NZ Manufacturer December 2018 by Media Hawkes Bay Limited

December 2018

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9 TECHNOLOGY

MANUFACTURING Unleashing the creative entrepreneurs.

YEAR IN REVIEW A ‘snap shot’ of successful companies in 2018.

19 MANUFACTURING SMART

Taking plant-based meat global.

Manufacturing

– A year in review

Professional 3D CAD Design software

Dieter Adam, Chief Executive,The Manufacturers’ Network

It is the time again to look back on the year that was – how did our manufacturing sector do, and what were the major developments that impacted our sector in another year of political change, both in New Zealand and around the world? Internationally, issues around trade have dominated much of the economic headlines, with the trade war between the USA and China, but conflict between the USA and Europe not far behind – not to mention Brexit, the trade implications of which appear to be just as uncertain as the question of whether it’ll actually happen or not. While these trade disagreements have not yet had a major impact New Zealand exporters, they remain as a downside risk if they start impacting the wider flow of goods and supply chain which our companies are involved in. The exchange rate experienced some depreciation throughout this year, however, much of this has been eroded over the last month. While 2018 has experienced a more favorable exchange rate than the highs experienced in 2014 and 2016, it remains systemically higher than the average of the previous decade, with the AUD cross-rate remaining as the biggest concern. Domestically in 2018, we have seen a number of policy changes which will impact our sector. The improvements made to the Government’s R&D policy, increasing the proposed tax credit rate to 15% while halving the eligibility threshold to $50,000, have been a good step forward, and the move to use a committee for monetary policy decisions at the Reserve Bank makes solid sense. On the downside, the Employment Relations Amendment bill has been moving through the parliamentary process largely unchanged, with the only material concession being a weakening of the

requirement to participate in collective bargaining by introducing opt-out provisions, the details of which are as yet unclear. This government’s declared goal of redressing a perceived imbalance between employers and trade unions has already seen very substantial public sector wage increases which – were they to influence wage demands in our sector without corresponding increases in labour productivity – would pose a serious threat to our sector.

2018 version

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Technology improvements for manufacturing companies, particularly in the area of automation and Industry 4.0, have continued to become more accessible, and, critically, are becoming cheaper with faster payback times. At The Manufacturers’ Network we have continued our work in helping our members investigate and share knowledge and experience in this area, including study tour with Callaghan Innovation to the U.S to give manufacturers an opportunity to see some practical examples of Industry 4.0 and related advanced manufacturing technologies in practice. I also want to reflect on recent data on the manufacturing sector, stepping back and seeing how growth for 2018 compares to the last five years. The numbers I will be referring to go up to the September 2018 quarter – if you click the like below you can find this full article along with a number of graphs create based on the Statistics NZ manufacturing survey data. Looking at across sub-sectors, including the meat and dairy, manufacturing has seen a fairly steady

continued on Page 29

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2019

Media Kit with Editorial Calendar INCLUDES: Manufacturing Technology / New Products for Manufacturers / Disruptive and Future Technologies / Export Success / Trade Show Previews and Reports - SouthMACH 2019 / AusTech 2019 / BuildNZ 2019 Company Profiles / Analysis / Interviews / Food Manufacturing / Infrastructure / Smart Manufacturing / Industry 4.0 / Robotics & Automation / Productivity / 3D / Supply Chain / Women in Manufacturing / Additive Manufacturing /

CONTENTS DEPARTMENTS

5 BUSINESS NEWS

ADVISORS

Accelerate your business by using your voice.

6 MANUFACTURING TECHNOLOGY

Companion robot trialled in classrooms. 3D modelling important in design of New Zealand’s Pu-hoi to Warkworth motorway. Unleasing the creative entrepreneurs.

Leeann Watson

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

12 DEVELOPMENTS

Dieter Adam

Chamber supports changes to Employment Relations Bill. ATNZ Apprentice of the Year swapped uni for on-the-job training. Sensible approach to urban development bodes well.

14 ANALYSIS

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

Skills shortages hurting employers. Japanese business climate sunny for Kiwi entrepreneurs.

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.

15–17 YEAR IN REVIEW

18 SMART MANUFACTURING

Sunfed takes plant-based meat global. Robot for airworthiness inspections. New application to help work smarter. AI and robots could create as many jobs as they displace.

23 EXPORT NEWS

Free trade with Korea.

24 NEW PRODUCTS

Home battery factory opens in Australia. Energising heat for smart appliances.

26 FOOD MANUFACTURING

Enormous amounts of food wasted during manufacturing.

DEVELOPMENTS The little startup that could: Celebrating 15 years of Velocity.

31 REAR VIEW

New technologies can create huge numbers of meaningful jobs.

Dr Troy Coyle

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..

21 Craig Carlyle

28 SUPPLY CHAIN

Why the circular economy must link up the whole supply chain.

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

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

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

CONTRIBUTORS Dieter Adam, Holly Green, Alice Loy, Annette Azuma, Rachel Macrorie, Jack Stenhouse www.mscnewswire.co.nz

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

DESIGN & PRODUCTION Kim Alves, KA Design T: + 64 6 870 8133 E: kim.alves@xtra.co.nz

This final issue of NZ Manufacturer for the year includes profiles of New Zealand companies who -varied they may be in their processes – are doing well on local and international markets. Innovators like Paul Barron from Tauranga who is seeing his ideas of wool surfboards reach fruition.

WEB MASTER Bruce Metelerkamp E: bruce@hha.co.nz

PUBLISHING SERVICES On-Line Publisher Media Hawke’s Bay Ltd

Or Lincoln Agritech Ltd.’s Milk-Guard device that detects processing losses in dairy plants which could save the industry millions of dollars a year and help prevent pollutants from entering waterways.

DIGITAL SUBSCRIPTIONS E: publisher@xtra.co.nz Free of Charge.

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

Other companies we are profiling include . North Shore-based Rivers Carbon which has come up with a lower cost way of making carbon fibre products for everyday sectors such as construction and mining.

Vol.9 No. 11 DECEMBER 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 December 2018 /

I’ve got a thing about Productivity. It’s been bugging me all year because we all know how much it affects and assists in the country’s efforts to improve our quality of life and contribute towards the balance of payments. Sometimes it is difficult to see just how much it is rising. When you think about Productivity you think of companies making more through incentives such as increased salaries for staff and a goal to be the best they can be through a strong and committed focus to aim to be better. Innovation to the fore to this end.

ADVERTISING

Profiling some winners

MJH Engineering the steel fabrication company, based in Seaview, Lower Hutt housing industry-leading automated machinery. Some of New Zealand’s largest building construction projects can be attributed to its name.

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Waikato company, Stafford Engineering Ltd has designed a new machine nicknamed “The Iguana” to mass produce a natural skin care range made from fish skins to meet growing international demand for the product. ActivLayr, a skin care product made by West Auckland nanofibre producer Revolution Fibres. And Sanpro Industries Ltd, the Petone company which supplies the world. The Sanderson name has become the industry standard to all the big names in the exhaust system industry. All these companies are highly Productive and their journeys have been full of adventures, trial and error and achievement. Next year…there will be another set of profiles on companies forging ahead…will yours be one of them?

Best wishes and Merry Christmas.

Doug Green

Success Through Innovation

EDITORIAL

A country’s ability to improve its standard of living over time depends almost entirely on its ability to raise its output per worker. - Paul Krugman, laureate of the Nobel Memorial Prize in Economic Sciences.

You have to learn the rules of the game. And then you have to play better than anyone else.” -Albert Einstein

BUSINESS NEWS

Accelerate your business by using your voice Ask any business owner or board-level executive involved in manufacturing about the demands of growing a business, and they would probably readily agree that it’s tough. Apart from juggling various elements to keep the business on a growth trajectory, there are the endless administration tasks. Regularly producing reports, quotes, estimates, proposals, plans and invoices can be daunting, and may even negatively impact on productivity. However, the challenge no longer needs to be overwhelming thanks to technology. Speech recognition is now more accurate, more powerful, and more usable than ever before, and it can help facilitate the growth of a business. Adopting a desktop speech recognition solution - like Nuance Dragon Professional Individual for the PC - can improve a business’s everyday performance and productivity. Save time producing documents Dragon does the typing for you as you speak and, as we talk three times faster than we can type, the productivity

Commercial & industrial growth

implications are considerable. Dragon quickly and accurately turns your spoken words into text. It lets you put your voice to work to easily dictate and edit documents, proposals, reports and more. With Dragon you spend less time producing documents, and more time on activities that boost the bottom line. Plus, as Dragon works with all Microsoft Office applications, you can also create spreadsheets and presentations by simply using your voice. The solution also lets you speak to send emails, and as it’s compatible with popular web browsers, you can also deploy Dragon to search the web and use social media with unparalleled speed, ease and comfort. Dragon rewards the user by helping you gain precious time. Work that may have taken hours – typing a large document or clearing your inbox – can now be achieved faster and without the need to type, and the time

saved can be allocated to boosting productivity, improving customer service and increasing revenue. Work hands-free There’s also less strain on your hands and wrists. Dragon gives you the flexibility to work hands-free and therefore, in a more ergonomic and comfortable way. As you use your voice to get things done on your computer, Dragon helps to reduce the physical stress of typing. Flexibility to work while on the move

can frustrate. The Dragon Anywhere app, however, lets you dictate and edit documents by using your voice wherever the job takes you. Correspondence, reports and documents can be created while out in the field, and when back in the office, you can simply pick up where you left off because Dragon Anywhere synchronises seamlessly with the desktop version. As the pace of business continues to accelerate, technology such as Dragon can give you both the capability and agility to effectively speed through documentation and focus on what matters most – growing your business.

Dragon also addresses the issue of mobility. In the modern business age, you are inevitably on the move, consulting with colleagues, meeting with clients and suppliers, and networking. The Android or iOS mobile usually becomes the primary interface, but its size creates challenges. Tiny keyboards and small screen sizes

Employment growth

Economic output

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

getba

getba.org.nz

Greater East Tamaki Business Association Inc.

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NZ Manufacturer December 2018

MANUFACTURING TECHNOLOGY

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

INNO3D 2018 well attended October 10th was a milestone day for NCCS with the annual INNO3D event, showcasing what is new in Solidworks 2019, along with industry partners presenting some of the latest products and trends in the design and manufacturing space. INNO3D 2017 was a large event but this year’s event was even bigger and broke all records. With more than

220 keen design and manufacturing industry professionals in attendance, and 10 industry partners showcasing their latest technology, the event was well received by all. David Auld and David Trought from Outerspace Design gave the audience a first-hand chance to see the award-winning

Fusion Guitar designed using SOLIDWORKS and featured on Channel 10’s Australia by Design: Innovation program. Solidworks 2019 along with Solidworks CAM offers Customers access to best in class design to manufacture technologies and workflows. This will improve collaboration and interactive experiences during design and engineering. Companies will be able to deliver more diverse and better products to their Customers in shorter timeframes. This

latest

Solidworks

release

packed with enhancements based on insights and feedback from the large worldwide Customer base. Solidworks took many of the common ideas along with gains available using current hardware iterations and based Solidworks 2019 on that. Year on year INNO3D is the largest event of its kind in Australia and New Zealand and NCCS plans to showcase Solidworks 2019 along with Solidworks CAM again at Austech 14-17 May 2019.

Companion robot trialled in classrooms La Trobe University researchers are bringing education into the digital age with the introduction of social robots into special needs schools. In a first for Victoria, the University has teamed up with Waratah Special Developmental School to trial a robot called Matilda as a classroom companion.

Khaksar said.

Matilda has been working across four classrooms to assist teachers in creating positive social engagement and entertaining learning activities for students.

“This study is about assisting both teachers and students, especially those in special needs education, who can face particular challenges in their learning environments. It will measure how social robots can motivate children with special needs to better learn and engage in the classroom.”

Research Project Manager Seyed Mohammed Sadegh Khaksar, from the La Trobe Research Centre for Computers, Communication and Social Innovation (RECCSI), said the robot is being personalised to empower teachers and enhance their work. “Matilda can recognise human voices and faces, detect emotions, read and recite text, dance and play music,” Dr

“Our aim is to adapt these features in a way that will complement a teaching environment and provide tailored support to teachers and students.

Dr Khaksar said feedback from teachers – taken before, during and after classes – has been crucial in helping shape and develop a more effective companion robot. “The teachers taking part in this trial are able to tell us what it is they

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need from Matilda and which of the existing services need to be adapted or changed to better suit their needs,” Mr Khaksar said. “For example, one of the services we are co-developing with Waratah Special Developmental School is a bullying support service to be programmed into Matilda.” In addition to teacher feedback, student interaction has proved overwhelmingly positive. “The results are immediate. As soon as the kids see Matilda in the classroom, their faces light up and they become more interested and engaged,” Dr Khaksar said.

“We’ve seen an increase in students’ willingness to engage with the robot and an improvement in communication and social skills. Our students are listening and attending to the robot, responding when their name is called and following the robot’s instructions. “We’ve found our students are highly motivated to participate in activities facilitated through the robot and they are demonstrating an increased ability to wait and take turns after spending time with the robot.” RECCSI Research Manager and Associate Professor (Debbie) Mei-Tai Chu said this type of technology is in high demand.

“Because the robot is patient and non-judgemental – as well as being interactive – the students have been able to form a type of bond with it.

