become the first wave energy device developers to feed electricity into the US grid and the device was developed here in New Zealand. Their half-scale Azura Wave

Recent economic modelling has shown that Marine energy could be a $1.3 billion per annum export industry for New Zealand by 2030 making it an important part of our countries high value manufacturing future.

HyAccess extended consumables available Hypertherm’s patented HyAccess for more systems Hypertherm, a manufacturer of plasma, laser, and waterjet cutting systems, is expanding availability of its HyAccess extended consumables to the Powermax65, Powermax85, and Powermax105 systems, in addition to legacy Powermax and MAX systems. Previously, the consumables were only available for Hypertherm Powermax30, Powermax30 XP and Powermax45® air plasma systems. “Since the introduction of HyAccess consumables last fall, we’ve heard from dozens of customers wanting to know if we could make HyAccess consumables available for higher amp Powermax systems,” said Brenda Mahoney, product marketing manager for Hypertherm’s torch and consumable team. “They were amazed by the opportunities these consumables opened up and excited to use HyAccess to cut and gouge thicker metal.”

consumables extend 76 mm longer than standard consumables for better visibility and accessibility when cutting or gouging in hard to reach areas or confined spaces. The improved visibility and access achieved with HyAccess eliminates the need for certain secondary operations or multiple cutting passes. Metal workers specializing in equipment and vehicle repair, structural work and jobs requiring angular cutting or gouging now have a new tool to make hard work easier. HyAccess consumables are available from all authorized Hypertherm distributors. The consumables are offered individually or as part of an all-in-one kit that includes two electrodes, two nozzles (one for cutting and one for gouging), a retaining cap and swirl ring. Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair.

Just like the programmed pre-set stations on a radio, the new “Set-and-Forget” feature allows welders to pre-set their most frequently used welding helmet settings. By holding down the external button, welders can seamlessly switch between different welding applications without having to re-set the welding helmet. Each memory mode has an individual setting for dark shade, switching sensitivity and dark-to-light delay. For example, by holding down the external button, the welder can switch between low-amp TIG and high-amp MIG welding in a matter of seconds.

The new 3M Speedglas Welding Helmet Series 9100XXi is available with flip-up functionality, head protection, hearing protection and with powered or supplied air respiratory protection. Featuring Speedglas’ legendary comfort and performance and the new True-View, Grab-and-Go, One-Touch and Set-and-Forget features, the Speedglas Welding Helmet Series 9100XXi is in a class of its own.

Headland Machinery welcomes new partnership with Goratu Since 1954, Goratu have produced quality milling and lathe machinery. Goratu focuses on exporting their innovative technology around the world and provides customers with two leading brands - Geminis horizontal and multiprocess lathes and Lagun milling technology. Located in the Basque region of Spain, Goratu invest time in research and development of their technology to ensure it is safety certified and innovative in design and accuracy. Headland are proud to announce this new partnership with Goratu giving Australia and New Zealand the chance to work with world-class technology.

the likes of Makino, Nakamura-Tome, Studer and more, to bring Australia and New Zealand the largest range of precision CNC Machinery. Headland supplies innovative and high-quality machines and services to customers throughout Australia and New Zealand in the manufacturing industry.

As part of Headland’s machinery range, Goratu joins our CNC division with

Thermal camera fits in pocket The Flir C2 is a fully-featured thermal camera, yet it is small enough to comfortably fit in your pocket. Designed to help identify heat patterns that indicate where hidden problems may exist, the Flir C2 is this year’s must-have inspection tool for builders and NDT operators. Featuring Flir’s patented MSX real-time image enhancement and a simple-to-use touch screen with auto-orientation, the camera creates thermal images with stunning clarity.

of the scene. Plus, the C2 includes a built-in work light and flash that helps illuminate poorly lit work areas. With a simple point-and-shoot operation, the C2 can store radiometric JPEGs with the push of a button. The images can be downloaded later using the free Flir Tools software that allows the user to adjust thermal image levels, isolate and add temperature measurements, change color palettes, and create persuasive reports.

MSX adds key details captured by the onboard visible camera to the C2’s thermal images so numbers, letters, texture and other characteristics are clearly recognisable without compromising the thermal image. The C2’s 4800-pixel resolution, high sensitivity detector captures and displays subtle thermal patterns and small temperature differences and a wide 41° field-of-view frames in more www.nzmanufacturer.co.nz

NZ Manufacturer July 2015

The most difficult thing is the decision to act, the rest is merely tenacity.

