NZ Manufacturer July 2018 by Media Hawkes Bay Limited

July 2018

www.nzmanufacturer.co.nz

THE CIRCULAR ECONOMY A circular future with stewardship at the centre.

ANALYSIS Law changes to watch out for.

WOMEN IN ENGINEERING Sulo Shanmuganathan, Technical Director.

Internet of Manufacturing Trek, Chicago - Kim Campbell, Chief Executive, EMA

The trek, which took place in June, was organised in conjunction with Callaghan Innovation, who partly subsidised attendance, and the Manufacturers Network (TMN) of Christchurch. The anchor for the trek was the attendance at the Internet of Manufacturing Midwest Conference in downtown Chicago. Also trade visits were arranged to Haas (America’s largest machine tool manufacturer in California) and Trumpf Midwest based in Chicago. We also had a private seminar in Chicago and visited two business hubs, UI Laboratories and M Hub. The participants were a mixture of tech savvy New Zealand companies and one or two from Australia.

Connected Manufacturing (IoM) 1. AI and robotics have been around for a very long time and, contrary to perceived wisdom, have been slow to be implemented and are not moving as fast as the protagonists of technology would like you to think. 2. The potential is large. Proprietary enabling technology available through Alexa, Siri, Watson, Microsoft Azure and others has brought the entry points to very affordable levels for certain kinds of data interrogation. Retro fitting older equipment and connectivity are now possibilities for all manufacturers. 3. Outstanding and unresolved issues affecting both very large companies (Caterpillar, GE, Boeing) are cyber security, legacy systems and industry standards; all problems for which no one has a ready answer and are definitely slowing implementation. Related but solvable problem is in systems latency. 4. Data is seen as the “new oil” and the stats are staggering. By 2020 there will be 50 billion connected devices in the supply chain eco system. By 2020 predictive maintenance will be the killer app across all

equipment (Smart Grid, Smart Cities, Smart Networks). The supply chain optimisation through AI creates difficulties with vendor locking and creates tensions between proprietary and open systems. 5. 1% of all industry data is getting used (McKinsey) allowing for a 700% increase in productivity gains or $100 trillion in realised value by 2025. Data is growing at a combined rate of 40% per annum. 6. If these vectors are applied to maintenance costs alone, savings of 50% in outages and increases of 15% in output are possible. 7. The technology for mass customisation is already in place, but questions remain about how much of that actually will be driven by consumer demand. 8. Only 15% of companies have a discernible digital strategy leading to the prediction that 75% of S&P listed companies from 2012 will have disappeared by 2027. The implications therefore are for companies to get on the programme, leading to the question, “What would a company who was to put you out of business look like”, and become that company. 9. The trend for manufacturing companies to move from “rules” based automation to the use of AI and machine learning to reduce variability in manufacturing so that each part is better than the last. This type of computing works best with low latency and edge computing rather than the cloud, where security and latency become an immediate problem.

continued on Page 13

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CONTENTS DEPARTMENTS

STORY 1 LEAD Internet of Manufacturing Trek, Chicago. NEWS 5 BUSINESS New book an insight into NZ businesses. TECHNOLOGY 6 MANUFACTURING Two uncertainties shaping our future.

ADVISORS Leeann Watson

Objective 3D appoints new technical services manager. 3D printing aircraft parts using new laser technology.

9 DEVELOPMENTS Kiwi insurance provider introduces

Dieter Adam

comprehensive manufacturing cover. Call to end lubricant packaging waste. Health and safety improving – survey.

CIRCULAR ECONOMY 11 THE Product stewardship is a cornerstone of the

circular economy. Tooling up to manufacture a circular economy.

14 ANALYSIS Law changes to watch out for. IN ENGINEERING 16 WOMEN Sulo Shanmuganathan, Technical Director,

New areas of application for collaborative robotics. Improving anomaly detection and prevention: What is your data telling you?

Is Chief Executive of BusinessNZ, New Zealand’s largest business advocacy body. He has held a range of senior positions at Westpac and is a barrister and solicitor.

21 ANALYSIS Modern workplaces need fit for purpose legislation.

PRODUCTS 22 NEW New Konecranes spare parts warehouse. Olympus launches new portable, powerful videoscope. Showa 707HVO: Highly visible, safe for users.

Old world thinking won’t deliver high growth economy. What do field service workers have to do with manufacturing?

28 Drives for pallet conveyor technology.

First demonstration of drone-based deliveries along power-line routes.

behavioural science).

Revolution.

Dr Troy Coyle

Craig Carlyle

NEWS 29 BUSINESS Boosting your bottom line. 30 COMMENT How to break up with plastics (using VIEW 31 REAR How to have a good Fourth Industrial

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.

Is HERA Director, she has extensive experience in innovation, research management and product development, most recently as Head of Innovation and Product Development & Pacific Islands Export Manager at New Zealand Steel..

focus on food contact plastics. 24 Global Alternative proteins report published. 26 DEVELOPMENTS Gallagher’s takes supreme ExportNZ award.

SUPPLY CHAIN

Chief Executive, New Zealand Manufacturers and Exporters Association has a Ph.D. in plant biotechnology, consulting and senior management roles in R&D, innovation and international business development.

Kirk Hope

Holmes Consulting LP.

MANUFACTURING 17 SMART Charging forward with the battery revolution.

Is the Chief Executive of the Canterbury Employers’ Chamber of Commerce (the Chamber).and is a strong voice for Canterbury business.

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

Increasing the number of

women engineers

PUBLISHER

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

CONTRIBUTORS

Dieter Adam, Holly Green, Kim Campbell, Leeann Watson, Sulo Shanmuganathan, Ruban Phukan www.mscnewswire.co.nz

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MEDIA HAWKES BAY LTD T: +64 6 870 4506 F: +64 6 878 8150 E: mediahb@xtra.co.nz 1/121 Russell Street North, Hastings PO Box 1109, Hastings, NZ NZ Manufacturer ISSN 1179-4992

Vol.9 No. 6 JULY 2018 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.

NZ Manufacturer July 2018

This issue’s profiled woman engineer is Sulo Shanmuganathan, Technical Director, Holmes Consulting LP, New Zealand. Her story is on Page 16. If you are a woman engineer or know of one with an interesting story to tell, contact publisher@ xtra.co.nz and we can discuss your participation in a future issue.

WEB MASTER

You will have noticed in recent issues NZ Manufacturer supporting the Diversity Agenda, in association with Engineering New Zealand. Presently, only 14% of our engineers are women and the aim is to raise the total to 20% by 2021.

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In June, the EMA and the Manufacturers Network and manufacturers attended the Internet of Manufacturing Midwest Conference in Chicago. Trade visits were arranged and business hubs visited. (This visit also featured in June issue editorial and on Page 30.)

networked manufacturing and Industry 4.0 space. But at the end of the day our manufacturers have to find out what works for them. Kim Campbell’s article (starting on Page 1) provides insights and reflections on what was a successful trip. The Circular Economy – of which we all need to be involved – features on Pages 11 and 12 with leading articles from Adele Rose, 3R Chief Executive and James Griffin who leads the Sustainable Business Network’s Circular Economy Accelerator (CEA).

There were thirty seven participants from twenty six New Zealand and three Australian manufacturing companies and from two government funded innovation agencies, Callaghan Innovation and the Australian IMCRC. The week was a great opportunity to gain insight into what U.S companies are doing in the

Doug Green

Success Through Innovation

EDITORIAL

BUSINESS NEWS New book an insight into NZ businesses BusinessNZ is welcoming a new reference book that offers an insight into the New Zealand business scene. 100% Kiwi Business: 9 Kiwi Success Navigators is authored by Executive Director of the Buy NZ Made Campaign Ryan Jennings, and has been written for those growing their business or starting a new one. It contains interviews with 100 business owners and CEOs across a range of industries. “BusinessNZ is committed to New Zealand’s success through advocating for thousands of businesses across New Zealand,” says Chief Executive Kirk Hope. “The businesses in this book are representative of our broad membership, from those just beginning their journey to others at the pinnacle of their success. “The lessons and learnings in this book will be of relevance and benefit across the entire business ecosystem and, I hope, provide encouragement. Successful business helps to make New Zealanders better off. “ The book, which was a two-year

labour of love for Mr Jennings, reveals two very Kiwi traits - creativity and pragmatism. “Kiwis are wired to give things a go purely due to where we are situated in the world,” says Mr Jennings. “We’re a long way from where the hubs are, which requires us to be creative. It’s something we’re great at and which the rest of the world values.

“The first is around failure, which is another word for learning. If you’re scared of failure, you’re scared of learning. There is a chapter on the psychology for success - some of our greatest successes in the book and in NZ come from the failures.” The second involves what he describes as a world of tribes that have very different norms from the mass.

“The focus of this book is on businesspeople who are currently on their journey, rather than being a retrospective study of business success. There are a lot of conversations about where NZ is heading, but Kiwi business owners are just getting on and doing it.”

“The opportunity for business is to connect with those tribes. Facebook groups, across world markets - the doors are off. It’s never been easier to contact and go to new markets. The onus is now on businesses to find their audiences; it’s not a door that you open, it’s a group that you join.”

The book identifies nine success navigators, ranging from exiting the business - always begin with the end in mind, says Mr Jennings - to creating and capturing value.

Mr Jennings says the insider insight gained through writing the book has yielded useful learnings for his day job. The Buy NZ Made Campaign, which allows businesses to use the Kiwi trademark to promote

And it contains two further revelations.

their NZ-made goods and services, is celebrating its 30th anniversary this year. “It has given me new insights into the economic potential for existing and new businesses applying the New Zealand brand both at home and overseas.”

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NZ Manufacturer July 2018

MANUFACTURING TECHNOLOGY Two uncertainties

Great business turns on a little pin. -George Herbert

shaping our future

When we think about the future, most of us try to predict it by extrapolating from a wide range of assumptions that we make about today. But most predictions tend to be wrong, from the automobile being written off as a “fad” in 1903 to a 1977 article querying why anyone would want a computer in their home. A context of high volatility, uncertainty, complexity and ambiguity only exacerbates the likelihood of error. We propose a different way to explore the future, using the concept of critical uncertainty. This allows us to consider a few plausible futures and become more resilient to the challenges they hold. It reduces the risk of blind spots and unwelcome surprises. It can also help us identify ways in which we can proactively shaping the future. We have aggregated the results of a call to identify critical uncertainties. We analysed more than 90 answers and articles shared by members of our network of experts, using text-based software. Several patterns and commonalities were identified. The two most significant ideas are explored below.

as to how far AI might permeate society, as well as around who will own the capability, according to Mark Esposito, Fellow at the Cambridge Judge Business School. Current debates around AI typically focus on how it empowers large organizations, while displacing a large number of workers from their jobs, highlights David Li, Founder of the Shenzhen Open Innovation Lab. However, these debates often overlook the potential of AI to empower smaller groups or disruptors that are yet to emerge. As machines become smarter than us, they are taking over jobs and tasks historically done by humans. We rely on them more and more to make decisions. Whether or not we will trust them remains unclear, writes Vyacheslav Polonski, Researcher at the Oxford Internet Institute. The uncertainty around AI also reflects the emergence of China as a leader in the field. China had four times

This is a network view of the inputs received from subsets of the World as many AI-related Economic Forum Expert Network. Each single contribution represents a patents in 2017 as node, while the two topic areas are the most central part.

Scale, scope and type of AI adoption AI remains an underdeveloped scientific capability, owned by several large companies. There is uncertainty

the US, according to the Startup Genome Report 2018. Others have pointed out the importance of the ecosystems that emerge around AI. These can be very different, depending on context, and may have their own sets of diverging applications and implications.

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Reallocation of power and the ability to collaborate

Most predictions about the future - including those of experts tend to be wrong

After the Second World War, we moved from being ‘subjects’ to ‘consumers’. Now we seem to be moving from ‘consumers’ to ‘citizens’. People are taking a much more active role in shaping society. Key to this is healthy public debate, and the extent to which citizens’ voices are heard and taken into account by organizations shaping the development and use of technologies, says Hilary Sutcliffe, Director at Society Inside.

The uncertainty around AI also reflects the emergence of China as a leader in the field. The structures and institutions that have traditionally allowed each of us a voice also face increased uncertainty. The efficacy of democracy is being questioned. Increasing numbers of people, particularly youth, have lost faith in democratic systems and structures, says Andrea Bandelli, Executive Director at the Science Gallery International. Seventy-two per cent of Americans born before the Second World War

state that it is “essential” to live in a democracy, while only 30% of millennials do. This pattern is found across all long-standing democracies, including Great Britain, the Netherlands, Sweden, Australia and New Zealand (Foa and Mounk 2017). There is an urgent need for the reform and evolution of democratic systems. Whether or not we will succeed, or create alternative systems, remains to be seen. More generally regarding the role of the citizen, one principal uncertainty is whether or not we will be able to work collectively towards greater sustainability. This includes developing a common vision that can be embraced by different sectors of society and geographies across the world. It is unclear whether or not SDGs represent this vision, says David Bray, Executive Director of People-Centered Internet.

So what? Which different directions could these critical uncertainties take? What could be the implications for individuals, organizations, regions and the world? Exploring and discussing these alternative pathways will not only make us more prepared and resilient, it will offer opportunities to shape these developments towards the future we want.

Before anything else, preparation is the key to success. - Alexander Graham Bell

MANUFACTURING TECHNOLOGY

Objective3D appoints new

Technical Service Manager

Objective3D, the leading provider of Stratasys and Desktop Metal 3D Printers has announced the appointment of Arron Jack as the new Technical Services Manager. Arron, a highly experienced technician will be working with the Objective3D technical services team to empower its customers by more efficient usage of their Professional 3D Printers as well as to strengthen Objective3D’s drive and growth for greater market share in both Australia and New Zealand. Arron is well known to product designers and manufacturers across Australia and New Zealand having spent almost two decades in a variety of technical roles in the 3D printing industry, the most recent with Fuji Xerox Australia. Objective3d Managing Director, Matt Minio, said: “We’re very pleased to have Arron join our team. Arron’s technical experience spans the wide range of 3d printing technologies including Stratasys FDM and PolyJet. “After sales service and support

for professional 3D printers are critical. Arron with his detailed knowledge and experience will assist in keeping our growing number of customers’ equipment operational. This will further strengthen our close relationships with our customers and enhance our potential for developing other opportunities.”, added Matt Minio. “Arron is an integral leader in our service team”, added Objective 3D Technical Director, Darryl Wootton, “We have been benefiting from his extensive background in a number of ways. He hit the ground running and immediately began contacting our customers and undertaking both onsite and over the phone. Arron’s appointment is already resulting in more timely resolutions to customer technical service issues which is a key requirement in the market.”