“La Trobe is at the forefront in creating solutions for social innovation. Our hope is that La Trobe’s robotic technology, which delivers emotional assistance and companionship over physical services, will be employed widely across Australia,” Dr Chu said.

“The robot can speak to students, read and act out characters in books, as well as set tasks. But it can also repeat things hundreds of times if necessary and not tire of it.”

“Using this personalised approach over a one-size-fits-all model is vital, as it allows users in various contexts to independently develop unique services tailored to their specific needs.

Waratah Special Developmental School Principal, Jennifer Wallace, said school staff have found the ability to work collaboratively with La Trobe researchers beneficial.

“Matilda is not only enabling the kids from Waratah Special Developmental School to develop better communication, but also social and cognitive skills.”

“It’s been a fantastic experience to help develop specific activities and adjustments for the robot, to address the individual needs of our students and monitor their progress,” Principal Wallace said.

The study into social robots for special needs classes is set for completion in late 2018. Matilda was originally co-created in partnership with NEC Corporation.

Rapid-Response Tooling SSL CUTS LEAD TIME FOR CUSTOMIZED COMPOSITE TOOLING BY EMBRACING 3D PRINTING. CHALLENGING THE NORM

Over the last 30+ years, composite materials have become increasingly relevant to a number of industrial sectors with applications that demand the high strength of metals without their associated weight. Although the composites industry has made significant breakthroughs in material science and production methods over the years, producing complex composite parts can still be a lengthy and challenging task that requires specific knowledge and expertise. Traditional production methods for high-temperature composite tooling involve the expensive and time-consuming process of CNC machining. Although machining is a repeatable and reliable production method, the need for an operator and the subtractive nature of the process result in high costs, long lead times and significant material waste. Stratasys FDM® technology can address all of these pain points.

Evolving Innovation SSL, based in Palo Alto, California, is a premier designer, manufacturer, and integrator of satellite systems. They work at the forefront of satellite and composite technology. Maintaining industry leadership means SSL is continually innovating and evolving their approach to composite part and spacecraft fabrication with improvements to materials, processes and techniques. In partnership with Stratasys and using Fortus® 3D Printers, the latest technique that SSL has implemented is additive manufacturing for rapid-response, customized, high-temperature lay-up tooling. Although often overlooked, tooling applications are proving to be among the most effective use cases for realizing significant and immediate value with additive manufacturing, and SSL has implemented the technology for many such applications.

A Game Changer for Tooling For years, SSL has used FDM technology for prototyping and even some production parts. More recently, the SSL team benefited from using 3D printing to produce customized high-temperature lay-up tooling in situations that are highly time-sensitive, require rapid response, and necessitate complex, custom geometries. In one such case, Stratasys was able to provide SSL with a highly tailored lay-up tool capable of the required 350 °F (180 °C), high-pressure autoclave cure cycle in less than 48 hours (shipping time included), a 50% reduction in lead time. The time savings was critical in this case, highlighting one of the core advantages of 3D printing.

SSL uses 3D printed tooling in their satellite development.

According to Jude Zils, SSL Technology Manager, “Stratasys additive composite tooling solutions have allowed SSL to respond to design releases and changes with unprecedented speed at significantly reduced cost, without compromising part quality or performance. This game-changing technology is facilitating a level of customization and rapid response that our customers can really appreciate.” Additive manufacturing allows SSL to eliminate the high costs and lengthy lead times typically associated with composite tool production. In situations that are extremely time-sensitive, lead time is measured in hours and days rather than the typical weeks or months for traditional composite tooling. Depending on part complexity and size, a tool build can take just a few days, and quite frequently less than 24 hours. This, compared with many days or even multiple weeks for traditional machined tool assemblies, affords SSL unprecedented levels of flexibility. These time savings not only permit SSL to meet the increasing demands of shorter customer lead times, but also allow much greater design freedom and shorter product iteration cycles that result in superior levels of part performance and functionality. www.objective3d.co.nz

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NZ Manufacturer December 2018

MANUFACTURING TECHNOLOGY

Don’t let what you cannot do interfere with what you can do. - John R. Wooden

3D modelling important in design of New Zealand’s Pu-hoi to Warkworth motorway Design Joint Venture (DJV), a collaboration between engineering consultants, Beca and Tonkin + Taylor has highlighted the power of Seequent’s Leapfrog Works 3D geological modelling - hoi to Warkworth. software in the design of a motorway extension from New Zealand’s Pu With an estimated cost of more than NZ $700m (including maintenance over 25 years), the 18km Pu-hoi to Warkworth motorway extension includes a road corridor that cuts through steep hills and valleys, and the creation of seven bridges including three viaducts. Combine this with the cutting of 7 million cubic metres of earth (and the filling of 5 million), and the challenge of soft alluvial sediments – and it’s easy to see why a project wide ground model is essential as a basis for geotechnical design, and to mitigate project risk.

accurately define the geology. Chris Monk, Engineering Geologist, Tonkin & Taylor, says, “There were three areas of focus. North, which showed low-lying topography; Central, which has significant cut and fill embankments and; South, which contained two viaduct structures. It was important we could use a modelling tool that worked flexibly around the different geology and surface types to give accurate outputs. We modelled 210 cone penetration tests (CPT) and brought in data from 420 boreholes,

Ground improvements works. Image courtesy of NX2 Group.

Meeting population demands

355 hand augers and 220 test pits.”

As the population of Auckland reaches over 1.5 million, and the demand on the Northland area increases, the region of Warkworth is classed as a growth centre. The number of cars travelling the route daily is set to rise from 19,700 in 2012 to 31,300 in 2026 – the extension will provide a better connection with all of the associated safety and traffic flow benefits.

Working in dynamic 3D

The design work was subcontracted to Design Joint Venture (DJV) a collaboration between engineering consultants, Beca and Tonkin + Taylor. Seequent’s Leapfrog Works, which is specifically designed for the Civil Engineering and Environmental industries, was used as the 3D geological modelling software to more

Detailed design started in October 2016 and is ongoing. The team started collecting ground investigation data and used this to input into their 3D geological Leapfrog model. Leapfrog Works’ dynamic and continuous modelling transformed the way that the Geotechnical team worked.

and reducing the effort in having to re-produce work. Stuart Cartwright, Senior Engineering Geologist, Tonkin + Taylor, comments, “Leapfrog really helped us on what has been a significant and challenging project. The length of the proposed motorway and its alignment through such steep topography made the ground model development challenging.” The Geotechnical team were able to leverage the great visualisation of Leapfrog Works to bring together and better communicate across such a wide range of project stakeholders including the Construction Joint Venture (CJV) team, quantity surveyors, surveyors and geotechnical engineers and bridge designers. “By being able to show the model in 3D and cut sections at any desired location instantaneously enabled others to visually understand the geological conditions of the site with much better clarity. We collaborated much more as a whole project team as we were able to hold informal review sessions/workshops to show progress. In the past we would have gone with paper sections, but the 3D model outputs and graphical interface changed the way we communicated and collaborated,” says Cartwright. Minimising the cut and fill footprint Leapfrog was initially used by the DJV in the tender phase to create a

3D geological model of the route. The model was then imported into the Bentley ‘OpenRoads’ civil design software. This allowed the slope profiles and cut and fill quantities for different alignments to be quickly and easily compared and for optimization of the earthwork’s mass-haul to assess the most cost-effective alignment. Understanding the material makeup of the mass-haul balance is crucial for minimising the cut and fill footprint. This not only reduces waste, but being able to understand earth composition means that extracted earth can potentially be used to fill in another part of the site, saving time and money. Environmental impact such as tree removal can also be minimised. Stuart Cartwright comments, “The contact surface between the weathered Pakiri Formation soil and underlying unweathered rock, was critical for assessing likely cut slope profiles and excavation footprints, Leapfrog made this process much easier to complete.” Looking forward As major infrastructure projects become increasingly large and complex with multiple stakeholders, having a 3D ground model to support the understanding of the geology allows geotechnical teams to improve efficiency of design. Easily maintaining a dynamic model over the course of the proposal and design is transforming the way ground engineers are working. This is a real step forward to enabling the civil engineering industry to become more responsive in an increasingly digital world. “Having a dynamic model that evolves as new data is provided has saved the team time from not having to recreate a new model every time, leaving us more time to focus on analysis,” says Monk. The motorway is expected to take 5 years to build and will be open to traffic in late 2021.

Using Leapfrog Works meant geological surfaces could be mapped by a geologist, rather than engaging a CAD technician to work alongside a geologist, resulting in a smoother workflow, and faster turn-around times. As project engineers needed sections, they were able to go straight to a single point of contact to quickly create the desired section – saving time The 3D subsurface model encompasses the full length of the 18.5km alignment.

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Judge your success by what you had to give up in order to get it. -Dalai Lama

MANUFACTURING TECHNOLOGY

Unleashing the creative entrepreneurs By Alice Loy

The Fourth Industrial Revolution is upon us. If you are wondering how to take on the challenges of a shifting global economy, investing in creative industries entrepreneurs tackles economic, civic, and social challenges and is found in every community in every corner of the globe. From Boston to Bangladesh, creative entrepreneurs are building companies at the cutting edge of digital fabrication, augmented reality, design and entertainment. The creative economy is huge. And growing. It generates close to $3 trillion in economic output annually. That’s more than the global telecommunications industry. What’s more, creative economy revenues are expanding 8-12% annually, varying by country. In the USA, the creative economy grew straight through the Great Recession, as opposed to all other sectors. Growth will continue as a global middle class rises, expanding demand for entertainment, digital media, and original content and experiences. Consider this: Cirque du Soleil was founded by two street performers who grew it into a global phenomenon and sold it for $1.5 billion to investment firm TPG in 2015. Lynda.com, acquired by LinkedIn in 2015, was started by Lynda Weinman, a graphic designer turned educator. Fashionistas, filmmakers, and foodies are launching creative companies that drive value for investors and create high-wage jobs. However, the creative economy is a sleeping giant because leaders and investors, community and economic developers have mostly left the creative economy on the sidelines, its full potential sitting dormant. Many leaders think only of “the arts” when they hear the word creative. However, today’s creative companies are anchored in technologies and digital innovations. Take for example Embodied Labs, a VR film company whose films help medical providers understand patient experiences, reducing costs and improving health outcomes.

and engineers. Akin to tech founders, creative founders are driven by a desire to disrupt a market. Unlike many tech founders, most creative entrepreneurs are also inspired by social outcomes such as engaging disenfranchised communities, providing a living wage, and building culturally connected communities. The creative economy is being built by visionaries who strengthen regional identity, increase livelihoods, and build connected communities. So how can you unleash the creative

filmmakers, or musicians. 2.) Host a small gathering with innovative creative founders and investors and ask them to share where they believe your regional creative economy could be more competitive. What assets and competitive advantages do you have that entrepreneurs and investors have already discovered? When we do this, we find investors who are already working with creative companies. They are usually interested in further building out their portfolio along these lines.

They recently closed $17 million with a lead investment by Alsop Louie Partners from Silicon Valley. Meow Wolf is not alone in their ability to see a market before it has fully convened. Lee Francis, Founder of Native Realities, launched the world’s first Indigenous Comic Con to give indigenous youth a chance to see themselves as superheroes. Today Indigenous Comic Con and Lee’s publishing company Native Realities, are leading a global movement to reframe how indigenous youth see themselves in pop culture.

The Fourth Industrial Revolution, is disrupting social and economic structures,

300,000,000 indigenous people are eager to move with them.

entrepreneurs and talent in your community? Here are three tips to get you started:

And the founders are excited to meet investors who share their vision for the region’s future.

1.) Find ambitious creative entrepreneurs who have been overlooked. They might be building the next Cirque du Soleil but everyone else sees them as clowns. With fresh eyes, you might see a billion-dollar business in the making.

3.) Assume you just don’t get it--yet. Creatives are disrupting markets and they see a future the rest of us don’t see.

I have worked with start-ups who became extremely successful entrepreneurs who have told us that early on “no one took them seriously” because they were designers, or

Today, with over 1 million visitors and $15 million in revenues in less than two years, Meow Wolf’s out-of-this-world exhibit helped multiply their first investors’ funds within three years.

Take for example the story of Meow Wolf, an “artist collective” based in Santa Fe, New Mexico. When Meow Wolf started out, they sought business support but were told more than once their venture should be a non-profit. They are artists, after all.

Lvonette Albuquerque, Founder of Galpão Aplauso, in São Paulo, Brazil, believed she could build a world class theatre company employing youth living in São Paulo’s favelas. Today, she has trained over 10,000 youth, nearly all of whom go on to find well-paying jobs after the program. The Fourth Industrial Revolution, like all good revolutions, is disrupting social and economic structures, forcing leaders to rethink old strategies and adapt to new realities. Relentless creativity and imagination will win the day. Fortunately, a giant ally is waiting in the wings. All you need to do is wake it up.