FOOD MANUFACTURING

—Amelia Earhart

US market offers huge potential for New Zealand wines New Zealand wine exports to the United States are growing faster than to our traditional international markets of Australia and the UK, and that pace is being matched by increasing recognition at the top competitions. In the five years from 2010-2015, exports of Kiwi wines increased three times faster than the UK and Australia. For the 12 months ended April 2015, New Zealand exported 5.88 million cases of wine to the US – up three million since 2010. During that period, exports to Australia increased to 6.4 million (4.8 million five years ago), and in the UK to 6.3 million (4.7 million). Giesen Wines began exporting to the US in 1997 and these exports now make up 10% of total sales. Alex Giesen said the US market is changing dramatically from a New Zealand perspective. “This is the fastest growing mature market and is increasing at a faster rate than Australia and the UK. We think it will become New Zealand’s biggest market by value and volume in the next 12-24 months. At the moment, it’s second by value and third by volume. www.nzmanufacturer.co.nz

“With the growth the US has experienced in sales of New Zealand Sauvignon Blanc over the past 10 years, we’re quickly gaining the reputation as a serious winemaking country.”

“Americans love the fruit forward, easy

Giesen’s wines are winning impressive plaudits from international judges at US competitions. At the LA International Wine Competition Giesen won two Best of Class medals, five golds, three silvers and three bronze. And at the most recent New York International Wine Competition, it was named Marlborough Winery of the Year.

hotter climate in California, the wines

“The US has a real thirst for our wines, and particularly Marlborough Sauvignon Blanc. It’s a very easy drinking, fruit forward varietal that’s always popular. Marlborough Sauvignon Blanc is really driving this category in the US now and this is being mirrored in its award success.

to understand style of the wines, at a very accessible price. Most Californian wines are almost twice the price of most New Zealand wines and, due to a lack the crisp fruit characteristics and backbone of acidity we get from the cool Marlborough climate.” As part of its drive, Giesen moved to a new importer, Pacific Highway Wines and Spirits, in 2013 to help further the company’s reach in North America. And this year, it’s added three new sales managers and repackaged the Giesen Estate Marlborough Sauvignon Blanc for that market. Giesen said 88% of Giesen’s exports to the US were Marlborough Sauvignon Blanc,

replicating

overall

industry

trends where total exports to the US stand at 87%.

“There are a lot of people in the US excited about what Giesen brings to the market by way of depth of portfolio and plethora of styles. The United States is (Americans are slowly) working out that the lower end priced/ entry level Sauvignon Blancs are pretty one dimensional and, for an extra couple of dollars a bottle, they are getting something light years better. The sub $12 market sales are dropping off and are now being picked up by the $12-$20 category.” While Sauvignon Blanc is by far the predominant category, Giesen is increasing its exports of Pinot Noir, Chardonnay, Riesling, and Pinot Gris. “The US market is familiar with Sauvignon Blanc, and now it’s starting to understand Marlborough’s ability to produce outstanding examples of other varietals such as Pinot Gris, Syrah and Pinot Noir.”

Introducing

Work spares us from three evils: boredom, vice, and need. – Voltaire

title text

NZ Manufacturer July 2015

A point of difference in today’s busy FMCG market.

Developed by AsureQuality, inSight™ provides shoppers with independently verified information about the products they are about to buy. After a successful application process, producers can place the inSight™ logo and a QR code on their product packaging. When shoppers scan the QR code at the point of sale they can access information about the product, including: • • • • •

Environmental sustainability Social and ethical concerns Nutritional information Safety and quality Origin

Call us now on 0508 00 11 22 to find out how inSight™ can add value to your business. www.aqinsight.com

www.nzmanufacturer.co.nz A new innovation taking product assurances into the 21st Century

NZ Manufacturer July 2015

THE FUTURE OF MANUFACTUCTURING

The only way to do great work is to love what you do.

—Steve Jobs

Where to for IoT? By Stephen Broadbent, Country Manager New Zealand at Rockwell Automation. –How do you see the Internet of Things (IoT) being beneficial for manufacturers? Or is it too many elements in the one box? The IoT enables companies to establish an information-enabled business, linking consumer information, distribution, manufacturing and supply chain allowing manufacturers to become flexible and competitive on a global scale. Manufacturing generates more big data than any other sector making analytics evermore relevant. By combining the data source elements of the consumer, supply chain and manufacturing into the plant automation platform, improvements in control can be made in real time.

Manufacturing generates more big data than any other sector making analytics evermore relevant. For example traceability is particularly important to the food and beverage industry. Data oriented decisions or changes in manufacturing can be made rapidly providing secure, lower cost to market while allowing businesses to add value to their products to meet consumer demands.

Can the IoT make business more efficient? If so, how? It is estimated that by 2020, one billion new middle class consumers will add $8

trillion to consumer spending. These global population trends will result in increased demand for manufacturing, resources and infrastructure. The value proposition that the IoT can bring will deliver improved asset utilisation and enterprise risk management for manufacturers.

of the entire supply chain from raw product to tracking of distribution and authenticity facilitating global ‘track and trace’ and product recalls.

Mobility tools powered by the IoT will provide dashboard style access to real time consumer and manufacturing information. Various management layers will have improved visibility to drill down to a particular line or process and look at parameters such as machine availability, scrap rates, predictive maintenance and energy usage.