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NZ Manufacturer July 2018

MANUFACTURING TECHNOLOGY

The road to success is always under construction. - Lily Tomlin

3D printing aircraft parts using new laser technology A team of RMIT University researchers led by Professor Milan Brandt are using laser metal deposition technology to build and repair defence aircraft parts in a two-year collaboration with RUAG Australia and the Innovative Manufacturing Cooperative Research Centre (IMCRC). The technology feeds metal powder into a laser beam, which when scanned across a surface adds new material in a precise, web-like formation. The metallurgical bond created has mechanical properties similar, or in some cases superior, to those of the original material.

and readiness of aircraft.”

shipping costs.

“It’s basically a very high-tech welding process where we make or rebuild metal parts layer by layer,” explains Brandt, who says the concept is proven and prospects for its successful development are extremely positive.

The technology will apply to existing legacy aircraft as well as the new F35 fleet. The technology is also being adopted in RUAG’s recently established robotic laser additive manufacturing cell.

An independent review, commissioned by BAE Systems, estimated the cost of replacing damaged aircraft components to be more than $230 million a year for the Australian Air Force.

Engineers repairing a landing gear

Head of Research and Technology at RUAG Australia, Neil Matthews, says that by enabling onsite repair and production of parts, the technology could completely transform the concept of warehousing and transporting for defence and other industries. Currently, replacement parts typically need to be transported from local or overseas storage and suppliers. “Instead of waiting for spare parts to arrive from a warehouse, an effective solution will now be on-site,” says Matthews. “For defence forces this means less downtime for repairs and a dramatic increase in the availability

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The research project is the latest collaboration over the past decade between RUAG Australia and Brandt, who is Director of RMIT’s Centre for Additive Manufacturing and a leading expert in the field.

mean big savings on maintenance and spare part purchasing, scrap metal management, warehousing and shipping costs. A move to locally printed components could mean big savings on maintenance and spare part purchasing, scrap metal management, warehousing and

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CEO and Managing Director of the IMCRC, David Chuter, believes application of this technology will be much broader than defence.

“As the leading Australian research organisation in this technology, we are confident of being able to deliver a cost-effective solution that fulfils a real need for defence and other industries,” says Brandt.

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“In fact, this could potentially be applied in any industry where metal degradation or remanufacture of parts is an issue.”

A move to locally printed components could

PACKAGING

“The project’s benefits to Australian industry are significant. Although the current project focuses on military aircraft, it is potentially transferable to civil aircraft, marine, rail, mining, oil and gas industries,” says Chuter.

NZ Manufacturer July 2018

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The laser metal deposition technology in the lab

Don’t let the fear of losing be greater than the excitement of winning. - Robert Kiyosaki

DEVELOPMENTS

Comprehensive manufacturing cover for emerging threats With the manufacturing sector experiencing strong growth and exports exceeding NZ$49 billion, the industry is in good shape. However, with the global trend for increased innovation and efficiency, new challenges and risks face the industry in relation to quality control. For Delta Insurance, this trend highlights the need for manufacturing companies to continually assess and minimise these increasing and evolving risks and they have developed what they believe to be a New Zealand-first – liability coverage specific for the needs of manufacturing companies, giving them comprehensive cover for risks such as product defects and related financial losses. Senior underwriter and casualty lines manager Dinesh Murali elaborates: “events such as product recalls or pollution incidents, can be prohibitively expensive and seriously impact a manufacturer’s bottom line.” The manufacturer’s liability package takes a modular approach and carries some unique coverage sections which are usually not addressed in such policies. “It can be a tedious and expensive exercise for typical SME businesses when they need to

purchase several insurance products independently” says Mr. Murali. “Multiple insurance covers usually make the cost prohibitive. We have put everything under one package at a more affordable premium.” According to Mr. Murali, the cover addresses the risk of product recall and product defects unique to the manufacturing sector, as well as cover for financial loss, slow and gradual pollution, crisis management and consequential loss. It can also be packaged with other cover such as cyber liability. With a 62% increase in recall rates for food products last year and a trend that looks set to continue, manufacturers need to ensure they are covered for such an event. Delta’s policy covers a range of scenarios that result in a product recall, including accidental contamination from pathogens, undeclared allergens and other foreign matter, malicious product tamper and incorrect labelling. Additionally, non-food manufacturers are also covered for a product recall scenario, given the range of new and evolving risks they are confronted with today. Kiwi manufacturers are increasingly vulnerable to possible

quality control issues given their reliance on overseas suppliers (for outsourced components or manufacturing processes). They are also exposed to increased risk of cyber-attacks through widescale use of programmable logic controller software, embedded technology connecting to the ‘internet of things’ and general advancement of Industry 4.0 technologies. In addition to product loss and product recall costs like advertising and shipping, there can also be other costs involved including damage investigations, sample testing, advice from experts, business interruption and loss of sales and customers. “There is also the danger of significant reputational damage if companies do not have the resources to manage these critical issues. We can help to provide all the legal, PR and other expertise when things go pear-shaped” says Murali. As the only locally owned and operated specialist liability underwriting agency in New Zealand, this strategy has been successful for Delta with other products. They are currently the largest insurance provider to the thriving kiwi technology

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sector and have introduced the first local liability products in New Zealand for the environmental and UAV (or drone) industries. “We are similar to the New Zealand manufacturing industry in the sense that we don’t want to be all things to all people.” says Mr. Murali. “We’ve sought out niche markets where we believe we can truly add value by providing tailored, high quality products.” Mr. Murali concludes: “Manufacturers need to get the puzzle right and minimise their risk while achieving growth. They make hundreds of good decisions every day. They just need to make sure they are equipped to deal with the one decision that doesn’t come off!” Delta Insurance is a New Zealand-based insurance provider, a Lloyd’s of London Coverholder and are backed by multinational insurer Allied World. They provide a range of specialty commercial insurance products and have an office in Singapore.

NZ Manufacturer July 2018

DEVELOPMENTS

Amateurs sit and wait for inspiration, the rest of us just get up and go to work. - Stephen King

Health and safety improving - survey New health and safety legislation is helping businesses become safer, but more work is still needed, says BusinessNZ. Deloitte has surveyed a range of New Zealand businesses to find what has changed since the passing of the Health and Safety at Work Act 2015. The survey shows half the businesses surveyed say they are safer because of the reforms, more people in the workplace are involved in health and safety, and more effort is going into

controlling risks. BusinessNZ Chief Executive Kirk Hope said the survey vindicates the approach in the new legislation of requiring engagement by everyone in the workplace and focusing on managing risks. “The survey indicates that more debate around health and safety is happening at Board level, as well as among management and workers. This is positive because the Act requires Boards

to be proactive in their governance of health and safety, however only half of the Boards surveyed are taking a proactive approach and about a third simply wait for management to raise health and safety issues. “There may also be a concern about costs borne by small businesses in coping with the requirements of the Act in managing health and safety risks connected with their suppliers and clients.

“The survey indicates that most businesses are achieving better health and safety because of the Act, but with some aspects of health and safety management still requiring improvement.”

ACA holds Corrosion Under Insulation workshop The economic impact of corrosion and its degradation of infrastructure and assets is estimated to be 3 to 5 per cent of GDP, which for the New Zealand economy is more than $10B annually. Companies require effectively trained

staff who have an understanding of the numerous types of corrosion that affect their industry, the impact of dangerous and expensive damage that corrosion causes to structures

such as pipelines, towers, bridges, oil rigs, buildings, water systems, and the preventative and remediation technology available. The Australasian Corrosion Association (ACA) regularly hosts special technical events for members and others working in the corrosion management and prevention sector, designed to provide attendees with information and guidance about ways to combat and manage corrosion. As part of this program, the ACA ran a two day Corrosion Under Insulation (CUI) workshop in New Plymouth at the end of last month. Presented by internationally renowned CUI consultant Peter Bock from Houston, USA, the workshop was dedicated to the design, specification

and inspection of corrosion control systems to prevent CUI in new or aged equipment. Topics covered included causes of CUI, current state-of-the-art CUI coating systems, inspecting and evaluating aged CUI in the field, as well as suitable CUI repair coating systems. Bock has more than thirty years’ experience in elevated temperature coatings and CUI, and has published numerous articles on CUI issues. In addition, he has spoken at NACE, SSPC, ICC and other national and international conferences regarding CUI problems and solutions. Allied to this as CUI has an impact on durability, the ACA hosted a one-day seminar entitled ‘Designing for Durability in the Built Environment’ in July, in Parnell.. The seminar covered a range of topics including Fastener Durability in Timber Structures, the Role of Stainless Steels in Architecture and Using Metal as a Cladding Material.

Participants gained the knowledge and tools to offer the most effective solutions—implementing and promoting durability planning. The New Zealand Building Code (NZBC) sets the performance standards to which all structures are required to comply. The main purpose of the NZBC is to ensure structures are safe, healthy and durable for everyone who may use them. The B1 Structures clause of the code clearly states how engineers, and users, can work toward ensuring compliance. A rigorous peer review process is an integral part of the design. Some in the industry feel that there are limitations within the B2 Durability clause of the NZBC. This has led to misunderstandings on achieving compliance, especially in regards to Acceptable Solutions or using the Verification Methods for some construction materials.

Call to end lubricant packaging waste Major lubricant industry brands are calling on importers and distributors in the market to join them in tackling the issue of millions of lubricant packages being discarded every year. A Waste Lubricant Container Product Stewardship Scheme has been established with the aims of exploring recycling options for lubricant containers. It is estimated that around 7 million (20 litre and under) lubricant and grease containers, plus an unknown number of 200 litre drums, are sent to landfills each year. The scheme will aim to “close the loop” on lubricant packaging and contribute to the development of a Circular Economy in New Zealand, with a focus on supporting the development of processing capacity and end use markets.

NZ Manufacturer July 2018

“Considering that most lubricant containers are manufactured from High Density Polyethylene (HDPE) or metal, both highly recyclable after pre-treatment, this provides the ideal opportunity to capture these resources onshore,” says Adele Rose, Chief Executive of 3R Group, the project managers. To achieve this, members intend to work together as part of a voluntary, industry-led scheme to recover, reuse and recycle waste lubricant containers for urban and rural customers. This will maximise the number of containers diverted from landfill and reduce the

need for virgin resin imports. “The scheme is focused on creating an environment for market pull through of the collected material, supporting the economy through improved resource use and employment opportunities. The scheme will create a united industry position that will help bring positive behavioural change to the way that waste lubricant packaging has traditionally been disposed of,” Adele says. 3R began working with the industry after being approached by Z Energy Ltd earlier this year to facilitate an industry

The scheme will aim to “close the loop” on lubricant packaging and contribute to the development of a Circular Economy in New Zealand.

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working group to develop stewardship for waste lubricant container recycling. Initial meetings with the industry made it clear a nation-wide solution was needed. Z Energy are joined by well-recognised brands - Aegis Oil Co, Allied Lubricants Ltd (HWR), Castrol NZ, Farmlands Co-Operative Society Ltd (Gulf Oil), Lubricants NZ (Vertex & Elf), Oil Intel Ltd (Total Lubricants), Penrite Oil NZ Ltd and Valvoline NZ Ltd. Other brands are expected to join up over the coming months. Single use plastic packaging has become a highly publicised international environmental issue. This scheme offers the chance for the New Zealand lubricant packaging industry to take a leadership position on the issue.

The best way to succeed in this world is to act on the advice you give to others. - Unknown

THE CIRCULAR ECONOMY

Product stewardship is a cornerstone of the circular economy

Adele Rose – 3R Chief Executive

Mention the term ‘product stewardship’ to the first person you bump into on the street and chances are you will be met with a blank look. The truth is, it’s not a widely known concept in New Zealand. It also is and isn’t a simple one either. Suggest that manufacturers and retailers should take responsibility for the products they make and sell throughout the lifetime of those products (the definition of product stewardship), and the blank look will probably turn into a puzzled one. Fast-forward to the year 2050 and this will be a different story. The terms ‘sustainably produced’, ‘fair trade’, ‘organically grown’ and the like were little known or not even coined 20 or 30 years ago but are now part of everyday life. In the same way talking about product stewardship will certainly be common place 32 years from now. The reason for this is product stewardship is a cornerstone of the circular economy – another little-known phrase which will certainly become common place long before 2050. The circular economy is the economy of the future, and ironically also one from the past.

Circular principals In generations past there was a far higher value placed on things. When your TV broke you didn’t immediately throw it away, you had it repaired if possible. Things like children’s toys were more durable and weren’t bought on mass. We generally had less stuff, and the stuff we had lasted longer, was repaired and reused. Simply getting rid of something and buying new wasn’t the knee-jerk reaction it is today. Moving to a circular economy isn’t about nostalgia or an ideologically nice thing to do. It’s also not because it’s the environmentally responsible thing to do, but rather because the linear economy and its basis of infinite growth from finite resources is intrinsically flawed and cannot survive. We cannot survive it. In a future in which the circular economy is in full swing having a product stewardship scheme will be standard practice. Consumers will expect it, so much so that it won’t even enter discussion – it will simply be the way things are.

Stewardship in the here and now So where are we now? Currently there are 14 voluntary, Government-accredited product stewardship schemes in New Zealand, ranging from container glass to concrete, and agricultural plastic to waste oil. These vary in size and effectiveness and rely on manufacturers and retailers to ‘do the right thing’ by voluntarily contributing to schemes which collect and recycle or properly dispose of the products. Granted, each scheme covers a number of different products, but 14 schemes isn’t a high number. It also isn’t particularly impressive considering the Waste Minimisation Act 2008 - which has stewardship at its heart - has been around for 10 years.