Or Beacon Hill VR, a software firm with artists and gamers on staff who create and bring to life animated AR characters. We suspect leaders overlook the creative economy because they are unfamiliar with its numbers. Creative entrepreneurs are market disruptors building a better and more inclusive future. The innovators behind creative companies are designers, coders, gamers, musicians,

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NZ Manufacturer December 2018

MANUFACTURING TECHNOLOGY

Nothing is really work unless you would rather be doing something else. -J.M. Barrie

Lightweight electricity solution emerges for deployed defence units A micro gas turbine designed to provide electricity to defence units in the field has been demonstrated to leading industry players in Australia. ecoJet Engineering’s 20kW gas turbine is about 10 per cent of the weight of a comparable internal combustion diesel engine and can be configured to run on a range of liquid and gaseous fuels, including propane, natural gas and diesel. ecoJet Engineering received funding at the beginning of this year from the South Australian government and the RAAF Air Warfare Centre Innovation Hub to progress its concept design for a 20kW micro gas turbine into a viable prototype unit. The demonstration unit is the first stage in developing the next generation in deployable power generators for the military. The demonstration unit generator weighs just 48kg, excluding the control system and the fuel tank, compared to 433kg for a current military diesel generator. It is also about two-thirds the size of the diesel engine, measuring about

600mm long and 250mm wide

combusted gases.”

ecoJet co-director Alexander Wright said the mobility of the unit, the versatility of the fuel source and potential for more efficient electricity production were among the advantages of the system compared with traditional diesel generators.

The collaboration between Wright, James Kim and Warren Day that led to the formation of ecoJet Engineering began in 2015 with an Honours project at the University of Adelaide that achieved one of the world’s smallest ultra-micro gas turbines.

He said the demonstration unit already had flow rates comparable with current diesel generators. “And that’s comparing a prototype unit with a commercially mature product,” Wright said. “We have a lot of scope for improving our efficiencies above that with things like heat recuperation, bearing advancements, the use of advanced materials such as ceramics and graphenes and multi-stage turbo machinery, which is uncommon for turbines of this scale. “It is quite efficient and it’s not restrictive of other technologies, it can work quite well in parallel with solar and battery storage so it’s not a competitor to other products exclusively – it can complement other systems.” The micro turbine works in basically the same way as a typical jet engine where a compressor draws in air and passes it into a combustion chamber where fuel is injected and ignited as it passes through a turbine, creating rotation. “What we’ve got as part of our novel solution is an integrated shaft assembly where the shaft that connects the turbine and the rotor has an integrated generator attached to it.

ecoJet co-director James Kim with the 20kW micro gas turbine.

“The generator spins with the turbine to create electrical energy from the rotational energy extracted from those

Through further studies at the University of South Australia, the collaboration won a Venture Capitalist grant in 2016, which helped launch the company. ecoJet Engineering also pitched its ultra-micro gas turbine design at this year’s Land Forces event in Adelaide where it was named best innovation. Major players in the global micro gas turbine industry include Capstone Turbine Corporation (US) and Bladon Micro Turbines (UK) but Wright said their focus was more on industrial applications in the 30kW and greater range. He said the ecoJet micro gas turbine also had potential as a domestic product to complement renewable technologies such as solar and help households become independent from the electricity grid. “A military product is a commercial product with a bunch of extra stuff on top so we can easily tweak it to suit both markets because we are very much looking to break into both areas,” Wright said. “We’re planning a fairly development timeline and as part of this demonstration we’re looking for further investment from defence and government grants.”

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

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rapid

A render of ecoJet’s 20kW micro gas turbine.

Last

Wednesday’s

Canberra

demonstration included five sessions throughout the day with various stakeholders

including

representatives

from

senior all

three

Australian armed services, the Air Warfare Centre and the Defence Innovation Hub. “It was a really good opportunity for us to understand from the Defence side where they would use this particular application,

what

requirements

they value more highly such as size over weight or fuel efficiency over fuel versatility so it was really helpful in terms of the next stage of development,” Wright said. “It was received well and we had some good conversations around some of the funding opportunities for the next stage of developing the technology and the specific capabilities.”

Success means having the courage, the determination, and the will to become the person you believe you were meant to be. -George Sheehan

INDUSTRY 4.0

Optimising operations with event-driven alerts Future manufacturing systems need to be more flexible, to embrace tougher and constantly changing market demands. They need to refine plant data to real-time information for decision making, to facilitate competitiveness through informed and timely decisions (Theorin et al., ‘An Event-Driven Manufacturing Information System Architecture’). With the number of Australian manufacturers falling from 96,000 to 84,000 over 10 years, companies have been warned to either innovate or face potential collapse. Want to survive this decline? Look to companies like Asahi Beverages, Dulux Group and Coca-Cola Amatil as an example of how to incorporate real-time technology and a data driven approach into your production processes. Each of these companies, all using Operations Feedback Systems (OFS) as an Industry 4.0 software solution, have integrated their manufacturing data, feedback and workflows into an annotated event thread, enabling them to achieve sustained operational improvement. These companies are amongst thousands of other Australian manufacturers who have realised the importance of monitoring their production processes with IIoT tools.

The Importance of Making Timely Decisions Delays in manufacturing lead to inefficiencies and product failures, ranging from missed delivery windows to spoiled goods. In fact, Food Technology and Manufacturing Australia found that, on average, production plants waste up to 40% of their capacity through stops, speed losses, interruptions and defects. What does this amount to? According to Frain Industries, just 10 minutes of downtime each day on a typical food packaging line can result in as much as $87,500 a year in lost profit.

Using Software to Increase Quality OFS founder, Shoni Even-Chaim, realised it wasn’t enough to simply provide manufacturers with raw data on their operational performance, it needed to be actionable and driven by human engagement. “When implementing OFS-Alerts we immediately noticed a significant reduction in defects and an increase in operator engagement. People want to improve - they just need the right tools and the right prompts.” OFS-Alerts is a module in the OFS software suite, which enables manufacturers to send alerts to any

web-enabled or portable devices (i.e. wearables, mobiles, tablets, etc.) within the organisation. OFS-Alerts are triggered by real-time events which occur on the production floor (i.e. equipment breakdowns, failed quality checks, etc.), allowing the relevant people to be notified at the right time. This is beneficial to manufacturers for a variety of reasons. 1. Controlling machine-level compliance: Real-time alerts have become increasingly important in highly regulated manufacturing industries, such as pharmaceutical, biochemical and chemical production. Alerts provide maintenance with notifications that enable them to respond quickly to issues on the production floor, reducing downtime associated with faulty machinery.

floor have not been resolved or actioned, alerts can be escalated. For example, if an electronic quality form has not been filled on time, an alert will be sent to the supervisor on duty, if that supervisor does not action this missed form, then the QA manager will receive a notification. Escalation drives an increase in operational performance by significantly reducing staff response times and increasing reactivity.

Where to now? Now, more than ever, manufacturers need to innovative in order to remain competitive. By harnessing the power of real-time data, manufacturers can increase their efficiency, improve their equipment performance and engage their staff; fundamentally transforming their business operations.

2. Timely call to action: Alerts can use real-time machine data to create a timely call to action for manufacturing staff. For example, alerts can provide logistics with updates on the status of the production of orders, so transportation is ready upon order completion. 3. Problem escalation: If problems on the production

DCS Freelance upgrade for process industries Security is a top priority in the age of Industry 4.0 and enhanced security is one of a range of new features and benefits included in Freelance 2019. Originally launched in 1994, Freelance is a cost-effective distributed control system (DCS) solution for process industries. It combines the advantages of a DCS with Programmable Logic Controllers (PLC) and is characterised by ease of use, scalability, flexibility and reliability. Freelance 2019 is the latest version of the DCS. The Freelance suite of solutions comprises Freelance Operations for use at operator level, a scalable process level option, and Freelance Engineering which is used to configure and commission the system including the operator interface. The new version provides significant improvements throughout the complete system. New features and benefits of Freelance 2019 Improved usability: Freelance 2019 provides a significant increase

in efficiency and usability for its Operations and Engineering solution by adding advanced navigation, filter and sort functionality. The user experience has been improved with a new, very modern UI. Scalable: A new controller, PM 904F, expands the Freelance AC 900F controller family in the upper range, supporting four communication interfaces. It also provides more application memory and enables the reservation of specific memory. As for all Freelance controllers user applications are 100% runtime-compatible which also enables smooth upgrade opportunities. More connectivity: Up to four monitors can now be connected to a single operator workplace. The available display types per monitor, as well as the arrangements of the monitors, are easily configured and fulfil the typical requirements for occupational safety and operator effectiveness. Enhanced security: Freelance provides an additional alternative to its user management capabilities known as “Security Lock” by a solution called

“Extended User Management”. This new option makes use of Windows user accounts, supporting both local and domain accounts. As a result typical requests for options such as central password management, rules for password complexity, or password aging can be fulfilled. Compatibility: Freelance 2019 can run on Windows 10 and Windows 7 in the same system architecture. This allows customers to do a step-wise upgrade to modern IT infrastructure which helps in reducing maintenance costs. Being user-friendly, cost-effective and robust has already made Freelance a popular choice for businesses of process industries in more than 100 countries worldwide. Its flexibility and extensive reach are demonstrated by the 1000s of installations of the solution in industries. Wacker Chemie in Germany uses Freelance with Freelance Operations as the tool to efficiently operate and monitor their ketene plant. In China, Freelance provided uniform configuration of field devices online at YunNan HongTa DianXI Cement

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obtaining the m a x i m u m automation with minimum e n g i n e e r i n g . New controller PM 904F Freelance was also to extend the Freelance integral to the controller family AC 900F modernisation of Glinojeck, a leading European sugar producer and was at the centre of one of the most sophisticated reverse osmosis desalination projects in the Middle East. As in earlier versions of Freelance customers have the option of staying automatically up-to-date by subscribing to the Automation Sentinel life cycle program by, for example, providing automatic cyber security patches. Available in a wide range of languages, Freelance takes five minutes to install on any standard computer and can easily be self-learned. The intuitive operator interface enables easy operation and diagnosis of the entire system and being just one file it is easy to back up as the entire application fits on a small memory stick.

NZ Manufacturer December 2018

DEVELOPMENTS

Be miserable. Or motivate yourself. Whatever has to be done, it’s always your choice. -Wayne Dyer

Chamber supports changes to Employment Relations Bill The Canterbury Employers’ Chamber of Commerce supports the recently announced changes to the Employment Relations Amendment Bill, but chief executive Leeann Watson says there are still some areas of concern that need to be addressed.

would like to acknowledge the role of NZ First in securing some beneficial changes. However, we believe that the Bill still has a way to go to more closely align with the interests of employers and employees in the modern workforce and modern economy.”

“It’s good to see that the coalition government has listened to business, with some of the proposed changes left on the cutting floor and parts of the legislation now more acceptable to business,” says Leeann Watson.

Leeann Watson says the ramifications on the ability of businesses in New Zealand to grow financially and employ more people could have borne greater consideration.

“, we are pleased that provisions on union access and multi-employer collective agreements have been softened to gain more of a balance between employer and worker rights. “This shows a willingness by the government to listen to the concerns of business and alter course, and we

“We are disappointed to see that the ban on larger businesses from using 90-day job trials remains, which we believe will diminish employment opportunities for more marginalised members of the labour force, the very reason it was first established. “We are also disappointed that the requirement for employers to conclude

a collective agreement remains. While Multi-Employer Collective Agreements can work in some industries, they can also provide an instrument for larger businesses to force smaller businesses out of the market in situations where the larger player can absorb costs more easily. “The issue of meal breaks also remains largely unaddressed. “New Zealand compares very well with the rest of the world, with high growth and low unemployment. And while we endorse the Government’s goal of developing a modern, nimble, productive and high-growth economy, we do believe more could be done to ensure this legislation reflects that goal.” Leeann Watson says the announcement does provide clarity for employers at a

crucial time of the year. “We are thankful for the timely clarity around these changes as businesses start investing time and resources into planning for the new year and - for many their new year recruitment drive. “We will continue to advocate for changes that will help to ensure our employment relations are fit-for-purpose and future-proofed, and support businesses as they manage the impact of these changes.”

Engineers call for practical action on climate change Engineers say taking action on cleaner energy is the most practical step New Zealand can take to tackle climate change. Engineering New Zealand President Dean Kimpton says its new report, Engineering a Better New Z e a l a n d : Cleaner Energy, reflects what the majority of engineers are really thinking – and wishing New Zealand would just get on with. “Many elements

of a more sustainable energy future are crystal clear already. For example, the transport system of the future won’t centre on individually owned cars the way it has in the past. “Let’s plan for tomorrow, not an extension of the past.” “Two areas where engineers see the greatest opportunity for making a difference to climate change are building a sustainable transport network and making electricity cleaner.” Engineering New Zealand Chief Executive Susan Freeman-Greene says the report makes 10 specific recommendations for actions that

New Zealand can take now to build a sustainable future. “These include increasing and improving storage, so we can use more renewable electricity, both of water for hydro and batteries. At the same time, we need to futureproof our physical distribution network so it’s less vulnerable to climate change and storms. “We also recommend user pricing that drives down peak demand across our urban road networks, reducing congestion and emissions. Making this practical involves prioritising next-generation mass transit without polarising the community, as well as enabling last-mile solutions like

scooters, cycles and car share. “One key to achieving these recommendations is engineering capability. We need the right engineers with the right skills, both in existing and emerging technologies. This won’t happen without the right planning and incentives. “Moving forward means everyone in this space working together: engineers, regulators and decision makers. There’s huge opportunities for collaboration between professions, sectors and industries, with many organisations already moving in the same direction.”