P r o d u c t i o n machines and ingredients can be rapidly batch managed to meet demand. IoT technologies help to enable secure, safe and efficient food production and distribution to global markets.

When linked to business drivers such as sales forecasts, production volumes, stock turns and profitability, more productive and efficient manufacturing can be driven through the entire business.

For the exporter of manufacturing machinery the IoT will provide a link to their equipment, enabling product updates and service information to be done remotely, saving on costly travel while enabling the end user to maximise machine uptime.

Is there a connection between the IoT and globalisation? Manufacturing facilities now have a global reach with consumer markets in different parts of the world, brand protection and compliance are vital for exporters. This is particularly relevant to the New Zealand market where exporters of niche OEM machines and food and beverage products are mixed with exports of commodity mass produced goods. IoT technologies can help manufacturers remain successful on a global scale by delivering integrated consumer supply information. Market demographic consumer data can be captured through their smart device. In turn, this can be linked back to the business enterprise system enabling a smart manufacturing layer. This information allows the optimisation

If the IoT of things means more automation are we looking at the need for fewer workers? The growing population will place ever increasing demands on the production of food, automotive and infrastructure. Production volumes will need to increase and workers will become more engaged with production data based on consumer demands. The use of visualisation dashboards on production lines will be more widespread. Employees can monitor the productivity data such as units per hour, energy use and shift volume requirements. Workers will be more informed and focused to help reduce scrap and downtime. It is not about having fewer workers but more about driving a more productive and engaged workforce.

As the level of automation in a facility increases the skillset for workers will change and workers will be deployed in different areas. For example, the change of focus from production to maintenance is likely to be key. Workers will be required to help ensure that the machines remain running and profitable.

How do we successfully and securely store all of the data, which is a result of the IoT? As a result of the IoT there has been a rise in cloud based storage systems and data centres. To address security concerns, Rockwell Automation teams with industry leaders, such as Cisco to build multiple layers of security into systems. Rockwell Automation has developed software products such as FactoryTalk® Historian and AssetCentre that are able to not only track production manufacturing data but also the use of your critical assets within a facility. FactoryTalk® VantagePoint can be used to dashboard information in real time both in a facility based system but also on mobility tools such as tablets and smartphones.

Horncastle Arena, Christchurch

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USING PROMO CODE: NZMANUF

NZ Manufacturer July 2015

Strive not to be a success, but rather to be of value. —Albert Einstein

THE FUTURE OF MANUFACTURING

The Future of Productivity and Growth in Manufacturing Industries Technological advances have driven dramatic increases in industrial productivity since the dawn of the Industrial Revolution. The steam engine powered factories in the nineteenth century, electrification led to mass production in the early part of the twentieth century, and industry became automated in the 1970s. In the decades that followed, however, industrial technological advancements

were only incremental, especially compared with the breakthroughs that transformed IT, mobile communications, and e-commerce.

this transformation, sensors, machines, workpieces, and IT systems will be connected along the value chain beyond a single enterprise.

Now, though, we are in the midst of a fourth wave of technological advancement: the rise of new digital industrial technology known as Industry 4.0, a transformation that is powered by nine foundational technology advances. (See Exhibit 1.) In

These connected systems (also referred to as cyberphysical systems) can interact with one another using standard Internet-based protocols and analyse data to predict failure, configure themselves, and adapt to changes. Industry 4.0 will make it

possible to gather and analyse data across machines, enabling faster, more flexible, and more efficient processes to produce higher-quality goods at reduced costs. This in turn will increase manufacturing productivity, shift economics, foster industrial growth, and modify the profile of the workforce—ultimately changing the competitiveness of companies and regions.

Top 10 emerging technologies of 2015 Technology is perhaps the greatest agent of change in the modern world. While never without risk, technological breakthroughs promise innovative solutions to the most pressing global challenges of our time. From zero-emission cars fuelled by hydrogen to computer chips modelled on the human brain, this year’s 10 emerging technologies offer a vivid glimpse of the power of innovation to improve lives, transform industries and safeguard our planet. To compile this list, the World Economic Forum’s Meta-Council on Emerging

Technologies, a panel of 18 experts, draws on the collective expertise of the Forum’s communities to identify the most important recent technological trends.

understanding that so often thwart progress.