Priority product The Act is a big part of getting from here to where we need to be. It’s a powerful tool, which hasn’t been fully utilised by previous governments. But as Bob Dillon said, “the times they are a changin’” and the new Government is seemingly far more motivated than their predecessors to make use of the Act. And this is where mandatory product stewardship (which the Act has the ability to create) comes in. Mandatory stewardship is the more effective route as it puts everyone on a level playing field and prevents non-participating producers from taking a ‘free ride’. In New Zealand mandatory stewardship can only happen when the Minister for the Environment declares a priority product under the Act. Priority product status has never been declared in New Zealand. However, recent comments by Associate Minister for the Environment Eugenie Sage point to a quickly growing probability we will soon see the country’s first mandatory declaration. End of life tyres are a good example of how mandatory stewardship is the best route to follow. The working group for end of life tyres, Tyrewise, has the backing of the industry but on the condition of tyres being declared a priority product. One reason being that they want to avoid free riders,

the second being that the industry recognises some product regulation tools will be needed to support local Councils.

The face of stewardship Another important part of the puzzle is of course what a product stewardship scheme, be it voluntary or mandatory, looks like. The waste hierarchy of avoidance, reduction, reuse, repair and only then recycle is the guiding standard which all stewardship schemes should look to. Properly implemented product stewardship goes back to the design phase in order to increase lifespan, reusability and repairability. In a circular economy future (underpinned by product stewardship) our whole way of thinking about product ownership will shift, with a greater emphasis on paying for services rather than owning the products which provide them. Philips’ Light as a Service is a much drawn on example of this new way of doing business. The model sees a customer pay Philips for the light it uses while Philips maintains ownership of the lighting fixtures. This means the company has taken complete responsibility for their products, from production through to end of life treatment. As a result, Philips develops more durable and repairable fixtures and is more motivated to maximise the resources which go into them. The circular economy in action.

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A place for recycling Recycling has long been seen by the public as the environmentally and sustainably responsible thing to do, and it certainly has its place. However, it is far from the first choice. What we don’t want from our product stewardship schemes of the future is to simply enable more recycling. This can so easily happen as recycling is the path of least resistance because manufacturers don’t need to change their products much – if at all. There are of course exceptions. Glass, being infinitely recyclable, is one example. The best way of dealing with the tens of thousands of tonnes of glass bottles and jars being used every year in New Zealand is to recycle them into new bottles and jars. Another example is PET (type 1) plastic. It too can be recycled again and again as rPET. This is where product stewardship can support the development of onshore processing capacity for materials.

The future In the year 2050 stewardship schemes will not only divert waste from landfill and recapture resources, but genuinely do so with the waste hierarchy at their core. They will also have sparked a myriad of new business opportunities. Mention the term product stewardship to someone in 2050, or even in 2030, and they will know exactly what you are talking about.

NZ Manufacturer July 2018

THE CIRCULAR ECONOMY

Success usually comes to those who are too busy to be looking for it.” - Henry David Thoreau

Tooling up to manufacture a circular economy James Griffin leads the Sustainable Business Network’s Circular Economy Accelerator (CEA) to hasten the adoption of a circular economy in New Zealand. He says the challenges awaiting manufacturers are both significant and exciting.

We need a fundamental transformation in design, manufacture, procurement and supply chain management. Otherwise humanity will find itself pumping waste and pollution around its economic system for aeons to come.

The potential benefits of this approach have been clearly identified. And they are enormous. In May we released a ground-breaking economic study completed by Sapere Research Group in partnership with ATEED. We discovered that Auckland could be up to $8.8 billion better off in 2030 if the city adopted a circular economy approach.

Once established, this will bring together business people and academics, working together to address the many technical and systemic challenges around remanufacture, repair or reuse.

The principles of this shift are well-established. If we are going to design the waste and pollution out of our way of life, all products need to be designed for longevity. They must incorporate the ability to repair, upgrade, reuse and disassemble them.

To make this happen, and reap the rewards, leading manufacturers will need to partner with system thinkers and academic institutions. This is what is driving the development of the CEA’s Institute for Innovation in Remanufacture & Reuse.

For this, CEA is currently bringing companies together into its Circular Innovation Programme. We have an initial systems diagnosis of key New Zealand business sectors is already underway. This will help identify the nature of the challenges ahead.

Circular economy thinking is already producing real world tools to change the way we make things. In the process we could remake our world.

And at the end of their life precious materials must be harvested and re-cycled in closed loops. This requires careful design thinking from the outset and throughout the manufacturing process. Otherwise we tend to lock ourselves into linear pathways and approaches. Think renewable energy. Think recycled and recycled materials. Think manufacturing for leasing and product stewardship rather than sale and disposal.

Businesses will also need to work together. We have to meet individual business challenges and overcome the systemic barriers to progress.

Think renewable energy. Think recycled and recycled materials. Think manufacturing for leasing and product stewardship rather than sale and disposal.

If you want to get hands on straight away with existing methodologies and tools for the implementation of closed-loop manufacturing systems, check out ResCom - Resource Conservative Manufacturing. This helps designers and manufacturers understand how collection, remanufacturing and reuse of products can lead to more profitable, resource-efficient and resilient business practices. It comes complete with industrial case studies demonstrating the benefits. We hope to begin translating resources like these to make them more directly applicable for New Zealand manufacturing in the near future. We will also be producing new tools and resources to assist manufacturers in making this shift. This kind of manufacturing will be increasingly demanded by business-to-business customers and brands, as well as consumers themselves. It represents the most effective and efficient way to continue to meet the needs of the marketplace, without undermining the resource base it relies on. Already governments and policy makers are moving to bring manufacturing into this kind of framework. The EU Commission has adopted an ambitious Circular Economy Action Plan. China has incorporated new laws to explicitly promote the Circular Economy into its five year plans. The resulting shut-down of waste importation to China has radically reshaped the market for waste materials. Other changes will soon materially affect manufacturing for export to and import from these areas. So now is the time to get up to speed on this idea. It is set to radically transform the manufacturing sector in the months, years and decades to come.

NZ Manufacturer July 2018

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COMMENT

The person who says it cannot be done should not interrupt the person who is doing it. – Chinese proverb

The importance of social media marketing for manufacturers Research by New Zealand’s leading search engine optimisation (SEO) specialists has revealed the extent to which social media is increasingly driving traffic to business’s websites. Using anonymised data collected from 200 Google Analytics accounts and 548 Google AdWords accounts, Pure SEO’s 2018 New Zealand Internet Search Trends and Insights report represents the largest ever analysis of New Zealanders’ search habits. This information will be invaluable for informing digital marketing strategies for manufacturers, particularly those who market directly to consumers. Pure SEO’s analysis of Internet searches in New Zealand for the year 1 January to 31 December 2017, identified new insights into how New Zealanders have been engaging with search engines over the past year, and what the coming year’s trends are likely to be. Pure SEO’s Chief Executive Officer Richard Conway says the analysis showed that in 2017 there was a 31.3% increase in website visits from social sources such as Facebook, Twitter and

LinkedIn compared with the same period in 2016. An estimated 95% of those visits came from Facebook. Mr Conway attributes the increase to social media technology becoming increasingly advanced, attracting more attention from New Zealand businesses. He notes that Facebook in particular continues to improve its targetting capabilities, allowing businesses to market straight to their existing audiences and attract new ones. “We expect the upward trend to continue as more New Zealand businesses discover the power of social media marketing,” he says. Mr Conway advises businesses to continue focusing on social media marketing: “As our statistics show, it is clearly a powerful tool for driving

website visits and building brand authority - this all aids more clicks and better rankings.” However, simply having a social media presence will not necessarily boost the Google rankings for a business’s website. “While it is important to continue building a loyal audience and boosting brand visibility and authority through social media, digital marketing strategies should also focus on earning authoritative links from external websites and activities that build a loyal audience. Although social media is an undeniably important channel for driving web traffic, Mr Conway cautions businesses to broaden their focus when developing their digital marketing strategy.

that is constantly evolving, creating new challenges and opportunities for business owners, marketers and advertisers. So much so, that what held true a year ago may no longer be true today. “There is no magic bullet and no quick fix, so cover the business for all possibilities by having a range of organic and paid search components that complement each other. If SEO growth slows, then Google product listing advertisements and paid search advertisements will still have the business covered,” he says. The full report can be viewed here: http://content.pureseo.co.nz/ new-zealand-internet-search-trendsand-insights

“Search engine marketing (organic and paid) is a highly specialised discipline

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Internet of Manufacturing Trek, Chicago, 10. The question of the societal shift and what happens when robots do all our work curiously remains unanswered, but here are a number of predications: a) The first jobs to go are the ones described (dirty, dangerous and dumb) and the bumper sticker used for this is “shift happens”. The implications being we move quickly to eliminate the unpleasant jobs which are also dangerous, understandably for mining, cleaning, lifting. b) Despite the predictions of mass unemployment, employment has actually increased and in most developed economies, there are skill shortages. c) All this will take longer and cost more than anyone realises. 11. For manufacturing the issue is to attract young talented people who do not see the opportunities and have not been exposed to the modern factory. IoM uses a high level of technology and a low level of active labour engagement and is right in the millennial sweet spot. 12. The implication for New Zealand manufacturing is - rather than

focus on big hit transformational changes, we should take early baby steps with simple sensors, post-automation and data integration. These use well understood proprietary technology. There are “killer apps” out there, but you don’t need these to participate in the digital revolution.

They do not have a probationary period because everybody is permanently on probation. One wonders why anyone would work there until you find out that everybody gets an extra week’s wages every month that the production target is met and everybody shares in a profit at the discretion of the management.

The staff see no need for a union. The message clearly is if we are to have a flexible work environment within the technological future, then firms will need to be more generous in sharing the spoils of success.

Temptation is to look for lots of “shiny things”, but really there is a need to find solutions to problems that are overwhelming the operation and seek to use IOT and to solving customers’ problems and not your own. This seems to me a real insight.

13. As a postscript, I visited Haas Automation. This is a non-union shop spread over 100 acres, with some 500 employees, with $1 billion in sales. Out of California they export 75% of what they produce which are components and robotic machine tools. Their underlying staff policy is employment at will, which effectively means they can hire and fire as they please. They have a waiting list for people to join the company.

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NZ Manufacturer July 2018

ANALYSIS

Spend eighty percent of your time focusing on the opportunities of tomorrow rather than the problems of yesterday. - Brian Tracy

Law changes to watch out for -Dieter Adam, CE, The Manufacturers Network The Government has launched a couple of working groups which will be critical over the coming years in the area of employment law and regulation. We already have the Employment Relations Amendment Bill, to which we submitted and presented our comments to the Select Committee, and now there is a review of the Holiday Act 2003, as well as a Fair Pay working group. After a number of high profile cases of underpayment of holiday entitlements by some employers (both private and public sector), the Government is reviewing the Holiday Act 2003. The review group will include representatives from Business NZ, Unions and Government, and will be chaired by Gordon Anderson, law professor at Victoria University. The group is set to report back in 12 months, though any legislation changes will likely be two or three years away, depending on political movements. In terms of detail, so far, we have a Cabinet Paper outlining the terms of reference, which include key objectives of the review to develop options that: • make the provision of, and payment for, entitlements to holidays and leave simpler and more readily applicable to the range of working arrangements in the labour market • provide clarity and certainty to employers and employees so that employees receive their correct entitlements and employers’ indirect compliance costs are reduced • aim to protect the entitlements to employees

overall

• are easy to systematise implement in payroll systems

and

One example of the issues in the current act described in the Cabinet Paper is the definition of a working week, when hours may be variable, or a company’s roster and production cycle does fit into a weekly cycle – the act does not provide clear guidance and simple rules for how to deal with such a situation.

system which is simpler and easier to implement for businesses would be helpful. The review needs to focus on reducing compliance costs for businesses and working effectively with existing payroll systems to correctly meet requirements – it can’t be an exercise of drastically increasing such compliance costs on manufacturers, who already face challenges in remaining competitive in a relatively high-wage country. The second is the Fair Pay Agreements Working Group, chaired by the Rt Hn Jim Bolger: “The Group has been established to make independent recommendations to the Government on the scope and design of a system of bargaining to set minimum terms and conditions of employment across industries or occupations.” It is set to report back by the end of 2018 and its core scope is defined as:

NZ Manufacturer July 2018

• how bargaining participants will be identified and selected – by industries, occupations, or both • what Fair Pay Agreements should cover in terms of scope • bargaining rules and dispute resolution processes, and ratification and enforcement of Fair Pay Agreements It is not yet clear how “industry-wide” might be defined in such Fair Pay Agreements, but we are fundamentally opposed to this government’s drive to keep using a steamroller to ‘level the playing field’ for pay agreements. As if the collective bargaining provisions in the proposed Employment Law reform weren’t bad enough, these moves completely ignore the commercial reality our members operate in. As manufacturers we know that two

We are fundamentally opposed to this government’s drive to keep using a steamroller to ‘level the playing field’ for pay agreements.

On the surface, some of these aims could result in useful change - a

• the criteria and process to initiate bargaining on a Fair Pay Agreement

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manufacturers across the country may appear to be in the same industry, either through what they produce or through employing similarly qualified workers, however, they may have greatly different abilities to pay their workers. A fair pay agreement which required the same wage standards across such similar, but very different businesses, would undoubtedly jeopardise the global competitiveness of our manufacturing sector. This Government is wasting time and effort on trying to turn the clock back and shape the labour market in a way that is completely out of step with the way our economy will and needs to develop. Our economy, and that of our peers, is changing to become more variable, flexible and dynamic every day – from consumer demands to production processes to workers’ expectations on how they are being treated. And on the other hand, we still are waiting to see any significant work to address the long-term challenges to our economy and manufacturing sector – how do we move to a higher value and productive economy which then can afford to pay the improved wage rates we want for our people? The Future of Work Commission holds some promise, but that is only part of the picture. It is still very early days, but the best thing to do is to get involved and support us in pushing back on these efforts. We will send a request out to our manufacturing members when discussion documents are available for feedback.