ATNZ Apprentice of the Year swapped uni for on-the-job training Mechanical engineering apprentice Caleb Orotaunga has been named the inaugural ATNZ Apprentice of the Year 2018. The award celebrates an apprentice who is a high performer, has a great attitude towards their work, is proactive on the job and enjoys what they do. It was awarded for the first time by Apprentice Training New Zealand (ATNZ), the not-for-profit organisation that employs more than 380 engineering apprentices and places them with host companies around the country. Caleb is in the third year of his engineering apprenticeship, working as a maintenance engineer at Kraft Heinz in Christchurch.

An apprenticeship wasn’t his first choice – he moved to Christchurch from Gisborne to study engineering at university but found student life financially tough and left after the first year. After a stint of temporary roles, he applied for an apprenticeship, which has allowed him to earn while he learns. ATNZ General Manager Susanne Martin says Caleb’s dedication to excellence makes him a deserving winner. “The ATNZ team first met Caleb in 2016 and he impressed us right from the start. He’s become a very competent

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engineer who has the ability to work unsupervised and bring fresh ideas and solutions to his role at Kraft Heinz. “His manager at Kraft Heinz holds him in high regard and even asked Caleb to fill in as workshop supervisor and run toolbox talks while he was away on holiday. He’s dedicated to getting the job done and operates with a high standard of health and safety, which is vital in this industry.” The other apprentices at Kraft Heinz often turn to Caleb for support with their tasks in the workshop and their theory work to complete their qualifications.

Martin says: “Caleb displays all the qualities you need to be a great apprentice and we’re extremely proud of him.” As well as the inaugural title of ATNZ Apprentice of the Year, Caleb has won $1,000 to spend on tools for his trade. The award was presented at a BBQ breakfast for tradies at NZ Safety Blackwoods in Middleton, Christchurch.

The first step toward success is taken when you refuse to be a captive of the environment in which you first find yourself. - Mark Caine

DEVELOPMENTS

NZ needs more earthquake engineers Major destructive earthquakes in Christchurch and Kaikoura have highlighted the need for qualified earthquake engineers and the University of Auckland is launching a new programme of study to help produce them. The Faculty of Engineering will offer a Master’s degree in earthquake engineering from next year, both for currently enrolled undergraduate students and for construction engineers already working in the industry. The shortage of specialist earthquake engineers is a global problem as population growth in seismic zones continues to increase while new research and innovation in earthquake engineering means there is a need for engineers to update their skills and

knowledge. The Masters programme also follows developments in countries such as Australia, the United States and the United Kingdom where recent graduates are undertaking postgraduate programmes of study as demand for specialist knowledge in particular fields increases. “Investigations into post-disaster repair and reconstruction in both Christchurch and Kaikoura have increased our understanding of the specialist expertise we need but demand has exceeded the capacity of the engineering profession,” says Head of Civil & Environmental Engineering Professor Jason Ingham. “Our Faculty is internationally recognised for its strengths in structural

The Faculty’s earthquake team, from left: Professor Jason Ingham, Dr Rick Henry and Dr Liam Wotherspoon.

and geotechnical engineering and so we are in the perfect position to offer students a programme of study that takes advantage of our outstanding

teachers and researchers to produce highly qualified earthquake engineers.”

Out of the fog: honeycomb films Research into porous films made via the condensation of humid air could lead to materials with applications ranging from medicine to photovoltaics. Researchers are producing honeycomb-shaped films using an approach that mimics what happens when we breathe on a glass surface. The films have potential use in numerous applications, from tissue regeneration and bio-sensing to solar cells, explains an article in the journal Science and Technology of Advanced Materials. Tohoku University materials scientist Hiroshi Yabu reviewed the latest research on the fabrication of honeycomb films using the ‘breath-figure technique’.

Scientists are also experimenting with changing the films’ shapes by stretching and shrinking them, and with ways to control water droplets and the resulting pore size and shape.

highly uniform, closely packed array and sink into the substance. When the solvent then evaporates, a porous, honeycomb-shaped film is formed.

possible applications in areas such as optics, photonics, surface science, biotechnology, and regenerative medicine,” Yabu says.

These honeycomb films have a wide range of potential applications depending on their individually unique properties.

Researchers are investigating various substances and fabrication techniques to make these films for different purposes. For example, depositing metals onto already-formed honeycomb films can change their properties, such as making them conductive to heat and electricity. In contrast, films made from polyion complexes of polyamic acids can withstand heat. Films that contain ‘photochromic’ compounds change colour when exposed to light. Highly water-repellent films can Schematic (bottom) and electron micrographs (top) of the growth be made using a type of of a honeycomb polystyrene film by the breath-figure technique. fluorine-based copolymers.

For example, peeling off a honeycomb film from a silicon wafer leads to the formation of nano-sized spikes on the wafer, making it ‘anti-reflective’; a property that could be used to improve the efficiency of solar cells.

This technique builds on years of research into understanding what happens when a fog forms after we breathe onto a glass surface, and how dew droplets form.

The films could also be used as scaffolding for tissue regeneration. Research is underway to develop biodegradable honeycomb films with properties that encourage the growth of specific types of cells and tissues.

Water droplets condense when humid air is passed over certain substances mixed with solvents. They form a

“The production of honeycomb films can be performed on an industrial scale, greatly broadening their

For example, adding nanoparticles or adjusting the airflow direction over the drying solution leads to elliptical pores, rather than round ones.

Sensible approach to urban development bodes well Urban development will be better enabled by the newly established Housing and Urban Development Authority, says the Employers and Manufacturers Association (EMA). The EMA’s chief executive Kim Campbell says, “The approach is a good one to speed up the brownfields development in cities where we need to keep up with population growth. “Many of the powers of the new Authority, e.g., compulsory acquisition of land, already exist in the planning

system but this Authority has greater power and an approach that allows it to speed up decision-making on developments. “This will better provide communities with good transport links and other infrastructure to create well-planned and liveable environments. “The key to the success of the Authority will be in the quality of governors appointed to run it - expected to be operating in 2020. “The Authority will be able to over-ride

existing planning law and consent its own plans and complete developments in shortened time periods, which requires a genuine consultative approach with existing communities. “If development is managed properly, people requiring ‘affordable housing’ will not be displaced from their communities so that fears of gentrification need not be a problem. “Urban Development Authorities operate very successfully overseas to speed up the provision of housing

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and infrastructure, attract private investment and provide new design thinking that we need. “We welcome this new model, but its creation also highlights shortfalls in our wider resource management system, including urban planning. The re-write of that must continue while the Authority provides immediate relief to the urban housing crisis,” Mr Campbell says.

NZ Manufacturer December 2018

ANALYSIS

People often say that motivation doesn’t last. Well, neither does bathing -- that’s why we recommend it daily. -Zig Ziglar

Why the Japanese business climate has never been sunnier for Kiwi entrepreneurs -Annette Azuma, director, Staples Rodway For businesses looking to expand their operations into international markets, there’s never been a better time to head for Japan. Several premier international sporting events will bring millions of tourists to Japan in the next three years and the Comprehensive and Progressive Agreement for Trans-Pacific Partnership (CPTPP) has been ratified by both Japan and New Zealand. With the Japanese market more globally-focused than ever before, the climate is perfect for those can adapt to Japanese culture and tastes. Staples Rodway recently co-hosted the Start Acting: Japan seminar with New Zealand Trade and Enterprise (NZTE), the Japan External Trade Organisation (JETRO) and Auckland Tourism, Events and Economic Development (ATEED). The event is the third in a highly popular series of Japan-focused business seminars, aimed at helping Kiwi businesses capitalise on the interest generated in New Zealand and build a long-term strategy for success in Japan. Fashion designer Karen Walker, keynote speaker at the Start Acting: Japan seminar, first entered the market in Japan two decades ago. This year she reached the pinnacle of any retailer’s aspirations, opening a store in Tokyo’s Ginza 6, the newest and most exclusive shopping destination in the country, and arguably the world. Her willingness to explore a new market, combined with a premium product that she has adapted specifically for Japanese tastes, are a blueprint for other Kiwis to follow. Statistics New Zealand reported two-way trade with Japan totalling

$4.1 billion last year and that’s set to rise. Already the world’s third largest economy, Japan’s population of 120 million is expected to welcome 40 million tourists annually by 2020, as Japan hosts the Rugby World Cup in 2019, the Tokyo Olympics in 2020 and World Masters Games in 2021. New Zealand’s sporting prowess lends itself as a marketing tool. The timing couldn’t be better given that the CPTPP has now been ratified by Japan, New Zealand, and soon Australia. According to Craig Pettigrew, NZTE Trade Commissioner for Japan, what’s really exciting about the CPTPP for our exporters is that it gives them preferential access into Japan for the first time. The reduction, or in some cases complete elimination, of tariffs in Japan will benefit exporters across every imaginable sector, including beef and lamb, dairy, wine, seafood, forestry and horticulture. Japan’s leaders have also indicated greater global business interests. Japan’s largest bank, MUFG, has just purchased Commonwealth Bank of Australia’s global asset management

arm. In September, Shinjiro Koizumi, who is predicted to follow in father Junichiro Koizumi’s footsteps as Prime Minister, visited New Zealand with other Japanese politicians to meet business delegates and showed great enthusiasm for Kiwi ingenuity and the America’s Cup. Understanding both local tastes and culture are essential for any Kiwi business looking to expand into Japan. This has been evident throughout the series. At Start Thinking: Japan, the first in the series, New Zealand Story presented the 2017 study “Through the Japan Looking Glass”, which showed that a Made for Japan approach is far more successful than our traditional Made in New Zealand marketing. NZ Hothouse Tomatoes discovered that adapting produce to suit Japanese palates by producing a sweeter, smaller tomato was necessary to generate demand. Businesses cannot assume the same products currently sold in China will also be suitable for Japan without customisation. Asia is not a single country with a

standard set of characteristics, and the complexities of the Japanese market make it worth investing in targeted research. The trade-off is that with such educated, sophisticated consumers, if you can succeed in Japan, you can succeed anywhere. A best practice approach to business is critical, with special emphasis on politeness. That means responding promptly to enquiries, being prepared to answer many detailed questions and building a relationship slowly. Even well-known listed companies have failed to capture the Japanese market because they did not invest in the right people to handle enquiries, with the right level of emotional intelligence and adaptability to Japanese values. It’s also crucial that your business is capable of meeting demand promptly. With such unprecedented scope for success in Japan, Kiwi enterprises are well advised to get in ahead of the rush. Get in touch with a local expert or trade agency and find out how your business can make the most of opportunities in Japan.

Skills shortages hurting employers Difficulties in finding staff with suitable skill levels are reaching critical levels for the majority of employers, who identify skills shortages as the major issue facing their businesses, according to the Employers and Manufacturers Association (EMA) 2018 Employers Survey. In the current, incredibly tight labour market, 79 per cent of employers say it’s “difficult” or “very difficult” to find skilled staff. This is an increase on 72 per cent in the previous two years. The EMA’s CEO Kim Campbell says, “Finding new staff is proving to be the biggest handbrake on employers’ ability to increase productivity.” The skills mostly lacking are technicians (for 32 per cent of employers), professionals (for 28 per cent) and machinery operators (for 20 per cent). “Increasingly employers are looking to the immigration market, technology, or taking on relatively unskilled staff to train them up.” Seeking skilled migrants from offshore

has become a solution for more employers this year with 33 per cent looking to solve their problem through immigration compared to 23 per cent a year ago. Employers are also addressing their skill needs in other ways. The majority of employers (55 per cent) prefer to employ people with basic skills and up-skill them to meet their needs. In addition, 44 per cent will re-train existing staff on the job, and 38 per cent prefer to employ people with required experience, although this latter figure has dropped by 12 per cent on a year ago. Recognising the ongoing need for employers to train their staff, the EMA offers more than 100 different training topics, delivered as seminars, conferences and courses up to Diploma level, and provided onsite at EMA or at employers’ own premises, or online. The Survey also showed that the majority of employers (70 per cent) are finding it “difficult” or “very difficult” to recruit for any position let alone

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skilled roles. This is an increase of 9 per cent compared with the same time a year ago. Mr Campbell says, “New labour laws are also causing concerns about taking on new staff, especially the proposed dropping of the 90-day trial for businesses with more than 20 staff. Retaining the 90-day trial for all sized businesses was number one on the employers’ wish-list.” Overall, reduced business confidence levels reflect other confidence surveys. In the 2018 Employers Survey conducted online in November, 14 per cent of respondents expect business conditions to improve in the next year, a decrease of 10 per cent on a year ago. Now 39 per cent expect conditions to worsen (compared to 28 per cent a year ago). But 47 per cent expect conditions to remain relatively steady in the year ahead, on a par with a year ago. The full survey findings include comments from employers and cover the following topics:

- Business outlook- Demand for skills- Impacts of technology on the workforceProductivityAgeing workforceEmploying youthImmigration- Workplace literacy and numeracy- Employment policies - Flexibility in the workplace- Collective employment agreementsPayroll audits- Minimum Wage - Involvement with WorkSafe New Zealand- The biggest issue facing employersEmployment change wish-list The 2018 Survey respondents (206) were mostly owner-operators with fewer than 50 staff, and were located in the EMA’s membership region from Taupo northwards. The main employment sector contributing to the survey was Manufacturing (28 per cent), followed by Wholesale Trade (8 per cent), Construction (7 per cent), then Retail Trade, Professional, Scientific and Technical Services and Health Care (each at 6 per cent).