5. Additive manufacturing

The 2015 list is:

7. Distributed manufacturing

1. Fuel cell vehicles

8. Sense and avoid’ drones

By doing so, the Meta-Council aims to raise awareness of their potential and contribute to closing the gaps in investment, regulation and public

2. Next-generation robotics

9. Neuromorphic technology

3. Recyclable thermoset plastics

10. Digital genome

6. Emergent artificial intelligence

4 Precise genetic engineering techniques

Successful innovation needs more than just R&D Kiwi firms need the tools to make the most of any increase in business research and development (R&D), according to new research by the Productivity Commission. Under the Business Growth Agenda the Government has committed to a target of increasing business expenditure on R&D to 1% of GDP by 2018. While valuable, this is just part of the puzzle of creating more innovative Kiwi firms. The working paper, “Measuring the innovative activity of New Zealand firms”, by Simon Wakeman (NZPC) and Trinh Le (Motu Economic and Public Policy Research) uses data from Statistics New Zealand’s Longitudinal Business Database to provide a new perspective on innovation at the level of the firm. “Innovation is a key driver of productivity growth and using resources in a more sustainable way. But New Zealand does not perform particularly well compared to other countries” said Paul Conway, Director of Economics and Research. “We have a lot of good ideas, but our weakness is when it comes to turning these ideas into commercial products.

and services and operational processes. Firms in the services sector tend to rely on new organisational processes and marketing methods.

Business innovation is about more than just R&D expenditure or activity. “Business innovation is about more than just R&D expenditure or activity. It includes how firms combine new ideas with those of others and how they translate ideas into new goods and services that customers want, ideally on international markets. Firms need to be clever at absorbing ideas and knowledge from their environment – including customers, suppliers, and even competitors – and at connecting the products they generate with the needs of others.”

“While there has been a general shift towards more firms engaging in R&D activity, fewer firms are introducing new goods and services. Firms are also earning a smaller share of their revenue from innovative products. This suggests the innovation process hasn’t been working as well as it could. “There is a loose connection between business spending on R&D and new innovations or the share of sales from new goods and services. We see this even in the industries where we would expect R&D to matter the most. Some younger firms are more innovative, even though they are not spending any more of their money on R&D. “Firms in different industries innovate in different ways. Manufacturing firms are more likely to introduce new goods

www.nzmanufacturer.co.nz

NZ Manufacturer July 2015

THE FUTURE OF MANUFACTURING

Change your thoughts and you change your world. —Norman Vincent Peale

3,000 products for energy solutions Energy efficiency continues to become ever more important, both for consumers trying to reduce their environmental footprint and save money, and for businesses seeking more efficient use of resources, along with the benefits of being environmentally responsible. Schneider Electric is a global company, whose New Zealand operations focus on providing a vast range of energy solutions, targeted at residential, business and industrial customers. Their solutions range from energy generation, to the light switches in a home or business, with a portfolio that features around 28,000 products. Schneider Electric employs up to 150 staff in their Christchurch premises, equating to a total of over 300 employees across the country, including a Head Office in Auckland and offices in Hamilton, Napier, and Dunedin. The Christchurch factory produces around 3000 different finished products, 75% of which are sold domestically, with the remainder primarily going into the Australian market. “Schneider Electric has a drive to offer solutions to use energy better, make life easier and ultimately save money” says Dave Chapman, Channel Manager – Residential at Schneider Electric. This goal is taken to heart, choosing to walk the talk, evident in the improvements to their Christchurch plant and premises – retrofitting their existing plant with a mix of their own sensors, energy efficient lighting control and energy management hardware and software to automate the building – a change that is saving them almost 30% off their lighting bill alone.

This was part of a $1m investment to transform the plant to be modern and energy efficient, while improving H&S outcomes and productivity. Many solutions such as these lighting improvements can be retrofitted into other manufacturing businesses to help reduce energy consumption, and their Christchurch plant serves as a live demonstration. Across the site they have created an interactive visitor experience with a journey that encompasses residential, commercial, and industrial solutions. They have installed interactive screens that illustrate in real time energy usage and savings. They have expanded their show-room facilities to include a complete residential studio unit providing a realistic view of your electrical options in a fully interactive environment.

Dave Chapman, Channel Manager – Residential at Schneider Electric,

their own solutions in production, for example, their Andon Signalling Lights, which have been incorporated into their own plant provides a signalling system on top of different work cubicles, for efficient timing and signalling of production progress for improved plant productivity.

They have implemented a global first for Schneider Electric with specialist short-lead time production systems for their make-to-order products. Continuous improvements using lean and 6-sigma processes have resulted in reduced lead times for certain products from approximately one month to only three days. These systems are now being rolled out to other Schneider Electric factories around the world.

Such improvements in their products and services offerings has been facilitated by a history of successfully incorporating other businesses into their own, one well known local example being PDL Industries (founded 1937), which was purchased by Schneider Electric in 2001. Another is APC which provides specialist offers and solutions for data centres, from small residential home solutions, to large data centres for businesses.

Supporting these changes Schneider Electric have adopted the use of

Research and Development continues to be a key part of their success and

ability to keep up with evolving technology, leveraging connections within a global company, which spends 5% of turnover on R&D globally, they frequently hold customer focus groups evaluating new designs and concepts. Along with providing products that can improve energy efficiency, Schneider Electric also provide free online education, called “Energy University”. This features numerous free courses tailored to teach people how to implement energy efficiency measures in their organization or business, helping users best utilise energy saving technology. Some topics include Industrial Insulation, energy audits, lighting basics and measuring energy performance. You can check these courses out at: www.MyEnergyUniversity.com.