Innovations in taste for world markets

NZ Food Manufacturer brings you the latest news and developments in food from the land to the plate For further information and to advertise visit

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WOMEN IN ENGINEERING

Sell the problem you solve, not the product. -anon

Women in Engineering Sulo Shanmuganathan, Technical Director, Holmes Consulting LP, New Zealand. Why do you do what you do and do you enjoy it? As a Technical Director at Holmes, I do many things ranging from meeting with our customers and understanding their priorities for solving infrastructure challenges, to helping colleagues develop technical solutions for some of these challenging infrastructure problems. In between the two, I do a lot of tasks to deliver our projects effectively and efficiently. What I do might be a small contribution towards improving our living standards and enhancing the infrastructure that would serve for present and future generations. Of course, I enjoy every single bit of my work otherwise I would not be doing what I do for the last 30 years. When I began my career in engineering the big and challenging projects lured me. As I grew older and became a bit wiser, I realised that even a small contribution has a huge impact collectively. I started to appreciate the human values and team dynamics to achieve the best for the project and ultimately for communities to which the infrastructure serves. The job I do now is more about how we can work collectively with other disciplines and professionals to bring about enhancements to our existing infrastructure and improving living standards. Greatest challenges? Personally, I like to convert my challenges into great opportunities for learning and growth. I was born in Sri Lanka and spent the first 25 years on the beautiful island of the Indian Ocean. So, when I first went to “Bonnie” Scotland, the biggest challenge was the communications

with the Scots, who have big hearts, warmth, and great hospitality. It did not take long to settle down and learn Scottish (I mean English). Jokes aside, living in a foreign country can be a challenge as well as a blessed opportunity to learn new skills. Another personal challenge that I had to deal with was going out to construction sites especially early on in my career and articulating my views to get buy-in from the experienced workers on site. I had this perception that people (especially crew on site) would ridicule my thoughts and send me back in tears - at least that was what played in my mind constantly, until I had a proper stint as a site engineer for Britomart Underground Station, where we (site staff and design team) worked collaboratively and respected each other’s ideas. I think that developing the self-belief and working towards greater-good lifted the lid of my fear of failure and other self-created obstacles. Most exciting project worked on? The projects that I got to work on, in the early part of my career, such as The Sydney Olympic Stadium and Britomart Underground Station really stretched my engineering skills. They were such cool projects providing me with unlimited opportunities to expand my knowledge and experience. Later in my career, I saw the value that each of us brought to the team and the way to bring out the best in every one of us. A good example is the rejuvenation of Makatote Rail viaduct, which took almost 6 years to complete from first we got involved. It was one of the most exciting projects to work on and work along with some of the talented team members.

Where did you study? I did my first degree in engineering at the University of Peradeniya in Sri Lanka. Followed by a Masters in Structural Engineering at the University of Dundee, Scotland with a scholarship from the Association for Commonwealth Universities (ACU). Subsequently, a Doctor of Philosophy from the Nottingham Trent University, England for the research on optimisation of CUBIC space frame structures. First work experience My first job was a teaching assistant at the university from where I graduated in Sri Lanka. I was helping undergraduates with tutorials and lab tests. It was interesting but I wanted to learn more to become a lecturer. That propelled me to pursue higher studies and travel overseas. Do you recommend this profession for young women? A big FAT YES. Women have a greater role to play in engineering our future. It is true that we have lacked women in science and engineering fields due to our lifestyle choices. For society to evolve and move forward, engineering requires a greater proportion of women taking significant roles. As we know, engineering in general has evolved over a few centuries now. We are more cognisant of the growing population and the availability of the limited resources. Engineering is more focused on preserving and restoring the planet than simply using the available resources. I think engineering is now more attractive for women than ever

Only 14% of all our engineers are women. We want to change that. Join us and scores of other Kiwi organisations that have galvanised around one common goal: 20% more women engineers by 2021. www.diversityagenda.org

NZ Manufacturer July 2018

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before for right reasons. Favourite Book? While I have a list of books that are my favourite, these two have been at the top of the list: The Road Less Travelled by M. Scott Peck The Power of Habit: Why We Do What We Do in Life and Business by Charles Duhigg Greatest inspiration? Acts of kindness, compassion, and unconditional love – all these inspire me beyond words can describe. I had a wonderful experience of trekking at high-altitude last year (with great difficulty, of course) in Tibet, where strangers (local Tibetan people) stopped to offer their oxygen canisters to those (foreigners) that could not acclimatise easily. Often, we see these acts of kindness in our daily lives, if we take a moment or two to slow down and watch around us. The virtues of humanity are the greatest inspiration for me. Favourite quote? As Mahatma Gandhi pointed out, we must be the change that we like to see around us. I always remember this quote when I get frustrated or become impatient and desire for changes around me. “We but mirror the world. All the tendencies present in the outer world are to be found in the world of our body. If we could change ourselves, the tendencies in the world would

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ADVISORS Mike Shatford

Sandra Lukey

Matt Minio

Phillip Wilson

is an expert in the field of technology development and commercialisation. His company Design Energy Limited has completed over 100 significant projects in this vein by consulting for and partnering with some of New Zealand’s leading producers. Among Mike and his team’s strengths are industrial robotics and automated production where the company puts much of its focus.

Managing Director, Objective3D Matt has extensive hands on experience as a user and supplier of 3D Printing technology. He comes from a mechanical design and engineering background with 25 years’ experience in multiple high end 3D cad applications across a range of industries, including aerospace and automotive. He has been heavily involved in the 3D printing evolution - from initial early prototyping to todays advanced 3d printing technologies producing production parts straight off the printer. As Managing Director of Objective 3D, he provides Stratasys, Desktop Metal and Concept Laser 3D printing solutions to a

Sandra Lukey is the founder of Shine Group, a consultancy that helps science and technology companies accelerate growth. She is a keen observer of the tech sector and how new developments create opportunity for future business. She has over 20 years’ experience working with companies to boost profile and build influential connections.

Phillip Wilson of Nautech Electronics has over 25 years of experienced in the development, commercialisation and implementation of advanced manufacturing technology, robotics, automation and materials. Serving companies operating within the aerospace, automotive, offshore, defence, medical and scientific industries on a global basis. More recently specialising in change management and business re-alignment for a range of commercial entities from medium sized SME’s to divisions of large corporates.

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NZ Manufacturer July 2018

If the only tool you have is a hammer, you tend to see every problem as a nail. - Abraham Maslow

Charging forward with the battery revolution The desire to super-charge increasingly smart, portable electronic devices using more efficient, large-capacity batteries is palpable. “We hear very sensational reports. For example, that you will soon be able to charge your mobile phone batteries in just a few seconds,” says Guangyuan Wesley Zheng, a chemical engineer at the Institute of Materials Research and Engineering (IMRE) at A*STAR. “While there is a lot of noise and hype, it’s very important research”. Electric cars, he points out “are going to play a significant role in transportation, Boeing and Airbus are talking about aircraft fully powered by electricity and more battery powered electrical appliances are becoming possible, like vacuuming robots.” Lithium-ion batteries have been the dominant battery on the market since their commercial debut in the early 1990s, used in everything from mobile phones to cars. Tesla, for example, a Silicon Valley-based electric vehicle manufacturer, is now building a ‘Gigafactory’ to dramatically scale up the production of lithium-ion batteries. However, lithium-ion batteries are reaching the limit of what they can achieve, says Zheng’s colleague, Zhi Wei Seh, a materials scientist at IMRE. “So, instead of making incremental improvements on what lithium-ion batteries can theoretically do, we are exploring drastically different, revolutionary battery technologies.” From lithium-ion to lithium-sulphur batteries Many research groups are looking into the potential of lithium-sulphur batteries as an alternative to lithium-ion batteries, but Zheng and She are among the most ambitious, both recently named among the MIT Technology Review’s top ‘Innovators under 35’ in Asia Pacific. Lithium-sulphur batteries are attractive because sulphur is cheap and abundant, and the batteries themselves theoretically have energy densities five times larger than lithium-ion batteries. “That means, if we put batteries of the same weight into a car, it could travel five times longer,” Zheng explains. That possibility could also pave the way for applications that lithium-ion batteries cannot handle, such as high-energy stationary grid storage systems for renewable energy sources like solar and wind power.

Boeing and Airbus are talking about aircraft fully powered by electricity.

NZ Manufacturer July 2018

Like all batteries, lithium-ion and lithium-sulphur batteries store energy in the form of chemical energy, which is converted to electrical energy during discharge. The basic configuration of a lithium-ion battery involves two electrodes made of different materials, both of which are able to store lithium.

into the electrode materials, lithium-sulphur batteries use a metal plating and stripping mechanism on the lithium anode and a conversion reaction, in which the electrode material is transformed from sulphur into lithium sulphide, on the sulphur cathode side1.

When connected to a circuit during discharge, the negative electrode (anode) undergoes oxidation, while the positive electrode (cathode) undergoes reduction. The change in the chemical composition of the electrodes stimulates an electric current to move from the anode to the cathode through the circuitry of the device being powered, and lithium-ions to move from one electrode to another within the battery.

Negating the need for ions to be inserted into electrode materials means that the theoretical energy density of a sulphur-lithium battery is much, much higher, at 2,500 Wh/kg.

When the ions run out the battery becomes flat. When a battery is plugged in to recharge, this process is reversed – the cathode is oxidised, while the anode is reduced – and both electrodes are returned to their original state. Energy density limits, which along with the lifetime of a battery determine the commercial proposition of a battery, hinge on the expense and ion-carrying limits of electrode materials. A lithium-ion battery’s anode is generally made from graphite, and the cathode from a mix of expensive metal oxides such as cobalt, nickel and manganese. Researchers have been steadily improving battery performance by incrementally adjusting the composition of electrode materials, along with the battery cell design. Nonetheless, because of the basic limits of how lithium ions are stored in these materials, the energy density limit of lithium-ion batteries is still theoretically capped at roughly 420 watt-hours per kilogram (Wh/kg), just enough to power electric cars over distances expected of conventional cars. But if we want to continue to charge forward lithium-sulfur batteries promise greater performance using a different storage mechanism, explains Seh. The basic function is similar to that of lithium-ion batteries: during discharging, the lithium metal anode is oxidized to form lithium ions that travel through the liquid electrolytes inside the battery to reach the sulphur cathode, where a reaction reduces sulphur to form lithium sulphide. As in lithium-ion batteries, the change in the composition of the electrodes stimulates a flow of electrons from one electrode to another through the circuitry of a device. Again, this process can be reversed during charging. Unlike conventional lithium-ion batteries, in which ions are inserted

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The possibility of lithium-sulphur batteries was discovered as early as the 1960s, but huge technical challenges still obstruct commercialization. On the cathode side, major problems include the low electronic conductivity of sulphur and lithium sulphide, as they are naturally insulating. Also, faster lifetime decay occurs during a battery’s energy cycling because of the build-up of lithium deposits, and because intermediate materials known as lithium polysulfides, which are important to maintain the cathode’s performance, dissolve quickly into the battery’s electrolytes, leading to a continuous loss of important active materials. Researchers have been trying to solve the first problem by coating sulphur particles in a conductive material. A breakthrough came in 2009 when a Canadian team developed a technology to encapsulate sulphur particles within a highly-ordered framework made of porous carbon, which is conductive2. However, as a sulphur particle’s volume expands by as much as 80 per cent upon reacting with lithium, it often cracked the protective coating, inducing the problematic polysulfide dissolution. Stable performance could thus be achieved only over 20 charge-discharge cycles (for comparison, the lifetime of a conventional lithium-ion AAA battery has roughly 500–1,000 cycles). Nonetheless, since 2009, research into lithium-sulphur batteries has been accelerating. Inspiration from an egg Both Seh and Zheng made significant advancements in the science several years ago when they were PhD students at the lab of Professor Yi Cui at Stanford University. It was Seh who looked into the volume expansion problem. “I came up with an idea similar to an egg structure,” Seh says. “Imagine the sulphur is an egg yolk and the white is empty space.” The team developed a technology to coat sulphur nanoparticles with titanium oxide, and then allow some dissolution of the sulphur to create a void inside the shell to accommodate the volume expansion of sulphur.

In 2017, battery whiz Zhi Wei Seh spoke to a mixed crowd about his research into batteries at the MIT Technology Review’s annual EmTech conference. Copyright : EmTech Asia 2017

As a result, the capacity decay after 1,000 cycles was as small as 0.033 per cent per cycle, which represented the best performance of a lithium-sulphur battery at the time. Inspired by this yolk-shell structure, the performance of lithium-sulphur batteries reported in literature improved greatly, Seh says, and now some groups have even demonstrated 10,000 cycles. Zheng, on the other hand, led a project to investigate one of the other issues that makes commercialisation difficult, the lithium anode. The anode tends to form dendritic and mossy metal deposits within the battery, one of the major causes of the battery’s short lifetime. His team initially considered using a carbon thin film to coat the lithium anode, but the coating cracked after a few cycles. After several attempts, they resolved the issue using a hollow carbon nanosphere approach. Unlike conventional approaches focused on modifying anode materials to prevent dendrite formation, their approach focused on accommodating shape changes of the anode. As the hollow carbon nanosphere coating is highly flexible and robust, it can withstand the large volumetric changes of the lithium anode during energy cycling, thus allowing the battery to continue functioning. “The result provided a new perspective on how simple nanotechnology can help address long-standing problems in lithium batteries,” Zheng says. His team has since made more iterations, including using a self-healing polymer and other coating methods, and he says these results also show good cycling at higher current densities. Road to commercialisation Since moving back to Singapore from Stanford in the USA and joining A*STAR in 2016, the two scientists have been exploring new angles of the lithium-sulphur battery question. Zheng is pushing hard for the commercialisation of lithium-sulphur batteries. Looking at the potential of advanced battery technology, he runs

Don’t wait for opportunity. Create it. -anon

New areas of application for collaborative robotics OnRobot, which recently emerged from the three international companies On Robot, OptoForce and Perception Robotics, presented its first new products at automatica 2018. The “Gecko Gripper”, “Polyskin Tactile Gripper”, “RG2-FT” and a technical upgrade of the existing “HEX” force-torque sensor product line based on OptoForce technology are intended to open up new areas of application for collaborative robotics and at the same time make implementation even easier. In this fast-growing market segment, OnRobot has thus positioned itself from the ground up as the innovative provider for collaborative applications one-stop shopping.

The newly founded OnRobot presented three new products and a technical upgrade at this year’s automatica. “Collaborating robots have the potential to become the comprehensive standard in industrial automation,” says Enrico Krog Iversen, CEO of OnRobot. “We want to contribute and unleash this potential by taking the next step: To make collaborative applications even easier to implement and to carry them into completely new areas of application - that is the basic idea behind all our new products that we presented at automatica”.