YEAR IN REVIEW

It’s not just about being better. It’s about being different. You need to give people a reason to choose your business. -Tom Abbott

Year in Review Some of the many innovative New Zealand companies who are making a difference and are successful are profiled in this special look back on 2018. They are successful locally and some have spread their net through quality of product to develop overseas markets. Ed.

Rivers Carbon Technologies

Technologies, and a Innovation Project Grant.

If you think about Auckland and carbon fibre technology, scenes of the America’s Cup and the industries that surround it spring to mind. Ventilation tubes in dusty Australian coal mines are probably not your first mental image. Yet this less than glamorous gear represents the start of a promising new trade, thanks to the ingenuity of Graeme Rivers, founder of North Shore-based Rivers Carbon

Callaghan

All sorts have come out of Rivers Carbon’s Albany workshop – from the foils for elite America’s Cup yachts to replica chassis for E-Type Jaguars. But while money may be no object in these high-end industries, the wonders of carbon fibre are generally outside the budget of ordinary businesses. Until now. Rivers Carbon has come up with a lower cost way of making carbon fibre products for everyday sectors such as construction and mining. After months of researching cores, cloth

shaft safety. It’s investigating using the new carbon fibre in everything from prosthetic feet to dinghies to construction beams.

types, resins, hardeners and trihydrate mixes, Graeme Rivers developed a ‘cold cure’ method of setting carbon fibre, rather than pressurising and cooking it in an autoclave.

A Project Grant from Callaghan Innovation allowed the business to expand its focus and develop a manufacturing process for a cost-effective alternative fibre.

Rivers Carbon settled on ventilation tubing for underground mining as its first application for the new carbon fibre. Currently the fibreglass tubes used in the mines are heavy and tend to crack and break.

Lincoln Agritech Ltd A new device that detects processing losses in dairy plants could save the industry millions of dollars a year and help prevent pollutants from entering waterways.

Both factors create health and safety issues. In contrast, Rivers’ Premium High Carbon Fibre tubes are light, durable, and can be easily lifted above the shoulder making them far easier to install.

Lincoln University-owned research and development company, Lincoln Agritech Ltd, developed the breakthrough technology and it was then commercialised by Christchurch-based start-up company, CertusBio.

The company exported its first shipment of ventilation tubing to Australia in March and has been producing consistently ever since. Staff at BHP Billiton Illawarra Coal’s West Cliff mine in New South Wales say they’ve had no injuries to people or breakages since they started using carbon fibre tubing, and the company is now looking at other applications for the material.

It is vital to extract as much value from dairy processing as possible by using reliable, fully automated systems.

Rivers Carbon is already making wheel hub covers for the motors on giant mining trucks and man doors for mine

continued on Page 16 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

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Productivity

Robotics & Automation

Company Profile

3D Manufacturing

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Editorial Copy Deadline – 12 February 2019 Advertising – For bookings and further information contact: Doug Green, P O Box 1109, Hastings 4156, Hawke’s Bay Email: publisher@xtra.co.nz

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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.

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YEAR IN REVIEW

Being good in business is the most fascinating kind of art. Making money is art and working is art and good business is the best art. -Andy Warhol

collaboration project between the Hutt City Council, the E Tu Awakairangi Hutt Public Art Trust, the Seaview Business Association and local businesses.

The result is a robust, automated biosensor capable of continuous monitoring in commercial operating conditions. Known as Milk-Guard, the device uses a lactose-specific enzyme to measure the percentage of dairy products present in waste streams and processing lines.

Hammond says the company is currently working on local projects including the Paramount Theatre, Wellington’s historic Stewart Dawson Corner, construction of Alpha Apartments and the Comfort Hotel and re-strengthening of the earthquake-damaged Queensgate Shopping centre.

These percentages are automatically sent to a dairy plant process control room, where operators can monitor them and make changes to the production process if necessary. CertusBio CEO Dr Matthew Jones said that due to the vast quantity of dairy products processed in New Zealand, large amounts of valuable products could be lost quickly. “Given the significant economic return to New Zealand from the dairy industry, it is vital to extract as much value from dairy processing as possible by using reliable, fully automated systems to accurately and rapidly monitor losses in dairy processing waste streams. “Dairy plant operators will be able to improve the resource and energy efficiency of their plant processes by reducing losses of valuable dairy products and ultimately increasing company profitability.” Dr Jones said current loss-monitoring methods were reliant on retrospective testing collected over 24 hours. “Because this testing is done after the dairy products have been processed, it doesn’t allow for adjustments to be made while the plant is operating, so losses can’t be limited in real time.”

Hutt Park Warehouse

houses industry-leading automated machinery, and some of New Zealand’s largest building construction projects can be attributed to its name. Founded by Malcolm Hammond in 1982 as a factory and machinery maintenance firm, MJH Engineering quickly evolved into the construction industry and from one employee it has grown to over 100 today and now spans three sites and includes a 5,000sqm workshop. Fabricating for clients across New Zealand, on any given day the MJH team could be working on a range of structural steel works for industrial warehouses, commercial buildings, multi storey tower-blocks, steel art works, residential buildings and seismic strengthening projects. “Our experience and capacity ensures we can undertake multiple large-scale projects safely, smoothly, and on time,” says Managing Director, Malcolm Hammond. A heavyweight when it comes to industry accolades as well, MJH was a finalist in the Steel Construction New Zealand (SCNZ) Excellence in Steel awards for its involvement in Wellington’s Deloitte House (20 Customhouse Quay) and for the Rankine Brown Emergency Shoring for the Liftshaft.

A Milk-Guard device in action at a dairy processing plant, operated by Dr Matthew Jones (CEO, CertusBio).

MJH Engineering ‘Think big’ is entirely applicable to MJH Engineering. The steel fabrication company, based in Seaview, Lower Hutt

Sanpro Industries Ltd

The landmark construction of 20 Customhouse Quay – a 15-level seismically advanced office tower featuring a diagonally braced diagrid perimeter structure with base isolation, represents a new generation of safety and resilience and meets up to 180% of the building code, says Hammond.

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“The diagrid structure is stiffer than conventional tower frames,” he said, “But it also uses about twenty percent less steel than conventional building designs.”

The Petone company supplies the world and the Sanderson name has become the industry standard to all the big names in the exhaust system industry.

The complexity of the project brought the skill of the MJH team to the fore as they created unique, precisely angled parts for components of the diagrid structure.

Sanpro Industries Ltd Managing director and Founder Malcolm Sanderson loves getting up and coming to work each day, especially when there is a new engineering challenge to be solved.

Other notable projects the MJH team has been involved with include the iconic 32-meter-high Wellington Airport Control Tower, which leans into the prevailing northerly wind at a 12.5-degree angle and the award winning $100 million-dollar Manukau Institute of Technology Tertiary Centre and Transport Exchange.

We focus on quality and support not price.

MJH was also integral in the recent construction of Wellington’s largest sculpture, Lightwing, designed by Andrew Thomas, at the Seaview roundabout. The $250,000 sculpture stands 6m high, 10m wide and is made of 20 tonnes of steel, which was very carefully fabricated and installed by the MJH team. Lightwing was a result of a five-year

The key to their success is being able to change direction quickly to keep up with market changes: “We focus on quality and support not price; to stay ahead of the competition and build up repeat business.” Their main customers are the five major manufacturers who make and supply parts to 95 per cent of car companies in the world - from Mercedes and Porsche

Malcolm Sanderson hosting an American customer.

Working hard for something we don’t care about is called stressed; working hard for something we love is called passion. -Simon Sinek

to Skoda and Kia, they all have a bit of Petone in them. Starting in the late 70s making mufflers in his parent’s garage at his home, Malcolm dreamed of a better and faster way to make the exhaust baffles rather than use the conventional method of rolling and welding perforated sheet - sparking the idea for the Sanderson perforating louvering machine range. With their first machine built for a Malaysian client over 20 years ago still in operation today, they have now sold over 200 machines worldwide and export to more than 30 countries. These days their biggest emerging market is Mexico. Following the decrees of US President Donald Trump to take back ‘in house’ American car manufacturing, Mexico is now going it alone. Although the United States remains their strongest market. They have joined the crème-de-la-crème of Hutt Valley businesses in that Chamber’s Business Hall of Fame.

Sheep wool to make Kiwi surf boards revolutionary move A Tauranga based surfboard manufacturer is opting for sheep wool over glass fibre to make a New Zealand surfboard from start to finish. Paul Barron had the idea for his wool surfboards when he spilled resin on his woollen jersey.

“At first it didn’t work, but I spent two or three years perfecting it, and the rest is history.

YEAR IN REVIEW

The idea works because surfboards require fibre for tensile strength, and epoxy resin for hardness.

Stafford Engineering Ltd

they want to produce but don’t have the expertise or capability to build it themselves.

Mr Barron worked on the idea of wool over three years and he was determined to make a New Zealand surf board.

Waikato company, Stafford Engineering Ltd has designed a new machine to mass produce a natural skin care range made from fish skins to meet growing international demand for the product.

“That’s where we come in. For us a machine is a machine and in the case of Revolution Fibres, they had a very good idea of what they wanted.

But why use glass fibre for strength, when there is plenty of fibre growing on the backs of New Zealand’s 27 million sheep, thought Mr Barron. “I had a jersey on, spilled some resin on it, and suddenly, light bulb moment, try wool. “At first it didn’t work, but I spent two or three years perfecting it, and the rest is history. “I wanted to make a New Zealand surfboard from start to finish.” Firewire, which manufactures surfboards in San Diego, then took up the idea. Company boss, Mark Price said his company had long sought to reduce the environmental impact of its surfboards during manufacture. Performance characteristics are said to meet or exceed fibreglass.

For us a machine is a machine and in the case of Revolution Fibres, they had a very good idea of what they wanted.

Custom-built by the company, the electrospinning machine nicknamed “The Iguana” manufactures ActivLayr, a skin care product made by West Auckland nanofibre producer Revolution Fibres. With more than 9000 components, and at 7m long, it is one of the largest machines of its kind in the world. Revolution Fibres Operations Manager Brent Tucker says while the company has been producing nanofibre for almost a decade, the Iguana enables a greatly increased production capacity to meet demand for ActivLayr both locally and internationally. “The Iguana is a fantastic collaboration between the best Kiwi minds from the science and engineering worlds. It allows Revolution Fibres to increase production to meet demand, but it also means we can grow the production of ActivLayr in New Zealand.” Roger Evans, Stafford co-founder, says most of its clients know what

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“The design of the Iguana is a collaboration of Revolution Fibres’ knowledge and requirements, and our engineering expertise to ensure the equipment performs and functions the way it should and produces the best possible outcome.” The nanofibre manufacturing process starts with fishing company Sanford supplying hoki skins, from which pure collagen is extracted. Using the process of electrospinning in the Iguana, Revolution Fibres transforms the collagen into nanofibre. During the electrospinning process natural ingredients such as kiwifruit and grapes, and hyaluronic acid (an ingredient to help the skin retain moisture), are infused to create rolls of anti-aging ActivLayr. Nanofibres – measuring between 100-500 nanometres in width (a human hair is 50,000 nm wide) – can create vast changes in mechanical strength, reactivity, and, in the case of skin care, absorbancy.

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NZ Manufacturer December 2018

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 host of industries across Australia and New Zealand.

NZ Manufacturer December 2018

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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.

The ladder of success is best climbed by stepping on the rungs of opportunity. -Ayn Rand

NZ startup Sunfed bags $9.4 million to take plant-based meat global Auckland-based food startup Sunfed has raised NZD $10 million ($9.38 million) in Series A funding, to lead the charge towards a solar-powered planet. The funding round was led by Australia’s Blackbird Ventures, and also included the New Zealand Venture Investment Fund, Quadrant Private Equity founder Chris Hadley, and K1W1, the investment company run by New Zealand entrepreneur Stephen Tindall.

away from meat consumption, Lee says, and Sunfed is intended to provide a real choice for meat eaters.

But the transition from software to hardware was “humbling, to say the least”, Lee says.

“We understand that meat tastes delicious,” she says, “so it’s a very difficult problem to solve.”

A former software engineer, Sunfed founder Shama Sukul Lee turned her hand to the meat-free foods market in 2015.

“Electric cars were around for a long time, but they were terrible,” she says.

“You don’t need as much capital upfront if you’re not building hardware. You can code all night, you just need a laptop and some coffee, you can hire someone in a different country, you don’t have to worry about geographical barriers, and you have a plug-and-play infrastructure,” she says.

Over the past three years, the startup has secured a small amount of funding to complete research and development, building its own hardware to replicate the look, feel and texture of meat, using only “clean” plant products. It also bagged NZD $1.5 million ($1.41 million) in funding from UK and US investors to commercialise the product in New Zealand.

Lee compares meat alternatives to electric vehicles.

Tesla, however, creates an electric vehicle that is “better than your status-quo car”, allowing the customer to feel empowered to choose an environmentally-friendly option without compromising on experience. “If the choice is good, the consumer will respond,” Lee says. The raise was led by Blackbird Ventures, and while Lee is happy to have Australian investors on board, she says the VC was a good fit.

This latest funding will fuel the next stage of growth, including expanding overseas, including into Australia.