Rockwell Automation TechED features the latest technology trends The global Rockwell Automation TechED event (formerly RSTechED) is the premier training, education and networking event of the automation world. This year’s event for the South Pacific region is coming to Australia and will be held on 28th – 30th July at the Melbourne Convention Centre. This three-day event is set to inspire, educate and innovate attendees while showcasing the latest technologies to help improve machine performance, optimise your plant and empower The Connected Enterprise. “Capital outlay budgets for new machinery are decreasing so our customers need to use software to www.nzmanufacturer.co.nz

optimise their plants- essentially they are required to ‘do more with less’ so they can remain competitive in the current market,” said Dean Tresidder, software product manager at Rockwell Automation. “TechED will build on the success of previous years and feature ‘hands on’ labs to show how technology can be used to get the most out of your plant with asset management, data management and software tools that will benefit system integrators,

machine builders and endusers alike,” he said. Participants will experience the Rockwell Automation Software Suite with more than 30 different lab and discussion sessions using current products as well as new and upcoming product releases. TechED will provide the opportunity to network with peers from around the world while working on the latest technology for improving manufacturing and production.

Technology is advancing at such a rapid rate, making it essential for you to keep up with the latest technology trends to stay a step ahead of your competitors. TechED is the not-to-be missed event of the automation world that will demonstrate how adopting new technologies can help you become more productive and your business more profitable.

NZ Manufacturer July 2015

Work spares us from three evils: boredom, vice, and need. – Voltaire

18 – 19 November 2015 Claudelands Event Centre

Hamilton Sponsor and Exhibitor Enquiries Welcome Expo Open Day 17 November More information:

www.nmec.co.nz

Lifting the Game of Maintenance Engineering

NZ Manufacturer July 2015

MAINTENANCE

I have learned over the years that when one’s mind is made up, this diminishes fear. —Rosa Parks

Engineers require de-icing at Heat Treatments puts out the Waikato network evening full house sign Heat Treatments Ltd have been around since 1946, but it took another millennium before the well known company threw its doors open to engineers at the Auckland Maintenance Engineering Society Network Session in June.

A hardy group of attendees braved a bracingly cold Waikato evening in June to find out how maintenance operates in the aviation industry with a MESNZ Network Evening at Aeromotive in Hamilton. In a well set up evening, tour groups toured through propeller shop, avionics, calibration and the aircraft hanger, viewing everything from the impact of ducks on propellers (and vice-versa), the new diesel powered Silentium aircraft engine and avionics upgrades.

The company’s reputation preceded it with heavy registrations for the society evening meaning more than 50 hopeful attendees were turned away once attendance limits were reached. Those who did make it were captivated by the range of equipment and services offered by the company; nitriding, vacuum processing, induction hardening, carburising, metallurgy, CNC machining, grinding, metrology and the Co-ordinate measuring

Steve Burrows and his team provided a unique opportunity to lift the hood on an industry not often seen by engineers and this was greatly appreciated by the attendees, who all learnt a great deal from the evening. The Maintenance Engineering Society is active across New Zealand, providing opportunities for maintenance engineers and manufacturing operations to network and share innovations and experiences; both at a national level at their annual conference or at these regional events.

machine, as well as the stories and history of a globally respected operation. According to owner Keith McGreggor, Heat Treatments was established in 1946 as a general engineering business but as demand grew it led to the establishment of Heat Treatment ltd in 1996 with the addition of machining and a fully equipped metallurgical laboratory. Engineers appreciated the generosity of Heat Treatments in hosting the MESNZ Network Evening and in particular Kevin McGreggor who kept everyone well catered with food and beverages.

The next Auckland, Waikato and Christchurch region network evenings can be found at http://www.mesnz. org.nz/activities/network-evenings/. The 2015 SKF National Maintenance Engineering Conference will be held at the Claudelands Showgrounds Hamilton in November.

Maintenance supervisors can boost productivity? The job of maintenance supervisors is to get the maintenance work completed on time, on budget and safely! They can be popular. They can be great communicators. They can be inspired trainers. They can be great repair people. But these things alone do not make successful maintenance supervisors. They are not successful maintenance supervisors unless they can keep the machines running, the fleet rolling and the occupants warm in the winter. When does an active supervisor look like when he is no longer bogged down in an office doing paperwork? Active supervision occurs when a supervisor spends substantial time on the shop floor helping workers solve problems. As strange as it might sound, on the psychological level a supervisor might have to be both mother (nurturing and supportive) and father (strict and tough) to members of the crew. Active supervision encompasses several roles: • Ongoing performance monitor: The supervisor knows how long each job should take and checks it periodically throughout the day. A four-hour job www.nzmanufacturer.co.nz