Innovative gripping with gecko and NASA technology The “Gecko Gripper”, for example, offers a completely new approach. The gripper was developed by the start-up Perception Robotics which merged into OnRobot. The inspiration for this model comes from nature and uses the same adhesive system for gripping as the feet of a gecko: millions of fine fibres adhere to the surface of the workpiece and generate strong van der Waals forces. For the “Gecko Gripper” technology, OnRobot licenses a concept originally developed by NASA Jet Propulsion Laboratory (JPL) and brought it to market maturity. The unique and fast moving solution makes vacuum grippers and thus the necessity of a compressed air system for handling large, flat objects unnecessary. In contrast to vacuum grippers, the “Gecko Gripper” can also handle perforated or porous workpieces such as printed circuit boards without any problems. The gripper is compatible with Universal Robots and Kawasaki robotic arms. The high degree of innovation has led to the system being among the three finalists of this year’s renowned IERA Award. The renowned robotics prize for innovation and entrepreneurship is awarded at automatica.

More sensitivity for demanding workpieces The “Polyskin Tactile Gripper” also comes from the innovation forge Perception Robotics. The solution specialises in sensitive gripping: Both fingers can be individually aligned and have integrated tactile sensors at the fingertips. The gripper can thus precisely measure the condition of the surface of workpieces and align its gripping processes accordingly. These properties make it a fundamental enrichment, especially when working with sensitive or irregular workpieces. The Polyskin Tactile Gripper is also compatible with Universal Robots and Kawasaki.

Gripper for precise assembly In addition to the already established “RG2” gripper, OnRobot is also launching a variation of the same on the market: The “RG2-FT” has integrated force-torque sensors and a proximity sensor, which also accurately detects the condition of objects. The gripper detects the danger of objects slipping off even before it happens, making handling even safer - for workers as well as for the workpiece. This gripper model is particularly suitable for use in precision assembly and is compatible with lightweight robots from Universal Robots and KUKA.

Fast installation for sensors The OnRobot product line for force-torque sensors based on OptoForce technology, “HEX”, however, is not a new product, but receives substantial technical upgrade. The innovations are primarily designed to make installation and handling of the sensors even easier and faster: Mounting is now up to 30 percent faster, partly thanks to overload protection now integrated in the sensor, which no longer has to be removed and mounted separately when attaching to the robot arm. Furthermore, the weight of the sensor could be reduced by 20 percent. A new, improved sealing ring also protects the “ HEX” products better against dust or water in the environment.

a San Francisco-based company called Volans-i in collaboration with a friend, Hannan Parvizian, to build drones, and operate a delivery service across long distances. They still use traditional lithium-ion batteries because lithium-sulphur battery packs are still being developed, but they ultimately need a battery platform robust enough to “deploy drones around the world,” Zheng says.

Zheng’s faith in the quick evolution of batteries is evident in his start-up company, Volans-i, which relies on advanced battery technology to help its drones do deliveries across very long distances. Seeded at the same start-up accelerator that founded AirB&B, Volans-i is bidding to work on vaccine delivery on Vanuatu for UNICEF. Copyright : Guangyuan Wesley Zheng

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NZ Manufacturer July 2018

Don’t worry about people stealing your design work. Worry about the day they stop. -Jeffrey Zeldma

Improving anomaly detection and prevention: What is your data telling you? By Ruban Phukan, Co-Founder of Progress DataRPM and VP, Product, Progress

The pace of digitisation means manufacturers today are under growing pressure to deliver perfect products in increasingly shorter timeframes, and at a lower cost. They can’t afford unplanned interruptions, unforeseen failures, or unexpected breakdowns, nor can they afford to wait until the quality check stage to identify issues that could have been avoided during the production line. According to Vanson Bourne, 82% of companies have experienced at least one unplanned downtime outage over the past three years, which can cost anywhere from $US50k-$150k per hour up to $US2 million for a major outage on an industrial critical asset. Industry research shows more than a third of the manufacturers lose 1-2% of their annual sales to scrap and rework. Data to the rescue! In order to reduce downtime, improve operational efficiencies and quality, manufacturers are heavily investing in data-led technologies. The Industrial Internet of Things (IIoT), machine learning and artificial intelligence (AI) for example are helping automate the process of analysing a growing number of datasets to understand and prognose machine health. Yet, most industrial anomaly detection efforts fail, with research from Capgemini showing almost 60% of organisations do not have the analytics capabilities to take advantage of the data generated from IoT sources. The issue is, many anomaly detection systems end up identifying either too many anomalies (false positives) or not enough (false negatives). Identifying true anomalies involves scouting for

NZ Manufacturer July 2018

those “unknown unknowns”, amidst a sea of changing industrial data patterns. Avoiding downtime: Illuminating the dark spots in your industrial data The key is to detect early signals of future problems, and take proactive actions to prevent them. There are a few best practices used for anomaly detection and prediction that every manufacturer should look to follow: 1. Rule-based/supervised vs unsupervised anomaly detection and prediction Rule-based systems are designed by defining specific rules, and typically rely on the experience of industry experts detecting “known anomalies.” The thing is, real business scenarios are quite complex and full of uncertainties. Unsupervised learning can help learn patterns of normal behavior and identify anomalies that are very different from the expected normal behavior. It is about enabling the production system to constantly learn, update and predict what is likely to happen next in the data stream, providing an intelligent way to detect and

predict the “unknown” anomalies with greater accuracy, much before the incident occurs and alert plant operators. 2. Top down approach vs bottom up approach

outliers or extreme value points, which

In the traditional top down approach, the same set of features are calculated for each sensor. But all sensors may not exhibit the same characteristics, and even those which do may not do so during all operational stages, making the data much more complex to analyse.

machines. But it brings in significant

In the bottom up approach, the different stages of each individual sensor are first identified from the data. Then the state space of the machine is developed acknowledging that each sensor stage is part of a dynamic process’s portion that determines the state of the machine at any time.

a mechanism where the algorithms,

An ensemble of baseline models for the normal conditions of the machine is then created, which helps identify anomalies based on how much the state of a machine is different from the expected normal state. 3. Manual vs cognitive approach A manual approach to anomaly detection is useful to detect common

Manufacturers still lack full awareness of when equipment is due for maintenance, upgrade or replacement.

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are commonly occurring across all human biases, it can only factor in known problems from the past, and assumes anomalies are only outliers. A cognitive approach to anomaly detection and prediction applies a “machine-first” approach. It creates which

can

adapt

changing

conditions, learn the data domain for each individual machine and transfer learning

across

similar

machines.

It then validates the learning with feedback from subject matter experts. You eventually get a fully automated and

cognitively

enabled

machine

learning system, where anomalies are detected and predicted before they occur. Manufacturers still lack full awareness of when equipment is due for maintenance, upgrade or replacement. Investing in data-led technologies and taking a cognitive approach can help build up rock solid foundations to design accurate anomaly detection scenarios, and build truly efficient predictive maintenance strategies.

If you don’t value your time, neither will others. Stop giving away your time and talents. Value what you know and start charging for it. - Kim Garst

ANALYSIS

Modern workplaces need

fit for purpose legislation - Leeann Watson , Chief Executive, Canterbury Employers’ Chamber of Commerce

Parliament’s Education and Workforce Select Committee has now completed its hearings on the Government’s Employment Relations Amendment Bill. Hopefully, the Committee will take on-board the strong feedback from the business community that any legislative changes need to be fit for modern workplaces and a high performing economy, and not based on failed approaches from the Seventies. The Government has stated that is aspires to create a high wage, high productivity economy, a goal that we all strongly support. However, I am concerned that this Bill will not deliver those goals. Four aspects of the Bill are especially worrying: 1. Employers with 20 employees or more will lose the right to include trial periods in employment agreements. Trial periods have given many employers the confidence to take on people without experience. 80% of employers used a 90-day trial period in the last year. This clause will discourage New Zealand’s larger employers from doing this and make it harder for young and inexperienced

people to enter the workforce.

under duress.

2. Allowing union reps access to workplaces without any permission.

4. Not allowing businesses a choice to opt out of a multi-employer collective agreement.

This caused issues in the past. Thankfully, employers and unions today have mutually respectful relationships, and we expect most unions would still provide notice regardless of legislation. So why return the country to an “us-vs-them”, anti-growth mentality from the 70s? 3. Forcing businesses to settle collective agreements even if they don’t or can’t agree. The right for either party to opt out of the bargaining process is fair and equitable. Removing this right from employers creates an uneven playing field, which is not only unfair but also a recipe for bad agreements created

These are not the end of potential changes, with the Government indicating a raft of new employment laws are still to come. Opinion Manufacturing Profiles Letters to the Editor Politics of Manufacturing Trade Fair World Diary of Events World Market Report Q/A Export News Machine Tools Business Opportunities Commentary As I See It Business News Appointments Around New Zealand Australian Report New to the Market Lean Manufacturing Equipment for Sale Recruitment Environmental Technology Manufacturing Processes

This compels businesses to join a multi-employer collective against their will. This is at odds with International Labour Organisation conventions which support everyone’s voluntary right to take part in collective bargaining or not. It protects the wishes of unions at the cost of freedom, productivity and growth. These are not the end of potential changes, with the Government indicating a raft of new employment laws are still to come.

goal the Government aspires too.

On the horizon are a set of rules creating what the Government has call “fair pay agreements”, which on the basis of what has been revealed so far look like a return to the days of industry awards.

We aren’t against reform, but we are against badly drafted legislation that doesn’t meet the Government’s goal nor the needs of employees or employers. I’ve been advocating strongly that this Bill needs re-drafting, and that we need to take a more collaborative approach to the employment relations system in New Zealand.

Those who remember the industrial relations environment of the 1970s and early 1980s will know that this system provided a confrontational, non-collaborative working environment that would seem to be the opposite to the high productivity

If this Bill proceeds as currently proposed, it will have major ramifications on the ability of businesses in New Zealand to grow financially and employ more people. That is not an outcome that anyone wants to see.

NZ MANUFACTURER • August 2018 Issue • Features

Productivity

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Fair Preview: FoodTech PackTech 2018

3D Manufacturing Climate Change Measurement and Inspection Trade

Diversity Campaign: Women in Engineering

Advertising Booking Deadline – 16 August 2018

Editorial material to be sent to :

Advertising Copy Deadline – 16 August 2018

Doug Green,

Editorial Copy Deadline – 16 August 2018 Advertising – For bookings and further information contact: Doug Green, P O Box 1109, Hastings 4156, Hawke’s Bay Email: publisher@xtra.co.nz

P O Box 1109, Hastings 4156, Hawke’s Bay

At NZ MANUFACTURER our aim is to keep our readers up to date with the latest industry news and manufacturing advances in a tasty paper morsel, ensuring they do not get left behind in the highly competitive and rapidly evolving manufacturing world.

Email: publisher@xtra.co.nz Tel: 06 870 9029

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NZ Manufacturer July 2018

NEW PRODUCTS

The two most important days in your life are the day you are born and the day you find out why. -Mark Twain

New Konecranes spare parts warehouse Konecranes has established a new 300m2 spare parts warehouse in Auckland, to enhance its global status and leadership in New Zealand. The new warehouse is the first Konecranes parts warehouse in New Zealand and incorporates new safety and testing facilities. It was built in response to strong and growing demand in the country for cranes and lifting technologies and their associated maintenance and service, across industries such as manufacturing, materials handling, infrastructure, primary production, resources, steel and civil engineering.

Konecranes is a world leader in crane service, with over 600,000 pieces of lifting equipment of all makes and models under service contract worldwide. Konecranes Auckland Branch Manager, Mr Nico Silvast says that customers will see several immediate benefits from the new comprehensively stocked warehouse. “Many companies in New Zealand source spare parts from Australia, or their global headquarters overseas, but it can’t compare to having stock locally available in New Zealand ready

to ship to both islands,” said Mr Silvast. “In most cases, we can now offer same-day delivery for spare parts, which is a huge boost to customers with production-critical cranes, where downtime is not an option,” he said. Another major benefit of the new warehouse is improved repair facilities, including a testing bench where products and components can be tested to ensure Standards Compliance. “Customers who need repairs on their cranes, hoists or components will now be able to send them to our new workshop, where the latest

Konecranes’ new spare parts warehouse in Auckland.

technologies will be tested to ensure compliance with the highest global and local Standards requirements,” said Mr Silvast.

Olympus launches new portable, powerful videoscope The IPLEX G Lite industrial videoscope features powerful imaging capabilities and a small, rugged body. Lightweight and able to go almost anywhere, the IPLEX G Lite videoscope provides users working in challenging environments with a remote visual inspection tool that has the image quality and ease of use to get the job done. The IPLEX G Lite is the successor to the compact and lightweight IPLEX UltraLite model, and can be used to capture images inside aircraft engines, piping, and other equipment without the need for disassembly. With two times the brightness of its predecessor, the IPLEX G is also suitable for a variety

of applications within the security industry and clean energy sector, including wind turbines. According to Jack Zhang, RVI Product General Manager at Olympus Asia Pacific, “Recent years have seen an increasing emphasis on safety management and quality assurance in fields such as aerospace, security and architecture. This has been accompanied by the use of industrial videoscopes for equipment inspections as these instruments can be used to conduct inspections without the need for disassembly.”

The IPLEX G Lite is small and lightweight making it easy to use with one hand, while also featuring enhanced image processing. The tip of the videoscope is fitted with a very small camera and can be freely manipulated, making these instruments ideal for tasks such as periodic maintenance or inspecting a component’s quality. Ease of use has been improved in the IPLEX G with the adoption of a touch panel monitor and electrically operated scope tip bending, enabling users to complete inspections more quickly. New recording and playback

functions have also been added; including constant video recording and the ability to add bookmarks to save time during video reviews and find critical moments quickly. When inspecting in oily environments, getting oil on the scope’s lens can make it difficult to see. To address this, the IPLEX G Lite is equipped with a new oil clearing tip adaptor that uses capillary action to draw oil away from the lens. The grooves on the oil clearing tip adapter drain unnecessary oil quickly and image keeps clean and visible, preventing your inspection being suspended. “The IPLEX G Lite also has an option that allows users to switch the light source from LED to infrared (IR) or ultraviolet (UV) illumination. IR is a very important feature, particularly for the security industry, capturing images in the dark while UV is used to detect fine scratches that are hard to see with the naked eye,” explained Zhang. Along with these performance features, the IPLEX G videoscope is designed to meet IP65 standards and U.S Military Defense testing (MIL-STD) to support its use for accurate and efficient inspection work, even under harsh conditions.