Lee was looking for an investor that was aligned with her vision, she says. And that vision is global.

“The overarching purpose of Sunfed is to accelerate humanity to being fully solar powered,” Lee tells StartupSmart.

“We want VCs that are aligned with this — that aren’t looking for a quick exit,” Lee says.

“The whole planet is essentially solar powered”, she points out.

“We want to make sure the company can grow and be sustainable.”

“In any energy system, the closer you get to the source of energy, the more efficient the chain gets, and so if we move closer to plants and skip the animal … then everything becomes inherently efficient and sustainable,” she adds.

The funding will allow for upscaling of the infrastructure and engineering piece, while also funding more R&D for the creation of new products.

Food is just another form of energy, Lee says, and meat has become “one of the most unsustainable forms of food energy on the planet”.

With a background in software engineering, Lee was initially faced with the challenge of using hardware to try to perfect the product’s texture.

At the same time, meat alternative products such as tofu don’t cut the mustard as a viable option for dedicated meat eaters.

“Nothing existed that could do it out of the box. We wanted to make sure we could control every single touchpoint, so we ended up building our own machines.”

There’s a trend of consumers moving

Sunfed is also hiring in its New Zealand locations, and for its new Australian business, Lee says.

When you’re building physical technology, you need capital from the get-go, she says. “We tried to bring all those principles of software — very fast, agile innovation — and applied it to hardware,” she says. When Lee and her team first started to work on Sunfed, “we didn’t know it was going to work”, she says. Her advice to other founders is simply to “jump in and don’t give up”, she says. In nature, all forms of life are able to adapt, she adds. “No matter what gets thrown at you, you can adapt, you can pivot — have confidence in that,” she urges. If you over-plan, Lee says, you may miss out on alternative possibilities you haven’t thought of, but that may well be better. “You may not know the answers, but just jump in, start getting the real-time data, and just respond to that,” she says.

Robot for airworthiness inspections

Invert Robotics’ remote-controlled climbing robots provide significant efficiency improvements for airlines and the aircraft maintenance repair and overhaul (MRO) sector. A patented suction mechanism enables the robots to adhere to and traverse aircraft surfaces, even when they are wet or upside down. A high-resolution inspection camera records and transmits video images to a ground-based screen for analysis by line-maintenance staff – enabling efficient visual inspections (GVI and DVI) following lightning or bird strike, for example. Rapid set-up and inspection can reduce schedule delays from more than five hours to less than one hour. The health and safety risks of staff working at height are also eliminated. Pre-maintenance robotic inspections on the tarmac or in the hangar can provide detailed repair assessments and a record of ‘current state’ for future comparison. Many labour-intensive MRO processes can now be automated with the addition of ultra-sound and thermographic technology to the robots. This frees up skilled aircraft engineers to do more complex tasks, reducing the time and cost of aircraft maintenance.

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NZ Manufacturer December 2018

Attack is the secret of defense; defense is the planning of an attack.- Sun Tzu, The Art of War

Aider releases AI powered digital assistant Small businesses now have a powerful, new intuitive tool at their fingertips to help drive success - and the bottom line. Aider, an artificial intelligence (AI)

Brendan Roberts, Aider’s co-founder,

powered digital business assistant

says the app is now ready for the

created specifically for small business,

Australasian markets.

has been in beta phase in Australasia

“We believe that AI is in the process of

for several months.

changing how the world of commerce

operates and we want to make this technology readily available to small business,” Roberts says. Making AI simple and easy to understand was critical in creating the app. Intuitive user interfaces and ready-made guides and questions ensures that Aider, is simple to use but also saves time, offers real-time insights and performs tasks for the business owner.

from one place, Aider uses business relevant data to immediately deliver info that is as broad, or as specific, as the user wants.

Utilising conversational platform and natural language processing, a user can simply ask Aider about sales, bills, inventory, or practically anything that makes running a business easier.

“Aider is unique in the way it brings all the essential information together in an easily understood format, all beginning with a simple conversation,” says Pete Weaver, Aider’s co-founder. “Traditionally, AI has been inaccessible except to large businesses. Aider changes that - in turn giving small businesses an edge to be even more successful, however they define that.”

With its expanding ecosystem of diverse business app partners, conveniently accessed

Founded in Auckland, New Zealand, Aider has customers in Australasia, with plans to expand to new countries in 2019.

New application to help work smarter The Asset Management Application from ABB is a digital solution that enables process industries to manage and protect their assets through predictive and preventative maintenance to avoid costly failures. Cost effective management becomes a reality through the optimisation of workflows and in-depth analysis of results, offering efficient asset management strategies that enable smarter, more informed decisions. The application offers industrial plants real-time condition monitoring of equipment, connected devices operation and maintenance of the installed base. ABB enables predictive and preventative maintenance by diagnosing asset conditions and predicting looming equipment problems on premise and, for the first time, at an enterprise’s global level. Moreover, the application enables the usage of advanced analytical methods such as machine learning and artificial intelligence to analyse equipment problems and optimise the performance.

important feature. It brings added benefits of wider collaboration across teams, management and operations. ABB Ability Edge ensures a secure connection between assets and the cloud, efficiently separating IT and OT. Edge technology can also act as a platform for applications to give customers the option to operate solely on premise rather than in the cloud.

NZ Manufacturer December 2018 //

The application is available for basic instrumentation equipment across all processing and manufacturing

By providing a precise cause of any equipment problems, the application also enables speedy identification and recovery, further reducing costs. The Asset Management Application will be launched in the second half of 2019. It sits within ABB Ability, ABB’s digital offering, which includes more than 210 Industrial Internet solutions and an Industrial Internet technology platform and cloud infrastructure. Drawing on insights across 20 plus industries and more than 40 years of experience in digital technology, ABB Ability helps customers develop new processes and advance existing processes by providing insights and by optimising planning and controlling for real-time operations. The results can flow into control systems such as ABB Ability System 800xA and ABB Ability Symphony Plus to improve key performance metrics of plants and assets.

As geographically dispersed production sites constantly grow, global connectivity, helped by advanced cloud technologies, is an

In the case of a problem, users can make informed and quick decisions, based on clear recommendations. Actions range from immediate attention to scheduling maintenance in the near future and the identification of issues that can be resolved during its routine maintenance of equipment.

industries, for detailed assets such as motor transformers or circuit breakers and complex electrical or rotating equipment, and mechanical handling equipment such as conveyor belts.

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ROBOTICS

Challenges are what make life interesting and overcoming them is what makes life meaningful. -Joshua J. Marine

AI and robots could create as many jobs as they displace Automation is nothing new – machines have been replacing human workers at a gradual rate ever since the Industrial Revolution. This happened first in agriculture and skilled crafts like hand weaving, then in mass manufacturing and, in more recent decades, in many clerical tasks. As the extra income generated by these technological advances has been recycled into the economy, new demand for human labour has been generated and there have, generally, still been plenty of jobs to go round. But a new generation of smart machines, fuelled by rapid advances in artificial intelligence (AI) and robotics, could potentially replace a large proportion of existing human jobs. While some new jobs would be created as in the past, the concern is there may not be enough of these to go round, particularly as the cost of smart machines falls over time and their capabilities increase. There is an element of truth in this argument, and research suggests that up to 30% of existing jobs across the OECD could be at potential risk of automation by the mid-2030s.

But this is not the whole truth for two main reasons, which we explore in detail in recent research published for the UK and a new report on China which will launch at the World Economic Forum’s meeting in Tianjin in September 2018. Firstly, just because a job has the technical potential to be automated does not mean this will definitely happen. There is a variety of economic, political, regulatory and organisational factors that could block or at least significantly delay automation. Around 20% of existing UK jobs may actually be displaced by AI and related technologies over the 20 years to 2037, rising to around 26% in China owing to the higher potential for automation there particularly in manufacturing and agriculture. AI and related technologies will also boost economic growth and so create many additional job opportunities, just as other past waves of technological innovation have done from steam engines to computers. In particular, AI systems and robots will boost productivity, reduce costs

and improve the quality and range of products that companies can produce. Successful firms will boost profits as a result, much of which will be reinvested either in those companies or in other businesses by shareholders receiving dividends and realising capital gains. To stay competitive, firms will ultimately have to pass most of these benefits on to consumers in the form of lower (quality-adjusted) prices, which will have the effect of increasing real income levels. This means that households can buy more with their money and, as a result, firms will need to hire additional workers to respond to the extra demand. We refer to this as the income effect, which offsets the displacement effect on jobs. Research put some numbers on these job displacement and income effects for the UK, which from past research is fairly typical of OECD economies as a whole; and China, the largest of the emerging economies. For the UK, the estimated net impact on jobs is broadly neutral, with around 7 million jobs (20%) projected to be displaced in our central scenario but a similar number of new jobs being created.

How AI can both destroy and create jobs through the displacement and income effects (this is a simplified analysis – in practice there will be a more complex range of economic effects at work as captured in our detailed modelling) Image: PwC

More detailed analysis suggests significant net job gains in sectors like healthcare, where demand will rise due to an ageing population but where there are also limits to the scope for automation because of the continued need for a human touch. Significant job displacement in areas like manufacturing and, as driverless vehicles roll out across the economy, transport and logistics will offset these

gains. For China, there is an estimated negative net impact on agricultural employment, continuing a long-standing trend, more than offset by large increases in construction and services. As for the UK, healthcare will be one area with considerable potential for net job gains given China’s rapidly ageing population. One result that might seem surprising is that the impact on jobs in China’s industrial sector is estimated to be broadly neutral. This reflects the fact that while there will be considerable scope for further automation in Chinese manufacturing as wages there rise, China will take the lead in manufacturing the AI-enhanced products (robots, driverless vehicles, drones etc) that will come out of this Fourth Industrial Revolution. More generally, the huge boost to the Chinese economy from AI and related technologies, which we estimate could be more than 20% of GDP by 2030, will raise real incomes across the economy. This will create new demand for goods and services that will require additional human workers to produce, particularly in areas that are harder to automate. No room for complacency – the challenge for government and business While fears of mass technological unemployment are probably unfounded, this is not a recipe for complacency. As with past industrial revolutions, this latest one will bring considerable disruption to both labour markets and existing business models.

Estimated displacement, income effect and net effect of AI and related technologies on jobs in China and the UK over the next 20 years

Estimated net effect of AI on jobs by industry sector in China (millions and %)

Image: PwC

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NZ Manufacturer December 2018

ROBOTICS

I’m convinced that about half of what separates the successful entrepreneurs from the non-successful ones is pure perseverance. - Steve Jobs

In China, we could see around 200 million existing jobs displaced over the next two decades, which will require workers to move to industry sectors and places where new jobs will be created.

required to meet the demand for additional workers.

Of course, China has seen even larger movements of workers from the farms to the cities since the early 1980s, but the process will not be easy.

• The latter will require increased investment in retraining workers for new careers, boosting their digital skills but also reframing the education system to focus on human skills that are less easy to automate:

Given China’s ageing population, an increase in immigration may be

• Both government and business have a role in maximising the benefits from AI and related technologies while minimizing the costs.

creativity, co-operation, personal communication, and managerial and entrepreneurial skills. • Businesses too have a role to play in encouraging a culture of lifelong learning amongst their workers.

who find it difficult to adjust to the new technologies. Such measures will be important if the huge potential benefits of AI and related technologies are to spread as widely as possible across society.

For government, AI will boost economic growth and, therefore, tax revenues. This should enable social safety nets, including state health and social care systems, to be strengthened for those

‘Living labs’ show how autonomous robots are changing cities Rachel Macrorie Research Associate in Urban Automation and Robotics, University of Sheffield Ready or not, autonomous robots are leaving laboratories to be tested in real-world contexts. With more and more people living in cities, these technologies offer ways to cope with ageing populations and poorly maintained infrastructures, while promoting safer transport, productive manufacturing and secure energy supplies. Urban “living labs” are one way scientists are trying to understand how autonomous robots – or Robotics and Autonomous Systems (RAS), to give them their full title – will affect our everyday lives. Autonomous robots are interconnected, interactive, cognitive and physical tools, which can perceive their environments, reason about events, make or revise plans and control their own actions. These technologies are designed to draw on big data and connect with the Internet of Things, to make our lives easier by increasing accuracy and efficiency. But the everyday dynamics of cities are complex, which makes them far less predictable than the usual test zones. City leaders recognise that real world experimentation can support innovation, as well as attracting international investment. As a result, cities around the world are competing to become urban test beds. But as a new white paper by researchers from Sheffield University’s Urban Institute sets out, there are some big challenges when it comes to promoting RAS technologies and ensuring meaningful trials in cities.

Last mile logistics Logistics companies are under pressure to meet growing customer expectations for quick delivery, while battling against traffic congestion.

Companies aim to fill this gap with last mile delivery robots. Alibaba recently announced that their bot, the G Plus, will go from being road-tested at their headquarters in Hangzhou, eastern China, to commercial operations by the end of 2018. In this trial, consumers download an app, place a grocery order and pinpoint where they want their goods to be delivered. Purchased items are placed into the driverless bot, which can carry several packages of different sizes. The robot has a built-in navigation system that relies on LIDAR – a technology that bounces light off nearby surfaces to create a 360-degree 3D map of the world around it. It drives autonomously, at speeds of up to 9.3 miles per hour, to the delivery location, where the customer enters a PIN code to retrieve their shopping. Similar tests are taking place in Milton Keynes, in the UK, and the US city of San Francisco. But these trials have not been without error – some delivery bots have experienced navigation issues, such as getting stuck or crashing into obstacles including people, not to mention resistance from citizens and activists interested in protecting public space and pedestrian safety.