issued in the morning should be done by the lunch break. When the jobs fall behind, the experienced supervisor thinks about how best to intervene. In some cases it might be logistical help, helping with equipment, or providing guidance about how to proceed. • Paperwork compliance officer: The accuracy of all analysis is derived from the work order. If the work order is complete and accurate then decision-making and root cause analysis become dramatically easier. Supervisors audit paperwork and return it when it is deficient. They should always look at work orders on the floor and ensure entries are being made at the same time as the activity occurs, not at a later time. • Obsessive-compulsive PM monitor: A supervisor reinforces the rule: “Do the PM as it is written.” A related issue is PM compliance. If a worker does not have the task list in-hand when they are doing the PM, how do we know what was actually done? The supervisor ensures workers carry the task list when completing PMs. • Teacher, Mentor: The supervisor

should either be continuously training or directing the training of crew members. Everyone has areas that they are better at and areas that they aren’t so familiar with. The easiest crew to schedule is the one where everyone can do everything. The effective supervisor should be reviewing the schedule every day and looking for training opportunities. These can be formal training sessions or letting the trainee ‘help’ an experienced hand. • Quality control officer: The supervisor is responsible for the overall quality of all work performed in his or her shop. Where there are quality issues the supervisor determines the cause of the problem which could be rooted in several areas: lack of knowledge or skill, lack of aptitude, lack of adequate physical strength or dexterity, a bad attitude, lack of the right tool, lack of the right part, some inadequacy in working conditions, inadequate time, or preoccupation brought about by a problem outside of work. • Safety officer: The supervisor should intervene any time an employee or visitor performs an unsafe act or is in

the shop without the proper personal protective equipment. The supervisor is a champion for safety and makes sure the shop is safe. • Tidiness cheerleader (5S): The shop must be kept clean for safety, efficiency and morale. All clean-up for individual jobs should be part of, and charged to, the individual job. The supervisor should arrange for periodic clean-up projects to keep the whole area and the yard tidy. No one said a supervisor’s job is easy. If your goal is to help your maintenance supervisor become more effective, encourage him or her to practice these 11 different roles and they’ll be on their way to significantly improving the productivity of their team.

NZ Manufacturer July 2015

Twenty years from now you will be more disappointed by the things that you didn’t do than by the ones you did do, so throw off the bowlines, sail away from safe harbor, catch the trade winds in your sails. Explore, Dream, Discover. —Mark Twain

ANALYSIS

Become a market leader – part one Katalin Csikasz, TechPro Plus Is your company working on becoming an industry market leader or would you like to have a competitive edge with the product you supply? TechPro Plus, an Auckland based company could potentially help you with this. Specialising in engineering solutions from product design to manufacturing; we are experts at finding innovative and unique solutions to industry challenges which can increase your chances of becoming a market leader in your industry. TechPro Plus has been involved in many projects of this nature over the years with two specific projects being of particular significance. The first project involved providing the industry with a reliable in-ground corrosion control solution; with the second using innovative, outside the box design features resulting in a reduction in the installation cost and complexity of telecommunication columns. In the first project the solution was specified by local and government authorities as a preferred solution, giving the manufacturing company a competitive edge. With the second project, the, innovative design solutions were accepted as the standard industry design and were subsequently used by all telecommunication companies in their major rollouts. This created an industrial design market leader position for the manufacturer and as a bonus provided significant project savings and faster installation for the telecommunication industry. You can read about the second project in more detail in the next edition.

Reliable in ground corrosion solution: In-ground corrosion is a major industry issue in New Zealand due to our soil, which is either volcanic or has corrosive volcanic traces. This can make in-ground asset protection extremely tricky from a durability point of view as the corrosion could compromise the structural integrity of the item. With no field proven practice available for this application in New Zealand, an industry need for an engineering solution to solve this challenge was recognised and became the catalyst of a major research and development project.

As the Principal Engineer of TechPro Plus I played a pivotal role in this project. We all know, the best way to avoid corrosion is to avoid placing anything in a corrosive environment. Unfortunately in this case, this approach was not practical. The next most effective way to minimise corrosion is to incorporate corrosion prevention into the design, followed by periodic inspections. The aim was to develop or find a field proven, innovative and cost effective corrosion resistance/ prevention solution for the Industry, which would not only provide the company undertaking the research with a competitive edge and an excellent reputation but ultimately recognition as an industry market leader. After an extensive world-wide search of available products and applications and thorough New Zealand testing of a number of proposed solutions; what was recommended was an application solution which was a huge success. The final Solution is now specified by local councils and government authorities as their preferred option for corrosion protection. The company has a competitive market advantage, due to this product application and is perceived as the market leader of in-ground corrosion protection for their industry. Has your company invested money, time and R&D resources into becoming a market leader? Or do you want to stay ahead of the competition or had an idea which the industry could benefit from? To take it further consider how your business could benefit from using the following model: • Identify Industry needs, challenges as well as customer and installer challenges. • Consider and brainstorm possible solutions, speak to industry associations and/or an industry expert.