NZ Manufacturer July 2018

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Never give up. Today is hard, tomorrow is worse, but the day after tomorrow will be sunshine. -Jack Ma

NEW PRODUCTS

Showa 707HVO: Highly visible, safe for users The inventors of the world’s first biodegradable single use nitrile glove now bring you a new addition to their biodegradable hand protection range: Showa 707HVO – a chemical resistant glove engineered with revolutionary Eco Best Technology (EBT), in high-visibility orange.

Investing in tomorrow Showa, which translates to “finding a balance between different elements” in Japanese, has paved the way in biodegradable innovation within the PPE glove market. Driven by the desire to make a positive impact on the planet, a large proportion of research is devoted to biodegradable products and to developing fibers that have no impact on the environment. In 2012, Showa’s Research & Development reached a major breakthrough with the invention of the world’s first biodegradable single-use nitrile glove. Showa 707HVO blends the best of

single use and chemical resistant technology to deliver optimum fit, feel and comfort while protecting against chemicals[i]. The 0.23mm thick unsupported, unlined biodegradable nitrile complies with EN ISO 374-1 (JKOPT) and 374-5, and is impermeable to protect against oils, hydrocarbons, grease, chemicals and abrasions. The 305mm long glove is chlorinated for easy donning and doffing, with a rolled cuff to prevent dirt from entering the glove. Typically to Showa, the gloves are manufactured using a unique hand former, allowing for a lightweight protection that fits like a second skin. The bisque finish on palm and fingers offers long-lasting grip and excellent tactility. Its fluorescent orange colour makes it highly visible and an excellent choice for food, janitorial or sanitation environments, or to separate applications on processing floors.

Portable power used to solve conveyor maintenance problem Leading mining equipment OEM Techmine Solutions has developed an innovative solution to a common mining problem – efficiently lifting thousands of metres of conveyor belts for maintenance. Techmine has developed a new lightweight hydraulic belt lifter that utilises an Enerpac XC-Series Cordless Portable Hydraulic Pump to safely and reliably provide the hydraulic pressure (700 bar, 10,000 PSI) required to lift belt sections up to 2,000kgs. “The new belt lifter effortlessly raises the belt in 20 to 25 seconds without requiring complex input from the user. An 1800mm belt lifter, comprised of three main parts, weighs only 29.5 kilograms once assembled. The main 13.7 kilogram lifting beam is ergonomic and easily portable,” says Mr Justen Wright, Principal Engineer, Techmine, and inventor of the new technology. Western Australia based Techmine has more than 75 years of experience working both on Brownfield and Greenfield project across all mining sectors and their maintenance processes. The company was founded on the principle of bringing safe, efficient and reliable conveyor maintenance solutions to the mining industry, to meet the rigorous demands of modern mining maintenance. Solving a sore point for the mining industry The Techmine Team identified a fundamental safety risk in existing

conveyor maintenance practices, and used their mining and engineering experience to develop a solution that would be highly valuable to mining companies across Australia.

belt lifter is charged and ready to lift any conveyor on the mine site safely and correctly, whether it’s for general shutdown maintenance or an unscheduled breakdown.”

“We discovered that when it came to conveyor lifting, equipment that wasn’t specifically designed for that purpose was being used simply because it was the only thing available – but there could be inherent safety and performance risks,” said Mr Wright.

Techmine has already had successes in trials with major mining companies, with others specifically seeking them out for a solution to this established problem.

“Mine sites should not be lifting anything without knowing the weight first, because if the weight is above the lifting device’s capacity, this can cause all sorts of problems. Our new belt lifter clearly displays the belt’s weight as the lift progresses, meaning it cannot be overloaded.” “Currently, it is too easy for mining operations to perform maintenance on thousands of metres of conveyor belts without knowing the load on their belt lifters. All it takes is one failure resulting in an injury or incident that may change a workers life forever as well as significant downtime and additional repair costs.” “So we developed a lightweight portable system that could be easily stored at a shift crew workshop for example. This means that the

Designed to satisfy the need for a long-lasting pump that can be used in hard-to-access areas, XC-Series cordless pumps are constructed of lightweight materials, equipped with a powerful, one-half horsepower motor and feature 28-volt, Lithium-Ion battery technology. With its bladder reservoir, Enerpac’s cordless pumps eliminate venting and offer leak-free operation in any orientation. Plus, the overall body, handle and trigger have been ergonomically engineered to maximise ease-of-use and portability. XC-Series cordless pumps deliver oil flow of 2.05 liters (125 cubic inches) per minute at its low-pressure setting and .25 litres (15 cubic inches) per minute when operating at full pressure, up to 700bar (10,000 psi). Additionally, the lithium-ion technology ensures XC-Series pumps provide end users

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Techmine’s new lightweight hydraulic belt lifter, featuring

with the battery runtime necessary to accommodate demanding application requirements. Enerpac’s XC-Series promotes operator safety by removing trip hazards associated with traditional powered pumps. Safety features include overload protection circuitry, which safeguards both the pump and the operator from excessive amp draw or temperatures, and a trigger lock-off mechanism that protects against unintended operation during transport. .

NZ Manufacturer July 2018

FOOD MANUFACTURING

For a list of all the ways technology has failed to improve the quality of life, please press three. - Alice Kahn

Global focus on food contact plastics brings new expertise into the Australasian market Engineered plastics have been making strong headway into food and beverage production, processing and packaging markets because they are light, tough, low-friction and harmonise well with automation and rapid washdown needs to achieve efficiencies while maintaining hygiene and safety standards. But – just like metals – not all plastics are right for all tasks, says engineered thermoplastics authority Laurie Green of Cut To Size Plastics. “It is one thing to know the relevant Australian and New Zealand Code and the guiding principles contained in AS2070-1999, but the onus still remains on the user of materials to ensure they are fit for purpose. This is a fast-changing field, and the devil can be in the detail,” says Mr Green, who, as Managing Director of Cut To Size, has seen more than 40 years of change and improvement in this specialised domain. Mr Green recently hosted global engineered plastics leader Wefapress to further strengthen Cut To Size’s long association with the company, which is joining with Cut To Size to expand in Australasia its food contact ranges and its ranges of lining plastics for bulk materials handling applications such as food and beverage, truck liners, agricultural technology, bucket wheel excavators, rail cars, wheel loaders, belt scrapers, silos, trough chain conveyors and an extensive range of mining and dry goods processing applications. Wefapress Managing Director Gerrit Beck and Senior Sales Manager Klaus Massfeller visited Cut To Size’s Yennora facility recently to provide expert product training on the latest evolution of the globally proven Flex Cover range, an Ultra-High Molecular Weight Polyethylene (UHMWPE) engineered plastics which embodies a number of advantages in order to prevent friction, wear and material flow problems common to bulk handling industries. The Australasian and German companies also focused on food contact products relevant to Australia and New Zealand producers and exporters because they comply with the highest global standards affecting this area, including major EU regulations on plastic production and processing in effect from 2011 that aim to eliminate the risk of the harmful effects caused by the migration of substances. “As in Australasia, such substances can include colour pigments, separating agents and additives,” says Mr Green. “The interaction between

NZ Manufacturer July 2018

foodstuffs and foreign substances can carry certain risks. In order to minimise these risks and prevent any possible contamination, the European Commission introduced a regulation in January 2011 on materials and objects made from plastic. Wefapress already considered these requirements essential. A large proportion of the materials we offer for the food industry meet the guidelines of the EU regulation and are therefore classed as Food contact standards are a major responsibility of producers ‘food secure’.” Declaration of conformity

Wefapress food-compatible available from Cut To Size

Contains information regarding food regulations and suitability guidelines on possible uses. The declaration is valid until a change is made to the material, consequently altering components migration rates, or until new scientific knowledge is developed.

“The food and beverage and processing industries work in accordance with strict hygiene standards, which also apply to interactions with plastics. Plastics must be deemed physiologically harmless before they can come into contact with food. “This not only protects the health of the consumer, but also the composition of the food and its organoleptic properties,” says Mr Green. The following individual provisions of framework regulation (EC) no. 1935/2004 are particularly relevant: EU regulation no. 10/2011 (PIM), which defines contact between plastic and foodstuffs. Such provisions are particularly relevant to Australian and New Zealand food and beverage companies seeking to select materials that conform with such standards.

(Good

• St 1000 FSP natural | green | signal blue

The material must be traceable throughout every stage of the value chain. Manufacture must be in accordance with Regulation (EC) No 2023/2006, also known as GMP (Good Manufacturing Practice), which regulates quality system, quality system, quality control system and documentation.

• St 500 FSP natural | green | signal blue | oxide red / red brown | pastel yellow / wood-coloured • St 6000 AST FDA FSP black • St 6000 ELS FDA FSP black • POM FSP natural | ultramarine blue • PETP FSP natural • PETP-SP FSP light grey • PA 6 G FSP natural | blue • PA 6 G + Öl FSP blue • PA 12 G FSP natural • PEEK FSP natural • PVDF FSP natural All of these materials are accessible from Cut To Size by Australian and New Zealand companies, says Mr Green.

Traceability and GMP Manufacturing Practice)

Key points

EU regulation no. 10/2011 relates to the manufacturing of all food contact materials and applies to the entire supply chain including manufacturing, processing and distribution. The conformity of products and processes must be ensured and confirmed across all stages of production. The final distribution company is then able to issue the final declaration of conformity.

Migration test

List of raw and auxiliary materials

Required for standard tests with food simulants, times and temperatures, which reflect real situations. The following elements are tested: OML (overall migration limit), maximum quantities a material is allowed to emit, as well as SML (specific migration limit), the maximum quantity of a substances that can enter into food.

Defines the materials to use for production: Only monomers, additives auxiliary materials (e.g. drilling emulsion, cleaning agents) from the Union list (appendix one of EU regulation no. 10/2011 may be used in the manufacturing of food secure products.

Cut To Size Managing Director Laurie Green, centre with, from left, Klaus Massfeller – Sales Manager, Wefapress, Gerrit Beck – Managing Director, Wefapress, Pat Flood, NSW Manager – Cut To Size, Frank Domajnko – Qld Sales Manager, Cut To Size

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Wefapress offers the following range of food safe products relevant to such applications as mechanical and plant engineering; drinks and bottling industries; agriculture industry; Food industry; Paper industry; Chemical industry; Conveyor systems and automation:

“Wefapress uses only suitable raw materials when manufacturing semi-finished parts, components and other products intended for direct contact with food. Products labelled “Food Secure Product” conform to EU regulation no. 10/2011,” and are highly relevant to Australian and New Zealand producers and exporters.

“We also check other material types in consultation with our customers, even for small orders. In this way, customers can benefit from our local knowledge and Wefapress’ global experience inworking with companies in the food industry for many years. Wefapress has been dealing with EU regulation no. 10/2011 on a regular basis since 2012. A large proportion of the company’s material types made from polythene (PE-UHMW and PE-HMW) and other thermoplastics conform to the regulation. These products all carry the Wefapress FSP (Food Safe Product) label. Wefapress and Cut To Size can also provide Individual calculation of migration: “We are happy to provide advice on how to calculate migration. We can provide you with access to empirical data in the form of available test results to save you time and money,” says Mr Green.

The Ministry for Primary Industries (MPI) and Plant & Food Research have released their joint report: The evolution of plant protein – assessing consumer response. The report was commissioned to assess consumer responses to protein and highlight the potential impacts to the New Zealand agricultural industry. New Zealand’s social, environmental, and economic well-being is linked to New Zealand’s ability to supply the rest of the world with protein. New Zealand’s animal-based protein export revenue alone accounts for 60% of New Zealand’s total primary exports.

Alternative protein reports published

This demand will grow as the global population is set to increase to 8.1 billion by 2025. “This is the very first exploratory piece of work MPI has done in this area. The report explores how consumers have become more aware of the long-term impacts of food production and signals change for traditional animal protein producers. “The findings will inform our work programme to support primary sector resilience in the face of these impacts and changing consumer habits. “The report also includes opportunities to create value through a point of difference for traditional New Zealand products,” says Jarred Mair, acting deputy director-general for policy and trade. “In order for New Zealand to retain a competitive edge in our primary exports, we want to ensure we are looking ahead at what the future consumer might demand in our products and what opportunities are available for our sector,” says Dr Jocelyn Eason of Plant & Food Research. To assess where markets are heading in the next 5 years the report analysed consumer responses to plant-based proteins released in the United States and consumer attitudes to proteins in China. Our research has shown that wealthy western economies such as the US will require an innovative product that meets consumer needs. The key findings of the report include: • Progress towards new protein innovations caused by increasing global pressures and changing consumer needs requires a long-term strategy to protect, to innovate, and to grow our primary industries. • Consumer preferences and awareness of the consequences of food production is creating a need for new products. • Dependency on a few markets and

products creates risks and therefore innovation and assessment of consumer and market trends are critical to ensure the long-term success of primary industries in New Zealand. The release of the report includes a package of 3 additional market insight reports that relate to alternative proteins and demonstrates the rapid change that may occur in the primary sector from new food innovations. These reports are in the public domain and are: 1. Impossible Burger (Authored by MPI)

case

study

2. Protein: A Chinese perspective (Authored by Plant & Food Research) 3. Opportunities in plant-based foods proteins (Authored by Plant & Food Research)

NOTES ABOUT THE REPORTS The evolution of plant protein – assessing consumer response Co-authored by MPI and Plant & Food Research, a New Zealand-based Crown Research Institute, which provides research and development that adds value to fruit, vegetable, arable and seafood products.

which is a patty developed to replicate the taste, texture, and smell of beef. Developed by Impossible Foods, the Impossible Burger made significant steps to meet this goal with the development of theme, a product designed to replicate the properties of ‘bleeding’ meat. The Impossible Burger report shows that this product is at the forefront of companies innovating and significantly improving meat replacement products, yet consumer sentiment analysis shows that further innovation is required to develop a product that is a large threat. Protein: A Chinese perspective Authored by Plant & Food Research. The global diet is changing, with an increased focus on plant-based protein sources. Much of the current understanding around the growing adoption of plant-based sources of protein is based on Western markets. This report outlines findings from

exploratory research in China to understand the significance of different protein sources in the Chinese diet and whether the Western trend is likely to gain momentum in this key market for New Zealand exports. Opportunities in plant-based foods – proteins Authored by Plant & Food Research New Zealand’s current protein production is focused on proteins sourced from dairy and meat. There is ongoing discussion in society and industry on where the sustainability limits are for meat and dairy production in New Zealand, and what role diversification of protein sources to include plant-based protein might play in our premium future foods. To take advantage of the new consumer trends towards plant-based foods and “flexitarian” lifestyles, there are significant opportunities for New Zealand to expand and develop plant-based protein sources.