Self-repairing cities Buried under city streets are millions of kilometres of pipe and cable networks that provide essential water, drainage and energy services. There is mounting pressure on cities and utility companies to maintain these ageing invisible infrastructures, while dealing with the challenges of growing urban populations, ecological turbulence and citizens’ expectations. Autonomous robots can detect defects

NZ Manufacturer December 2018 /

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in infrastructure – such as cracks in the asphalt – and identify and eliminate their triggers, whether it’s a leaking pipe or physical overloading. For example,

According to his developers, “Pepper has been designed to identify your emotions and to select the behaviour best suited to the situation”.

The University of Leeds, together with local councils and industry partners, are running a project on self-repairing cities to test a range of autonomous robotic technologies.

Programmed to meet the individual care needs of patients, social robots such as Pepper are now being trialled as personal companions, to augment the role of human carers.

There are drones that can perform remote maintenance of street lights; swarms of flying vehicles for autonomous inspection and repair of potholes on motorways; and hybrid robots designed to inspect, repair, meter and report the condition of utility pipes.

In 2017, care homes in Southend, Essex adopted the companion robot to interact with the elderly, raising fears that they could replace staff. Yet it’s forecast that the UK will need up to 700,000 more care workers by 2030.

These robots can go where human access is impossible (inside pipes) or undesirable (at height in the streetscape) and work systematically over long periods (during overnight closures). Such technologies could greatly extend the life of vital city infrastructures, reduce maintenance expenditure and lead to massive savings. But questions remain about how city areas and residential populations are selected to benefit from these upgrades. Authorities will need to ensure that it’s not just the affluent and well-connected areas of cities that benefit from RAS trials.

Robots that care Humanoid robots are touted as the solution to urban policing, customer service and social care challenges. Pepper – a white humanoid robot standing just over a metre tall – has already taken up employment meeting, greeting and advising customers in over 140 SoftBank mobile phone shops in Japan, and Nestle is planning on installing Pepper in 1,000 sales outlets.

Robots may help alleviate this pressure on care homes and hospitals, by allowing people to live independently in their own homes for longer, providing entertainment via memory games, and enabling better connection with loved ones through smart appliances. But while robots may be able to facilitate patient monitoring and help with physical tasks, arguably there can be no replacement for human emotional connection and sensitivities. No longer simply fantasy or limited to niche applications, autonomous robots are slowly becoming a part of our everyday lives. While developers strive for RAS technologies to be neutral in design and to work seamlessly with the city and its citizens, there will always be challenges associated with this aspiration. That’s why urban “living labs” are crucial in demonstrating the opportunities and limits of autonomous robots, and ensuring that policies and standards are put in place to protect human rights, and guard against widening social inequalities.

We are really competing against ourselves, we have no control over how other people perform. - Pete Cashmore, founder and CEO Mashable

EXPORT NEWS

Free trade with Korea a boon for Kiwi exporters - Jack Stenhouse, NZTE Trade Commissioner for South Korea.

The eleventh largest economy in the world, the Republic of Korea, is home to some technology and manufacturing giants – names we all recognise, like Samsung, Hyundai, LG and Daewoo. Korea’s economic success is founded on access to world markets, and that’s great news for New Zealand exporters. While it’s still early days, the Korea-New Zealand Free Trade Agreement signed in 2015 looks to be delivering on its promise to boost business and strengthen ties between our two countries. This relationship has been reinforced by President Moon Jae-In’s visit to New Zealand this week. J-Nomics and the rise of consumer spending Korea is our fifth largest goods export market, and two-way trade recently surpassed NZ$4 billion in value. Since the New Zealand-Korea Free Trade Agreement (FTA) came into force three years ago, two-thirds of our exports now enter Korea duty free, a figure that will eventually reach 98 percent. This softening of Korea’s traditionally protective trade policies translates to further opportunities for Kiwi exporters, and Korea’s focus on lifting wages and creating jobs brings more good news. President Moon Jae-In’s economic reforms, dubbed ‘J-Nomics’ aim to raise wages among lower and middle income earners, and increase domestic consumer spending. This, combined with a solid growth outlook, means Korea remains a reliable market for New Zealand businesses. While forestry products account for a decent amount of our exports to Korea

(to the tune of almost NZ$500 million), it’s an even more attractive and significant market for our food and beverage exporters, where the FTA has seen trade in the F&B sector increase by 35 percent to top NZ$700 million. We’re winning because Korean consumers value our reputation for safe, reliable and premium products, but there’s definitely room for ongoing marketing investment to increase consumer awareness in this area. Rewarding commitment Korea is a market that reacts well to commitment from an account management, promotion and branding perspective. This is evidenced by the stunning success of our avocado exporters who started to invest in the then tiny Korean market roughly six years ago. Through significant marketing and promotions investment, they educated Korean consumers about the avocado’s health benefits and culinary options, and rode a large and fast-moving wave to build a substantial market. Korea is now our second largest export market by value for avocados, surpassing more well-established markets like Japan. Health products and niche technology The east-Asian culture of preventative

medicine also provides strong openings for New Zealand companies, with products such as deer velvet, green-lipped mussels and manuka honey prized for their ability to ward off age-related illness. With one of the fastest ageing populations in the world, Korea has a large market for high-value, premium functional health food products. Koreans will gladly spend up large on these products for their parents or grandparents. But it’s not just F&B exporters seeing returns in Korea. There are also opportunities in the specialised manufacturing and technology sectors. While it’s difficult for Kiwi businesses to scale to meet demand from large Korean corporates, where we can succeed is with more niche offerings. For example, Hamilton Jet supplies jet propulsions to the Korean Coastguard; and Skyline Luge International has been wildly successful, with its luge operations in the town of Tongyeong clocking up 2.7 million rides since it opened in early 2017. Preparedness So what market-entry challenges might exporters encounter? Depending on your product, Korea can have a reasonably complex regulatory system and there are a number of non-tariff barriers, so it’s vital to do your homework so you know the landscape

before taking the leap into this market. As a strongly relationship-based business society, the emphasis is on building and maintaining relationships. These connections are often more important than the details of the contract, so you’ll need to make regular visits to the market, or at the very least conduct video calls with customers. Kiwi businesses can come unstuck due to the differences in communication styles. Fail to respond quickly enough to an email inquiry and you may find your customers or channel partners have moved on and the opportunity is lost. There are also boom-and-bust risks. Trends in areas such as health food or cosmetics come and go quickly in Korea. This can create unrealistic expectations for New Zealand companies around the long-term viability of the market. Kiwi companies have been known to invest in manufacturing facilities only to see the market fall out from under them. The lesson: don’t over-leverage yourself until you’ve tested the stability of the market. Likewise, be wary of working with just one of the small number of major retailers too early in the piece. If your product is removed from the shelf and that trade disappears, you could be left high and dry, so create a strong foundation in the market and understand the market dynamic before committing to a single large account. That said, forecasters are predicting another year of solid economic growth in Korea. This should continue to foster the conditions that have maintained a steady flow of New Zealand exports to Korea in recent years. With many traditional trade barriers now removed, it’s a great time to consider this market.

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NZ Manufacturer December 2018

NEW PRODUCTS

A business has to be involving, it has to be fun, and it has to exercise your creative instincts. - Richard Branson

Home battery factory opens in Australia German energy storage company Sonnen has begun production of home battery storage systems at its new factory in Adelaide. The German manufacturer aims to produce more than 50,000 storage systems over the next five years at the former GM Holden factory in the northern suburbs of the South Australian capital. An A$100 million South Australian government scheme to subsidise solar energy in homes was pivotal to securing investment from Sonnen, which moved its headquarters from Sydney to Adelaide this year. The Home Battery Scheme gives 40,000 South Australian households access to up to $6000 of subsidies and low-interest loans to pay for the installation of home batteries and solar. South Australia Premier Steven Marshall said the battery manufacturing facility will see the revival of the former automobile factory as a national centre

for solar energy technology. “Having Sonnen locate its manufacturing centre in Adelaide for the production of home batteries for Australia, Asia and the South Pacific is a significant step in the revitalisation of South Australia’s industrial base,” said Premier Marshall. “The assembly and manufacture of 50,000 energy storage systems in Adelaide over the next five years will create around 430 manufacturing and installation jobs in the state and locates South Australia at the centre of this developing industry.” Sonnen founder and CEO Christoph Ostermann said the company would manufacture more than 10, 000 batteries a year to meet the demand from Australian households for home battery storage systems.

“We are excited at the prospect of

“Sonnen will bring great benefits to

manufacturing in South Australia for

South Australia through jobs at its

the Australian and export markets and

Australian head office and factory

to participating in making Australia

in Elizabeth, lower energy prices for

the number one market globally

households that take up the battery

for energy storage system,” said

program, and increase retail energy

Ostermann.

competition.”

Heavy tonnage cylinders meet harshest maintenance challenges Enerpac high-tonnage cylinders are engineered to meet demand for heavy lifts in some of the harshest land and maritime environments of Australasia, including remote sites encountered in the Christmas-New Year maintenance season. Summit Edition HTC models – in standard capacities from 50-1000 tons – are designed to provide optimum reliability, durability, cost-efficiency and safety for industries and far-flung projects that cannot afford downtime as operations staff work to complete projects frames.

within

demanding

time

They are particularly suited to industries including mining and energy, onshore and offshore oil and gas, construction and infrastructure, bridges and pipeline plant, heavy manufacturing, materials handling, process engineering and maintenance across diverse industries. Backed by Enerpac’s extensive service

and technical engineering network throughout New Zealand, they offer outstanding durability, longer service life, and greater side-load resistance for increased heavy lift capability and safety margins. Advanced bearing and sealing technology provides side load resistance up to 10 per cent.

New HTC engineering incorporated into the cylinders includes advanced bearing and sealing technology to extend the boundaries for eccentric loads, while reducing cylinder maintenance intervals. The effects of corrosion and scoring are no longer a concern with the Summit ranges because of the cylinders’ black nitrocarburisation surface treatment for improved load and wear resistance, plus corrosion protection. The Summit HTC range is complemented by Enerpac’s latest CUSP-Series and CULP-Series high-tonnage ultra-flat cylinders. The CUSP-Series - featuring an integrated tilting function with 10 to 1,000-ton capacity, 7-17mm stroke and maximum operating pressure of 700 bar – is designed for harsh conditions which require low clearance, especially for industrial maintenance and construction applications. The complementary CULP-Series has an integrated stop ring with 10 to 50-ton capacity, 6mm stroke and maximum operating pressure of 700 bar.

Summit Edition cylinders are also highly compatible with Enerpac’s PLC-controlled synchronous lifting systems, which simultaneously control multiple cylinders used to precisely lift, shift, balance and position structures sometimes weighting many thousands of tons.

NZ Manufacturer December 2018 /

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In addition to the standard range of lifting capacities, individual HTC cylinders can be custom-manufactured to capacities exceeding 1000 tons.

NEW PRODUCTS

If you think your boss is stupid, remember: you wouldnâ&#x20AC;&#x2122;t have a job if he was any smarter. - John Gottman

Energising heat for smart appliances Materials that harvest heat and turn it into electricity could lead to more cost-effective devices. Scientists are getting closer to designing thermoelectric materials that efficiently harvest heat from the surrounding environment and convert it into electricity to power various devices and appliances, according to a review of the latest research in the journal Science and Technology of Advanced Materials. Devices made with these materials could avoid the need to recharge, change and dispose of batteries.

Inorganic thermoelectric materials efficiently convert heat into electricity, but are not very flexible. Researchers are working to overcome this hurdle. For example, a flexible thermoelectric device was fabricated using chromel (90% nickel and 10% chromium) and constantan (55% copper and 45% nickel) layers covered by a flexible sheet made of polyimide and copper.

For thermoelectric materials to be efficient energy producers, they need to be able to hold heat and conduct electricity well. Thermoelectric materials that can work near room temperature and are flexible would be especially advantageous, particularly for use in wearable devices.

Micro-thermoelectric generators based on inorganic materials have potential applications in environmental and building monitoring, animal tracking, security and surveillance, and medical treatment. They have already been introduced into commercial devices, such as a body-heat-powered watch manufactured by Seiko.

Three types of conducting materials are being investigated for use in thermoelectric devices: inorganic, organic and hybrid materials.

Most organic thermoelectric devices involve polymers. Semiconducting polymers conduct electricity and hold heat better than conventional

inorganic semiconductors. They are also lighter and less expensive. Unlike rigid inorganic materials, they are flexible and mouldable and can be produced in any shape using 3D printers. However, they are less efficient at converting heat into electricity. Researchers are trying to improve the thermoelectric efficiency of polymers by tuning the composition, length and arrangement of their molecules, aiming to increase the electrical conductivity and crystallinity of the final material.

improving the mixing process. For example, embedding organic molecules into inorganic titanium disulphide crystals makes them flexible and reduces their thermal conductivity. This improves the overall thermoelectric performance. Thermoelectric devices can potentially replace traditional batteries in many applications, but a lot of work on improving thermoelectric materials is required for achieving success in this direction.