• Test the market. Build a theoretical model which will assist you to predict how the market will behave. Is your solution a winner or not viable? • Protect your solution. If possible, patent, trademark, copyright and most importantly reach confidentiality with all parties involved. You don’t want your competition to find out about your secret project. • Develop your solution - do your own R&D, employ a company to do it for you or import a suitable product or product application. There are various Government Research and Development Grants available to New Zealand companies. • Market it • Lobby • Reap the benefits. Celebrate, enjoy the recognition and acknowledge the people involved and do it again…. Tech Pro Plus could provide a complete solution from start to finish or manage part of the process; including leading or liaising with your research and development team, with the aim of providing you with a market leading product, solution, or application. We would love to partner with you in exploring opportunities and ways for your company to become a market leader of your industry. www. techproplus.co.nz Part Two in the next edition - read about how to become an industrial design market leader by using the outside the box, innovative thinking.

continued from page 5

Exporting to India and the Middle East to India and the Middle-East, we took some time to check where we could improve, become more productive, and cut costs internally. This has had a positive impact on the rest of our business. Ultimately, even if we don’t export a lot to these countries, it has taught us a great deal.” Finally, regardless of the country you export to, it is vital to know your customer. This will help you determine whether they are trustworthy and will save you a lot of trouble in the long run. “With export, there is always risk. You can’t fetch back and re-sell if

the product is not paid for, damaged or faulty. Which is why it is vital to know what your customer expects of you. That one last late-night phone call can save you a fortune.” Conclusion: Exporting is a good way to grow your business, and India and the Middle East are ripe with opportunities. Just remember to take plenty of time to research the market before you decide to enter it. “Entering any new export market is like investing in a new business”,

says Dean. “You can’t do it on a whim. You should not be exporting just because you want a bigger turnover figure; you need to make sure that you can actually make a profit.” In this case, as with many things, your motto should be: If you can’t do it properly, don’t do it at all. Useful contacts: New Zealand Trade and Enterprise: www.nzte.govt.nz India New Zealand Business Council: www.inzbc.org www.nzmanufacturer.co.nz

NZ Manufacturer July 2015

DEVELOPMENTS

I am not a product of my circumstances. I am a product of my decisions. —Stephen Covey

Low-tech manufacturing, the new hidden champion of innovation We have been overlooking the value and innovation that goes on in so called “low tech” companies, according to a European expert on industry. Auckland University recently hosted Prof. Dr. Hartmut Hirsch-Kreinsen Chair of Economic and Industrial Sociology TU Dortmund University, Germany. He spoke about the latest research that is uncovering these “low tech” innovators. He says everyone has been in love with “high-tech”companies, the definition of which is companies that have an R & D investment of over 5% of turnover and “low tech” having 1% or less investment in R & D. However the so called “Low Tech” companies are vitally important because they employ 60% of workers – many more than the medium to high tech companies, and they are remarkably stable and innovative in a specific way.

Common attributes are step by step product improvement, incremental innovation, small batches and also large scale production, relatively stable market segments, close to important customers, flexible and fast delivery, and semi-skilled or unskilled workers. They have the capacity to integrate external knowledge and high tech components and are the recipients and carriers of high tech innovations. They learn by doing, trial and error and have the capability to manage networks. Policymakers (Callaghan Innovation and MBIE) should also focus on the so called “low-tech” businesses. Innovation is more than just R & D investment as low tech businesses are good at using high tech developed elsewhere and leveraging it in innovative ways. So what can policy makers do to support? Prof Kenneth Husted from Auckland University says;

• Support creative reconstruction (don’t write off industries as “sunset” just because they are going through change) • Stimulate collaboration sectors and size

across

• Support to aggregate local lead user needs (e.g. innovation consulting services - in the absence of a large business ecosystem) • Support locally embedded technology commercialisation and growth (e.g. technology parks) • Leverage public procurement to stimulate innovation (this is one I have been promoting for some time now) • Produce more people with tertiary qualifications in manufacturing. The upshot of all this is that we may need to question the validity of R & D

intensity indicators as a good basis for innovation policy.

The so called “Low Tech” companies are vitally important because they employ 60% of workers.

Sage waste absorbs oil spills Waste material generated by Malaysia’s sago palm industry has potential for use as an adsorbent for cleaning up oil spills, according to a study published in the Pertanika Journal of Science and Technology. Conducted by Zainab Ngaini and colleagues at the Universiti Malaysia Sarawak, the study found that when sago waste (consisting primarily of cellulose and lignin) is chemically modified using fatty acid derivatives, the resulting material is more hydrophobic than untreated sago waste, implying that it has less affinity for water and an excellent affinity for oil. The authors conclude that chemically modified sago waste may be suitable

for applications where engine oil needs to be removed from an aqueous environment. By contrast, untreated sago waste could be used for absorbing oil in a dry environment Sago palm is commonly found in tropical lowland forests and freshwater swamps. Sarawak is one of the world’s largest exporters of sago products with annual exports of approximately 43,000 tons. However, the mass production of sago produces large amounts of waste residues. From 600 logs of sago palm

per day, an estimated 15.6 tons of woody bark, 237.6 tons of waste water and 7.1 tons of starch fibrous sago pith residue are generated. Currently, sago pith residues are either incinerated or discharged into waterways, which eventually contributes to environmental problems. Until now, no studies have examined sago waste’s potential as an oil adsorbent, despite its resemblance to previously studied natural oil sorbents such as cotton, wool and bark.