This report explores how consumers have become more aware of the long term impacts of food production, signalling an impending change for traditional animal protein producers. This shift in preferences has led to a new wave of innovative meat and dairy substitutes that are being released to reduce the reliance on animal-based production systems protein in global diets. The Impossible Burger – consumer insights Authored by MPI, this report investigates the plant-based burger,

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NZ Manufacturer July 2018

DEVELOPMENTS

Catch a man a fish, and you can sell it to him. Teach a man to fish, and you ruin a wonderful business opportunity. - Karl Marx

Gallagher’s takes supreme ExportNZ award Gallagher Group has taken out the supreme award for the 2018 Air New Zealand Cargo ExportNZ Awards for Auckland and Waikato regions. Judges were impressed with the way the Hamilton-based business has become the leading technology company in animal management, security and fuel system industries over the past 80 years. Founded in 1937, Gallagher’s was initially a 10-person business which designed and delivered New Zealand’s first electric fence solution. Today, it employs 1100 people across a global network of 10 countries through three business units. It also won the Westpac Best Large Business (goods exports) category. Seven category winners were announced from 27 finalists at the awards, along with the supreme winner: 1. Baldwins Intellectual Property Excellence in Innovation Endace helps its customers manage critical data networks. Via its platforms it helps its customers to accurately detect, investigate and analyse network security and performance issues. Global

customers include banks, hospitals, telecommunications companies, healthcare providers, retailers, web giants and governments. (Auckland) Other finalists were: - Valocity Limited (Auckland) - Organic Initiative (Auckland) - Spring Sheep Milk Co. (Auckland) - Serko (Auckland) 2. DHL Best Emerging Business (goods exports) Auckland BioSciences is in the business of manufacturing and exporting premium New Zealand made animal derived serum and plasma. The four-year old company exports 90% of its products to 14 countries around the world for use in veterinary vaccines, which are critical to the health of global livestock populations. (Auckland) Other finalists were: Helix Flight Manufacturing Machines Limited (Waikato) - Loadscan Limited (Waikato) - Progressive Equipment Limited (Waikato) - Spring Sheep Milk Co (Auckland) - Zeffer Cider Co (Auckland) 3. EMA Best Emerging Business (services exports) Haka Educational Tours is part of the award-winning Haka Tourism Group and is a dedicated

academic and sport travel company. From curriculum focused school trips, to faculty led University tours and touring school sports teams, it provides a solution for all your global domestic student travel needs. (Auckland) Other finalist: - EverEdge Global (Auckland) 4. Ports of Auckland Best Medium Business (goods exports) Ross Roof Group is a family owned roofing company celebrating 75 years in the industry. With a strong focus on exporting their stone-coated steel tiles, they now operate in all regions of the world with six offices and 17 staff located in the USA, UK, Europe, Japan, UAE and Argentina. (Auckland) Other finalists were: - Hunter Filling Systems Limited (Waikato) - MIX Limited (Auckland) - Oceanmax International Limited (Auckland) 5. BDO Best Medium Business (services exports) More4Apps creates solutions for users of the Oracle E-Business Suite. In 2000 its developers identified the need for desktop software that enables the easy upload of transactions and other information to Oracle and it has been growing since then. It specialises in providing products for both

end-users and developers. (Waikato) Other finalists were: - Company-X (Waikato) - Mindfull (Auckland) Valocity Limited (Auckland) 6. Westpac Best Large Business (goods exports) Gallagher Group are a global leader in designing ground breaking animal management, security and fuel systems solutions. As a successful private company in New Zealand, Gallagher employ more than 1,000 staff worldwide throughout North America, Europe, Asia, South Africa, Australia and New Zealand. (Waikato) Other finalists were: - Invenco Group Limited (Auckland) - Milk New Zealand Dairy Limited (Auckland) - New Zealand Bloodstock (Waikato) 7. NZTE Best Large Business (services exports) Gentrack Group designs, builds, deploys and provides supporting solutions for some of the most progressive utilities and airports around the world. Pairing powerful platforms with deep market knowledge, Gentrack enables customers to lower service costs, foster innovation and confidently navigate market reform. (Auckland) Other finalist: - EROAD (Auckland)

Old world thinking wont deliver high growth economy EMA is asking the coalition Government MPs to explain how the old world thinking of the proposed Employment Relations Amendment Bill will deliver the productive, high growth economy they say they want. Via an advertising campaign using outdoor billboards, press and digital advertising it is asking Government MPs to “Please Fix the Bill”, at the same time encouraging its members to ask the same of the coalition Government. This is a national campaign involving all four members of the BusinessNZ family (EMA, Business Central, Canterbury Employers Chamber of Commerce, Otago Southland Employers Association). “We wholeheartedly agree with the Government’s goal of developing a modern, nimble and high performing economy, however we would like to understand how labour laws of yesteryear will enable this to happen,” says Kim Campbell, CEO, EMA.

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NZ Manufacturer July 2018

to nut out the answers to many of the above questions. Therefore it seems out of kilter to develop the legislative framework - which is the vehicle that enables the Government’s strategic aims to be delivered - before the strategic analysis and discussion has been had. Add to this the significant roll call of employment law legislative change that is also a significant factor in businesses putting a temporary hold on their hiring and investment plans including: - The Employment Amendment Bill

Relations

- Hobbit Law Review Each of these issues is a focus for business but combined they represent a significant rewriting of the employment relations landscape that has been the platform for New Zealand’s economic performance in the past decade - despite earthquakes and the Global Financial Crisis. Add in an unknown legal framework for reducing emissions, an electricity pricing review, a tax working group and lingering questions around costing/taxing water and you can understand why business is hesitant.

- Pay Equity - Employment Relations (Triangular Relations) Bill - Equal Pay - Fair Pay Agreements - Contractors as Employees - The Future of Work - Holidays Act Review

Women in Engineering

also change. As a man changes his own nature, so does the attitude of the world change towards him. This is the divine mystery supreme. A wonderful thing it is and the source of our happiness. We need not wait to see what others do.” – Mahatma Gandhi1

“We are deeply concerned that what is being proposed in the Employment Relations Amendment Bill 2018, plus a raft of other related legislation in the pipeline, is old thinking for a modern world. “New Zealand First MPs have the chance to modify parts of this legislation and work with small business to deliver an industrial relations framework that will help them grow their enterprises. “Let’s be clear. We are not against reform. But we are against poorly drafted legislation that has been cobbled together in a hurried manner. What we want is for the Government to pause, consider what the impacts of these changes could be, have an honest conversation around how placing more compulsion into the workplace will drive a modern, nimble economy and reflect on how we can work on this together in a constructive manner. “The Future of Work Forum has yet to convene. And this is the proper forum

How do you relax after a long day? Having worked over 30 years, I have learnt to organise my days better so that I do not have long days at a stretch. I do not find much joy by being busy or running from one meeting to another – sometimes it is unavoidable

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though. I have chosen my work such that I thoroughly enjoy all of it and even a long day does not seem to bother me too much. If everything I said above did not work then I take refuge in my meditation

practice to bring the clarity that I desire. Reference 1. 1964, The Collected Works of Mahatma Gandhi, Volume XII, April 1913 to December 1914, Chapter: General Knowledge About Health XXXII: Accidents Snake-Bite, (From Gujarati, Indian Opinion, 9-8-1913), Start Page 156, Quote Page 158, The Publications Division, Ministry of Information and Broadcasting, Government of India. (Collected Works of Mahatma Gandhi at gandhiheritageportal.org)

If you do not change direction, you may end up where you are heading. —Lao Tzu

DEVELOPMENTS

What do field service workers have to do with manufacturing? -Paul Baptist, Senior Director, Solution Engineering, APAC, Salesforce

We’re seeing manufacturers increasingly invest in their customer service and field service teams as customers demand the types of experiences companies like Airbnb provide. Anytime, anywhere, frictionless and personalised experiences are what customers demand. The lines between B2C and B2B customers have also blurred, meaning your experience must match the very best that’s out there, no matter your end buyer. The stakes have never been higher. The Salesforce 2018 State of the Connected Customer report, revealed 66 per cent of buyers say they are likely to switch brands if they are treated like a number instead of an individual. Every touch point a manufacturer has with a customer has to deliver the best possible, personalised experience. In-between buying cycles, field service is often your most important and regular touch point with customers. That’s why we’ve seen our manufacturing customers like KONE, Schneider Electric and Fisher & Paykel invest in their customer service experience.

service technicians around the world. By owning the quality of service and empowering its field service technicians, KONE is turning a service request or product break down into an opportunity to provide an outstanding customer experience.

What is the ‘customer experience crisis’? Customers judge your business based on their most recent and best interaction. Think of the companies that deliver outstanding service and repair experiences, like KONE or Fisher & Paykel for example. All manufacturers are judged by this standard today.

What’s the impact of field service workers in manufacturing?

Buyers expect every representative of a company to have information about who they are and their history with the business. Being asked to reshare the same information with different service staff is seen as a failure to provide good service.

A good example of investing in your field service team is KONE. It is working towards a future where the operating condition of more than 1.1 million of its escalators and elevators is linked with real-time customer information and maintenance schedules. This will be provided to its team of 20,000 field

I’ll expand on the Fisher & Paykel example. It simplified the process for customers to access service by automating confirmation reminders and providing tracking of their technician’s arrival time. This simple change not only removed friction from the service experience, but has reduced

Companies that deliver outstanding service and repair experiences include KONE or Fisher & Paykel.

training time around the world from an average of nine months to just three weeks per operator, saving $40,000 in training costs per operator.

How can manufacturers empower field service workers in the digital age? Manufacturers need to put relevant information in the hands of their technicians to deliver an experience that ‘wows”. This includes consolidated communications with the customer, the latest information on job scheduling, traffic routes to the site, suggested fixes, next best actions, and the ability to contact the customer easily. Insights from data analysis can also be used to automate administrative tasks and give field workers access to real time customer information anytime, anywhere. This frees workers to focus on the job at hand: identifying issues and fixing them.

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What does this have to do with Salesforce though? Salesforce works with a range of manufacturers around the globe. Some of our customers include Schneider Electric, KONE and component maker Lippert. Lippert implemented Salesforce’s Service Cloud and Field Service Lightning for increased efficiency, scheduling, and improved productivity. Lippert is now paperless and has full visibility into the interactions across it organisation. For the first time, the team can engage in real-time interactions with trackable, recordable results. With the help of Field Service Lighting, Lippert is servicing products like its recreational vehicles two days faster, increasing productivity for both technicians and support staff.

NZ Manufacturer July 2018

SUPPLY CHAIN

Right now, this is a job. If I advance any higher, this would be my career. And if this were my career, I’d have to throw myself in front of a train. -Jim Halpert, The Office Season 1, “Health Care”

Drives for pallet conveyor technology Pallet conveyor technology primarily requires economical drive solutions with high overload capacity.

Nord supplies optimally matched, individually configurable and flexible drive technology which reduces the number of versions and minimises costs, especially for transporting pallets and cage pallets with roller or chain conveyors.

For simple pallet conveyor technology applications, Nord has developed an efficient drive combination consisting of an asynchronous motor and a Nordac Base frequency inverter.

of the number of versions.

This drive solution is specially tailored to the requirements of pallet conveyor technology and provides dependable technology with a robust design.

The three-phase asynchronous motors provide powers up to 1.5 kW and feature high overload capacity, solid workmanship and a long service life. The frequency inverters are installed close to the motor and are equipped with an integrated PLC.

It can be combined with all Nord geared motors and can be flexibly extended according to requirements, or the customer’s specifications. Standardisation results in a reduction

This considerably reduces stocks of spare parts, optimises maintenance and saves costs in the sense of TCO (Total Cost of Ownership).

The freely programmable PLC processes the data from sensors and actuators,

provides diagnostic options and communicates with the higher level controller. A pre-installed software for control, parameterisation and diagnosis is configured for the special drive requirements of pallet conveyor technology. The drive units can be integrated into all common bus systems. The AS interface or I/O interface are especially suitable as a simple and cost oriented solution for communication in pallet conveyor technology. A different bus system can be used without any problems if there are more sophisticated requirements.

First demonstration of drone-based deliveries along power-line routes TEPCO Ventures, Inc., Zenrin Co., Ltd. and Rakuten, Inc. have begun examining the utilisation of “drone highways,” or the airspace above infrastructure such as power transmission lines, for drone logistics. The three companies also announced that they have safely carried out the world’s first demonstration test utilising a drone highway. TEPCO Ventures, a wholly owned subsidiary of Tokyo Electric Power Company Holdings, Inc., and map publisher Zenrin formed an alliance on March 29, 2017 to confirm the use of drone highways for safe drone-based deliveries. The concept, which is attracting increasing interest, is a focus of the “2018 Roadmap for the

Industrial Revolution of the Sky,” which

lines and towers, substations and utility

was approved by the Public-Private

poles, with Zenrin’s three-dimensional

Conference on Infrastructure Creation

maps of the sky, which are currently

for Drones in Japan in June 2018.

under development.

To develop a drone highway, TEPCO

Going forward, several test courses

and

studying

will be set up in eastern Japan’s Kanto

how to combine data on TEPCO’s

Zenrin

have

been

Region during 2018 to demonstrate

infrastructure, such as transmission

the practical use of drone highways.

Internet services company Rakuten, which has been operating a drone-based delivery service called “Rakuten Drone,” has joined the initiative. The first demonstration test, conducted in Chichibu, Saitama Prefecture, successfully achieved the world’s first drone-based delivery using a power line route for the flight path.

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NZ Manufacturer July 2018

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An acceptable level of unemployment means that the government economist to whom it is acceptable still has a job. - Unknown

BUSINESS NEWS

PNG’s APEC venue has NZ involvement PNG’s Star Mountain Plaza, which will host leaders from around the world at the APEC forum, is expected to open ahead of its planned schedule according to developers. The venue, was designed and project managed by a New Zealand architectural and project management firm. The landmark Star Mountain Plaza conference, accommodation and retail development is a multi-use facility, designed to help PNG attract more overseas visitors in future generations. Mineral Resource Development Companies (MRDC) managing director Augustine Mano says construction on the venue is now expected to be completed in September - two months prior to the start of APEC. Mr Mano says the project is on schedule due to the efforts of more than 800 team members who have worked in shifts 24 hours a day to ensure its early completion. This workforce is expected to increase by a further 200 over the next six weeks as the interior fit out progresses. “Our project will be delivered in multiple phases enabling Hilton to gradually assume control, It is with great pleasure that we can officially handover the the first area of the new five star hotel and Kutubu convention

centre to Hilton. “Over the coming weeks, more areas of the development will be handed over in the lead up to the final construction completion date on 13 September 2018,” he says. Mr Mano says in addition to the conference venue the introduction of the Hilton Hotel brand to the PNG market marks a coming of age for the nation. “The opening of the 212 room Hilton Port Moresby will have wide ranging and long term benefits for the country. “The first guests will be welcomed at the hotel soon after the construction is completed,” he says. Data from independent reports project the Star Mountain Plaza development to bring in more than $235 million Kina in tourism revenue and other economic benefits over a 20 year horizon.

programmes for its workers and has set a new benchmark for workplace health and safety standards. “This has been a model construction site guideline by international standards. We wanted to demonstrate how projects should be run and wanted to ensure that Star Mountain Plaza was not only known for its economic benefits to the country, but also its social contribution,” he says. Workers employed by the company have had free access to healthcare which included vision testing and free glasses for themselves and family members. “Our hospital screening programme identified almost half of our workers needed prescription lenses

for previously undiagnosed vision conditions. By providing them with free glasses we have helped provide a safer workplace environment for them and their colleagues,” he says. Other workplace benefits included the provision of three catered meals daily, unlimited bottled water and the supply of electrolyte supplements to prevent dehydration. Staff were also offered immediate access to private hospital care paid for by the company. The completed project will feature over 5600m² of planting, 566m² of artificial turf, water features and hard landscaping more than 12,000 examples of PNG’s flora, planted in one of the one of the nation’s largest ever landscaping projects of its kind.

“We are creating a legacy asset for future generations of Papua New Guineans. Along with the economic benefits of building the convention centre itself, we have also had the chance to train the local workforce in a wide variety of trades - something that will benefit the community for years to come,” he says. Mr Mano says the development has overcome a shortage of skilled local labour by introducing onsite training

Boosting your bottom line with a safer workplace Authored by Helen Masters, senior vice president and general manager, Asia Pacific, Infor

It’s the sound you dread: a bang, crash or shout heralding that one of your employees has been injured. In that moment, you know that many things have been lost — a person’s wellbeing (and possibly their life), the morale of other employees, and possibly, their confidence in the safety of their workplace. Underlying it all, the productivity, cohesion, and workflow you depend on to deliver a competitive, profitable product may also be impacted. The effects are a serious drain on companies and on the wider economy — work related injuries and fatalities cost the nation $61.8 billion in 2012, nearly 5 percent of GDP. Safer operations productivity

mean

higher

The old line about prevention being better than cure has never been more important than when talking about workplace safety. A safe workplace is essential to ensuring reliable, uninterrupted operations.

With strong safety programs, companies can significantly improve their productivity, while reinforcing their bottom line and not only boosting morale and wellbeing among their employees but also having a positive impact on the families and close friends of their employees.

management

There are no accidents

An effective EAM system:

The question for many businesses is how to get from here to there.

• maps out preventive maintenance schedules based on manufacturers’ specifications and actual equipment histories, helping keep critical assets in top condition.

In the transport industry, there is an assumption that there are no accidents, just collisions that could have been prevented with foresight and planning. It is hard to think of a sector where that basic principle does not apply. An end-to-end approach to workplace safety begins with a dedicated effort to keep equipment in safe working order, develop workplace procedures and rigorous training plans, and deploy sensors that set off alarms or simply shut down equipment when it is being misused. A safer workplace with enterprise asset

Most companies have maintenance plans based on spreadsheets that track inspection and repair histories for critical devices and equipment. A comprehensive, cloud-based enterprise asset management (EAM) system does much more.

• Uses Internet of Things (IoT) technology to spot changes in equipment function that point to deficiencies, inefficiencies, or emerging hazards early on. • Replaces hard copy maintenance routines with mobile checklists, and automatically uploads service records to a central server. • Captures content from multiple volumes and editions of hard copy manuals in electronic formats that are readily accessible and searchable.

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Through the lens of enterprise asset management, the connection between safe operations and productive business systems is clear. If you adopted a sound approach to EAM, you have probably seen a corresponding reduction in injuries, downtime, and associated costs. If you are responding to injuries and near-misses too often, that safety record is probably a bellwether for other costs and business impacts across the system — and an opportunity for significant savings. Unless your business is to do with health and safety, you may not have too many opportunities to literally save lives while boosting your own bottom line. Enterprise Asset Management can help you connect those dots, preventing as many shop-floor safety incidents as you can before they happen.

NZ Manufacturer July 2018

COMMENT

The factory of the future will have only two employees: a man and a dog. The man will be there to feed the dog. The dog will be there to keep the man from touching the equipment. - Warren Bennis

We are getting the ball rolling in New Zealand with single use plastic bags slowly being phased out. This article by Kim Borg provides insights into what our cousins across The Ditch think about all this.- ed.

How to break up with plastics (using behavioural science) Kim Borg Doctoral Candidate & Research Officer at Behaviour Works Australia, Monash Sustainable Development Institute, Monash University

Australia is responsible for over 13 thousand tonnes of plastic litter per year. At the end of June 2018, the Australian government released an inquiry report on the waste and recycling industry in Australia. One of the recommendations was that we should phase out petroleum-based single-use plastics by 2023. This means a real social shift, because the convenient plastic products that we use Bans, as Coles and Woolworths recently adopted for plastic bags, are one option – but are not suitable for every situation. They can also feel like an imposition, which can inspire backlash if the community is not on board. Behavioural science can offer a path to curb our plastic use.

Technology alone is not the solution First off, plastic is not evil: it’s flexible, durable, waterproof and cheap. The issue is the way we dispose of it. Because plastic is so versatile it has been adopted across a range of single-use “throw away” consumer products. Many people are working on technological solutions to our plastic problems. These range from better recycling techniques and biodegradable “plastics” made from algae or starch, to (my favourite) using the wax moth caterpillar or “mutant bacteria” to consume plastic waste. But these options are slow and

expensive. They can also have other environmental impacts such as greenhouse gas emissions and resource consumption. There are lots of reusable alternatives to many single-use products. The challenge is getting people to use them.

Behavioural science to the rescue My research involves applying insights from various disciplines (like economics, psychology, sociology or communication) to understand how governments and businesses can encourage people to change their behaviour for environmental, social means. Research has found that simply providing information through awareness campaigns is unlikely to change behaviour. What media attention and campaigning can do is increase the public visibility of an issue. This can indirectly influence our behaviour by making us more open to other interventions and by signalling social norms – the unwritten rules of acceptable behaviour.

Research has found that simply providing information through awareness campaigns is unlikely to change behaviour. 30

NZ Manufacturer July 2018

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Successful behaviour change campaigns must empower individuals. We should be left feeling capable of changing, that changing our behaviour will impact the problem, and that we are not alone. One positive example is modelling sustainable behaviours, like using KeepCups or beeswax wraps, in popular TV shows. Once we’re aware of an issue, we may need a little help to move from intention to action. One strategy for providing this push is a small financial disincentive, like Ireland’s famous “plastax” on single-use plastic bags. Many cafés also offer discount coffees to reward bringing reusable cups. We can also encourage retailers to “change the default”. Japan increased the refusal rate of plastic bags to 40% after six months of cashiers simply asking people if they wanted a bag. This approach could be used for other products too. For example, imagine your drink not coming with a straw unless you specifically ask for it. This would cut down on waste, while also avoiding the unintended consequences of banning a product that is important for people with a disability. Given that there is already strong support for reducing our reliance on single-use plastics, another simple solution would be to provide prompts in key locations, like carparks and workplaces, to remind people to bring their reusables. While we may have the best of intentions to carry reusables, our old habits can often get in the way.

Defaults and prompts can help to bring our good intentions in line with our actual behaviours. Consumer demand also encourages manufacturers to make more convenient reusable options, like collapsible coffee cups and metal keychain straws. Businesses can also make reusables more accessible by introducing product-sharing schemes like the Freiburg Cup in Germany or Boomerang Bags in Australia.

No ‘one size fits all’ solution Different situations need different solutions. Product sharing or reusable coffee cups might work in an office or café where the same customers return regularly but would be impractical at a gallery or museum where customers vary each day. For societal-level change multiple approaches are more effective than any one initiative alone. For example, if we wanted to phase out plastic cutlery nationally, we could start with an awareness campaign that encourages people to carry reusable alternatives. Then, once the community is on board, implement a small fee with some reminder prompts, and finally move to a ban once the majority have already changed their behaviour. The key to successfully phasing out our reliance on single-use plastic products is to change the norm. The more we talk about the problem and the solutions, the more businesses will seek out and offer alternatives, and the more likely we are to mobilise together.

REAR VIEW

How to have a good Fourth Industrial Revolution Trees, please: Take a break from technology. To encourage people to examine the impact of technology on our lives, the artist Lauren McCarthy decided to try to become a human version of amazon.com’s smart home intelligence device Alexa. McCarthy installed a network of remote-controlled smart devices, from cameras and microphones to light switches and appliances, and invited volunteers to stay in her home. Then she tried to anticipate and respond to their needs – like making a bowl of popcorn when she guessed they were hungry—instead of just responding to commands like Alexa does. Get-Lauren touches on common anxieties, starting with the questions of what humans can offer that machines cannot, and what control each of us has over our future and even who we are. “By allowing these devices in, we outsource the formation of our identity to a virtual assistant whose values are programmed by a small, homogenous group of developers,” McCarthy wrote. The Fourth Industrial Revolution has ushered in new technologies that are changing where and how many of us work, what we buy and how we buy it, what we learn and what we delegate to our devices, and how we connect with each other.

uncertainty. Assessing how we use technology in the workplace, home, and community helps identify where we are doing well and where we need to do more. That, in turn, gives us the material to create a roadmap for adapting.

Embrace the future of work All those stories of the “robots coming for your jobs” reflect public anxiety over how automation and artificial intelligence will affect the workplace. On the good side, new platforms have made it easier for independent workers to connect with clients, diversify their income sources, and keep more of the income they generate instead of sharing it with a corporation with overhead and shareholders to pay. At the same time, studies from the Oxford Martin School, McKinsey & Company, and others suggest that technology will affect most of the labour force. More than half of of US workers are not confident that the kind of work they do will exist in 20 years, according to a recent survey. Considerably more freelancers – 49 percent versus 18 percent of employees — think AI has already affected their work.

It’s easy for even tech-savvy individuals to feel that we are helpless in face of these tectonic shifts. What can a single person do? What power does anyone have amid massive social and economic changes? What is within our control and how do we adapt to what is out of our hands?

McKinsey concludes that the tasks that are least susceptible to automation involve managing others, decision-making, planning, and creative tasks. Somewhat more vulnerable are stakeholder interactions and unpredictable physical work. Data collection and processing are highly susceptible to automation. Robots are most likely to take over predictable, repetitive tasks.

Simply asking those questions is a good start toward managing technology instead of letting it control us. Seeking to understand the changes underway helps us to feel that we are doing something instead of facing complete

Considering these changes, take stock of your own skills. Which ones distinguish you and which ones need improving? Focus on the activities at which humans excel where machines cannot - creativity, teamwork,

innovation, judgment, empathy and fields that are least likely to be destroyed by new technologies.

or platforms for sharing rides, homes, or cars?

How would your colleagues, friends, and family assess your people skills? Ask them and improve your weak spots. Take a course, find a coach or accountability group, and check in with the people around you to see if they notice changes.

Now think about how you use each technology and how much it benefits you. Do you change your behaviour based on the readings from your wrist tracker, or do you ignore it? Is the amount of time you spend on social media or playing games healthy or a giant time suck? Does it leave you feeling better about yourself? Have you made informed choices about privacy and adjusted your settings appropriately?

If your job is among the most vulnerable, how can you add skills that fall in a safer category? Where can new technologies help you learn new skills and apply them for much less than it would have cost in the past? What skills are you helping the children around you to nurture?

Review your tech relationships Along with your work-related assessments, do a personal tech audit. Familiarize yourself with technologies that can help you outside of the office. Ask what is most useful for you, and what is just hype designed to sell you gadgets. Make tech work for you, not the other way around. What dull tasks can you delegate to technological tools? What things need the human touch? I hate scheduling, so love the idea of an AI personal assistant. But an AI scheduler can’t handle jamming too many appointments into a single day on a trip to a big, congested city, or manage conversations with VIPs. What technologies do you use already? Robot vacuum cleaners; programmable alarms and coffee makers; automated online tools; wearable technology; smart thermostats; parking assist? Health technologies from telemedicine to record management systems to apps that remind you to take your pills, help you meditate, or monitor your heart rate? Do you rely on social media and networks for searching for jobs;

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Use good tech hygiene. Take vacations from your devices instead of letting your smartphone be an electronic tether. Set boundaries for interactions; don’t tolerate online bullies or trolls. Adjust your privacy settings. Fight the negative physical effects of technology, like hunching over your phone or trouble sleeping because you looked at your device too close to bed time.

Create a roadmap Neither the utopian or dystopian visions of the Fourth Industrial Revolution is inevitable; the future depends on how each one of us responds. Regular check-ins at home and work will help you to map a way forward that gives you more control and reduces anxiety. Used right, technology can empower people by giving access to information and markets, and by increasing transparency and connectivity; creating new business platforms and models; and giving us more control over our environment and health. Making sure that happens is one thing we cannot automate.

NZ Manufacturer July 2018

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