Metroxylon sagu or commonly known as the Sago palm thrives in tropical lowland forests and freshwater swamps. The state of Sarawak in Malaysia is one of the world’s largest exporters of sago products with annual exports of approximately 43,000 tons.

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21-28 AUGUST 2015 Find out everything you need to know about careers in manufacturing. • Earn while you learn • No student loan • Got a trade? Got it made!

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NZ Manufacturer July 2015

You can’t use up creativity. The more you use, the more you have.

REAR VIEW

—Maya Angelou

The Evolution of the NZ Steel Industry: Dr Troy Coyle, Manager of Innovation & Product Development at NZ Steel. Innovation dinosaur or drosophila? We have an image problem. In experimental evolution, Drosophila (the humble fruit fly) is often used to demonstrate evolutionary processes. It is used because genetic changes for the fruit fly can be observed very quickly in response to natural selection. In business, the equivalent of the fruit fly is the IT or information technology company, such as Xero or the Wynyard Group. IT companies form the bulk of case studies in management texts and innovation case studies because they are quick to respond to changing market conditions, and also quick to demonstrate these changes in the market. They are perfect examples of rapid innovation. In contrast, the steel industry is perceived to be traditional, slow to innovate and slow to respond to changing market conditions. We’re not rolled out as case studies for innovation and we are often relegated to the categories of at worst ploddingly ‘low-tech’, or at best masters of ‘incremental innovation’. We’re not attractive for Government funding either because we aren’t exciting in terms of being able to demonstrate rapid change, hi-tech outcomes or capturing public imagination. In other words, we’re “innovation dinosaurs”. The most public excitement we generate is

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speculation on whether or not we will die out or find a way to survive in the new world.

“Apple hasn’t so much invented new as they have innovated (to converge technologies into well-built and -designed packages).” David Reiss, Spark Digital. There is no doubt that the world is changing and so we need to adapt and quickly. However, we are not going to turn into hi-tech, fast innovating firms any time soon. The question is how do we show the world we are adapting in a way that is meaningful and be excited about our evolutionary journey, albeit relatively slow-paced? Firstly, we need to demonstrate our value. We might not be doubling our revenue year on year but we do make a consistent and substantial contribution to the New Zealand economy. For example, New Zealand Steel alone contributes ~1% of GDP. The New Zealand metals manufacturing industry employs around 26,000 Kiwis. Together, we contribute significantly

to employment, import replacement and export. This means that investing a dollar in incremental transformation of the steel industry is likely to yield more value to the economy than investing a dollar in any radical innovation arising from an emerging high-tech but volatile IT industry. Certainly, studies of OECD countries show that growth is primarily based on the transformation of existing sectors vs new sectors, and the contribution of hi-tech industries is over-emphasised. Secondly, we need to find a way to better promote our innovation. Incremental innovation can be sexy too - we just need to articulate the story better. We need to tell it in a way that emphasises the longevity of the industry and the evolutionary time scales we work within. We can’t be compared to IT companies - they don’t tend to have long lives. They metabolise like shrews, all frenzied and short-lived. We metabolise like sloths, stead-fast and enduring. Yet, a fast-paced sloth is more newsworthy than a fast-paced shrew. That is, let’s focus on the steel industry in NZ bucking the global trends for steel innovation. What are we doing that is faster or better than the rest of the world? What is the story we can tell that makes us more newsworthy? Thirdly, if we want more air time with politicians; funding agencies;

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customers and the general public, we have to change the perception that we are a low-skilled, old-fashioned, slow-to-evolve, traditional industry. Other traditional industries, such as the timber industry, have been pretty good at telling their stories. Our story is arguably even more compelling, certainly in terms of innovation, so let’s start telling it in a way that identifies us as the new leaders of the old low-tech. That is, let’s finally be seen as the steadfast economic contributor who is managing to re-invent itself to maintain currency. In summary, to develop a new public persona for the NZ steel industry, we need to dress ourselves up; more like a glamourous, racing emo (you know, nouveau punk) shrew/fruit fly than a tweed-jacketed-with-brownleather-elbow-patches, sedentary sloth/dinosaur (talk about mixed metaphors!). We are there in principle and we’re still going strong; we just need to make sure we update our wardrobe when we go out in public!

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NZ Manufacturer July 2015

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