Research that aims to combine the advantages of organic and inorganic materials by blending them together is focused on finding optimal A flexible thermoelectric device embedded in a glove for generating compositions and electricity by body heat. (Credit: Dr Song Yun Cho, Korea Research Institute of Chemical Technology)

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NZ Manufacturer December 2018

FOOD MANUFACTURING Enormous amounts of The volume of edible food that is wasted is staggering. In 2017, the UN estimated that almost a third of all food that is produced is discarded. Edible food makes up approximately 1.3 gigatonnes of this (one gigatonne is a billion tonnes).

Formula for success: rise early, work hard, strike oil. -J. Paul Getty

food wasted during manufacturing

lose this food than it is to stop the production for a few minutes. So what is technically inefficient may also be a food and labour efficiency.

new product before it is actually nut free. New product development also creates a lot of potential food waste because

Machinery is needed to move and in some cases repackage the food so that contents match labelling. When volumes are particularly large, spaces are needed to store and break down pallets into amounts that a community cafe, food pantry, or childrenâ&#x20AC;&#x2122;s holiday or breakfast club can store and use while the food is still good.

For comparison, one tonne of wasted food is about the equivalent of 127 large plastic bin bags. This not only represents a phenomenal loss in terms of food that could feed people, but also a loss in resources such as water, labour power, soil nutrients, transportation energy and so forth. Recent analysis shows that about one third of the edible food that is wasted globally comes before the farm gate and about one fifth comes from peopleâ&#x20AC;&#x2122;s plates and refrigerators. This means that just under half of all edible food that becomes waste does so during manufacturing, distribution and retail. Food manufacturers tolerate about 5% waste within their food processes under normal production. And in the UK alone, there are more than 8,000 food producers operating at 9,500 production sites.

A pasta manufacturing plant.

Food manufacturing waste One main reason food is wasted within the manufacturing process is due to what some researchers refer to as inefficiencies. But we need to consider where these inefficiencies lie, and if they are avoidable.

Surplus food distribution has a number of other challenges not faced in a commercial system. A food manufacturer can throw money at a problem if there is a financial benefit.

Part of a complex system.

In addition, there is always food loss associated with machinery start-up. Volumes described on the label are calibrated based on normal speed of production, and it takes a few minutes for the machinery to meet this speed. As a result, the first few pallets of packaged food are also not able to be sold because the volume in each package is less than the calibrated standard. This is why stopping the production line when faults occur is actually more wasteful: restarting produces more unsellable edible food than redirection does. And if, for example, a manufacturer produces something associated with a food allergy, like breakfast cereal with nuts, and they want to switch the line to produce a cereal without nuts, the production line must be run for a significant time with the

For example, on an assembly line producing ready meals, there may be several machines operating to produce different parts of the meal. If something happens to one of the machines, rather than stop the whole system while the machine is reset, the food keeps coming but is redirected into waste. It is more efficient both in terms of both money and food resources to

between a whole range of people and organisations. Surplus food, for example, cannot be accepted by a food redistributor if there are not enough people in the warehouse to unload the food from the delivery truck.

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the production processes must be calibrated and training carried out to ensure that when high volumes are produced the taste and quality matches

But those operating in the surplus system are generally reliant on unpredictable resources and face problems that do not necessarily have a financial return on the investment. They often also rely on volunteers to fill their labour needs. Food arriving in the surplus system from food manufacturers is very unpredictable both in terms of type and quantity.

Food redistributors must therefore Contents must accurately match the packaging. work out how best to redistribute the food under time pressure. what was developed at a smaller scale in the testing kitchen. Machinery must This is not to say the problem is also be run for some time to ensure impossible. Those engaged with volumes are correct, packaging is moving surplus along for social good rather than financial gain are working printing properly and so forth. out new ways to use technology to Dealing with surplus food communicate food availability. Due to increasing public concern about the scale of this waste, surplus redistribution is becoming more common. But it is a comparatively new activity and so still somewhat experimental. There are many issues to work out. It is true that new tax policy, regulation and industry standards might encourage food manufacturers to help feed people with this surplus food, rather than waste it or send to anaerobic digestion. Despite this, focusing on regulations and policies is not enough to ensure that this food can reach mouths. This is because movement of surplus requires a lot of coordination

The food production process is full of competing inefficiencies. Marxstudio/Shutterstock.com

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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SUPPLY CHAIN

Success seems to be connected to action. Successful people keep moving. They make mistakes, but they don’t quit. - Conrad Hilton

Why the circular economy must link up the whole supply chain The long-discussed concept of the circular economy (CE) seems ready for takeoff. New information technologies like the internet of things (IoT), big data analytics or blockchain are the powerful means everybody is waiting for. The real door-opener is still to be found in the analog world: It’s about trustful collaboration. But only when all actors along the product life cycle find profitable ways to take resource scarcity into account, and only if they share both costs and benefits, will CE be able to unfold its full potential. So trustful collaboration is asking for a lot. It needs to convince decision-makers of the business opportunities they get once they trade their silo-oriented optimization rationale for a holistic-management approach that addresses the entire life cycle of the products and the materials involved. Making use of circular economy to prosper and differentiate products and services is suitable for business-to-business heavyweights, too. For example, ocean carrier Maersk created a digital twin of their latest container ships down to the smallest bolt. Through this, the company will ultimately know how much and what material is being used in their fleet. During routine overhauls or at the final disassembly, Maersk has a clear systemic view on which parts and materials can be reused, remanufactured, upcycled or continue to stay in the circular flow of shipbuilding.

Executing supply chain power It’s not by chance that most CE case studies are when economically strong asset owners and service providers such as Caterpillar and Maersk are in the driving seat. The same applies to powerful vendors, for instance tech

giants such as HP and Dell who have established highly efficient return systems for used products. Why is it that CE pioneers are often found among these kind of companies? The two most obvious reasons: on one hand, these players have understood the value of the materials involved to such an extent that they decided to take on responsibility for them. On the other, they have the business acumen to guide and influence the use phase of a product. Albeit, all of these cases studies are rather short value chains. CE examples covering entire chains are still yet to be found, which is no surprise at all – implementing comprehensive cradle-to-cradle scenarios is one of the biggest challenges facing supply chain managers. The degree of difficulty can be seen in the chemicals industry. Here a lot of companies have already gained deep expertise in extending the reach of sustainability management to the production level; for example, the “Production Verbund” of BASF, a role model for efficient and inter-connected material and energy flow in chemical production. However, compared to big asset owners, service providers or responsible vendors, the power of the process industry to convince value chain partners to participate joint CE strategies is much more limited. Chemical companies work upstream as a tier-one value creator after the extractive industries. Since most partners are downstream, laying out a CE scenario is like pushing a rope. However, both downstream and upstream, the headwind in favour of CE is blowing strong. Still, most companies optimise their operations and products within their own narrow

sphere of influence. Even the current most progressive perspectives towards sustainability are not yet broad enough.

Operating within the planet’s limits So what does this all mean with regards to CE? First of all, every constituent of a specific value chain needs to understand that the chain as a whole will lose, once an indispensable resource is gone. This can be in its own production, or in someone else´s. Thus the chain, too, must take into account the planetary limitations. Like each and every one of its constituents, the supply chain needs to operate within economic, environmental and social thresholds. Supply chain managers have to develop metrics that take the sustainability context into account, as well as building relationships with players across the entire chain. The concept only works if supply chain partners build up mutual trust in the sustainability information each partner is giving. Therefore, CE requires transparency about associated materials and financial flows of the product and its components during their entire life cycles. A bold example of this thinking was the environmental profit and loss analysis Puma published already in 2011.

The required transparency can easily be provided by the newest information technology of connected devices, big data analysis, cloud computing, or distributed ledger technology (aka blockchain). Coupled with IoT tracking and AI-enabled global data matching models, these are necessary ingredients to bridge the physical gap along individual processes in supply chains during a product’s use phase and at end-of-life.

Connecting the dots to the whole value chain The crucial IT foundation is in place. Most companies run modern enterprise resource-planning systems to synchronize material and financial flows. This enables and supports decision-making and optimisation within an individual organisation. The information is available, but the dots need still to be connected. Supply chain managers need to extend the focus of data analysis to the whole value chain. Only then they will get the right information to help both themselves and their supply chain partners harvesting the multiple benefits of a CE. The business cases of a circular life cycle are dependent on finite resources and must consider all value creation from the production, use, end-of-use to the recycling phase.

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DEVELOPMENTS

Don’t blow off another’s candle for it won’t make yours shine brighter. - Jaachynma N.E. Agu, The Prince and the Pauper

The little startup that could: Celebrating 15 years of Velocity Velocity - the University’s student-led entrepreneurial development programme – is celebrating its 15th birthday and the successes it seeded. Velocity (formerly Spark) was born of a big idea: to transform New Zealand into a growing and prosperous nation by reshaping its economy. ‘Godfather of Velocity,’ Geoff Whitcher, helped drive its creation. “Velocity was a recognition that creating a knowledge-based economy required more than a lift in spending on research and development. It also demanded a new breed of graduate one who is innovative, entrepreneurial, business-savvy, globally connected and capable of having both an economic and social impact.” Over the past 15 years, Velocity participants have ignited more than 120 ventures, attracted over $220 million in investment and created more than 700 jobs in more than 35 countries. Among the successes: • PowerbyProxi (wireless power technology). Fady Mishriki and Kunal Bhargava, then engineering students, were part of the team behind a design for wireless power that earned them runner-up in the inaugural 2003 Challenge. Four years later, Mishriki and entrepreneur Greg Cross formed PowerbyProxi to commercialise the technology, with Bhargava as engineering manager. Within six years, the company had built more than 50 wireless power applications for Fortune 500 companies. • Tectonus (earthquake protection). 2015 Challenge winners Tectonus

patented their novel ‘seismic joints’ that allow buildings and other structures to return to their original position after earthquakes and aftershocks. The state-of-the-art earthquake protection was used in Nelson’s new airport. CEO Pierre Quenneville was formerly Head of Department of Civil and Environmental Engineering at the University of Auckland.

for Innovation and Entrepreneurship (CIE), reflected on the success of the programme and its impact on the University’s entrepreneurial ecosystem. “We’ve done a lot of work over the last 15 years, creating business-savvy STEM graduates, which was at the heart of Velocity’s creation. The incredible growth of the CIE would not have been possible without the foundation that Velocity has built.”

• Green Spot Technologies (alternative flours). School of Biology academics-turned-entrepreneurs Silas Villas-Boas and Ninna Granucci were runners up in the 2015 Challenge with a fermentation technology that has been developed to make nutrient-rich alternative flours from fermented fruit and vegetable pulp that would otherwise go to waste. This year, the company moved to France on the back of $1.2 million seed funding.

Engineering graduate Tina Tian, COO of technology start-up Blackhawk Tracking Systems and Velocity mentor, credited the skills and knowledge she developed through Velocity for her success today. “Joining Velocity remains one of the best decisions I’ve made – the skills I gained are invaluable and I wouldn’t be where I am without these. We are a really innovative country, but there is gap in our ability to commercialise all the cool things we invent – Velocity is instrumental in being able to close that gap.”

Students, staff and Velocity alumni and supporters shared their stories of the programme’s impact at Velocity’s birthday celebration. Wendy Kerr, Director of the Centre

Law graduate Lucy Xie is passionate about social impact and used Velocity as a platform to launch her own social enterprise. She cited her winning Velocity Ideas Challenge submission as

Creating a knowledge-based economy required more than a lift in spending on research and development.

Geoff Whitcher.

the most important essay she wrote as a student. “At the time I had no idea it was going to change the course of my life. I’m still on my entrepreneurial journey and I want to thank the Velocity team, because I’m exactly where I’m meant to be.” Associate Professor Greg O’Grady has entered a number of Velocity challenges and won prizes in the $100k Challenge twice. “I try to get as many of my students involved in Velocity as possible. It expands their horizons, gives them a vision, and leadership and team-work skills. It gives them confidence to build products that can make a tangible, direct difference to someone’s life. Velocity inducts them into a culture of entrepreneurship that gives them the feeling they can have an impact and change the world.” The new Velocity CEO for 2019, Nick Goldstein, has just recruited a team of 32 students who will take the lead in 2019 for what promises to be another outstanding year.

continued from Page 1

Manufacturing – A year in review but modest level of growth from September 2013 to now – averaging around 2% real (inflation-adjusted) growth per year. However, 2018 has actually seen a slight fall in growth between March and September quarters. While a number of sub-sectors in manufacturing have felt a slowing of growth in this period in 2018, meat and dairy manufacturing is a largest contributor to this fall in sales. If you exclude meat and dairy, manufacturing has fared a bit better since 2013, experiencing around 2.7% real growth per year. Again, however, the rate of growth has slowed in the latter half of 2018 (June and September

Quarters). The transport equipment, machinery and equipment manufacturing sector had an average annual real growth of around 3.6% over the same 2013 – 2018 period. This sub-sector had a very strong start to 2018, but slowed off a little down to annual real growth of 2.6% for the September 2018 quarter, compared with the strong 8.6% annual real growth to the June 2018 quarter. Chemical, polymer, and rubber product manufacturing has had a slighter lower average real growth rate since 2013 at around 2.2%. 2018 had a reasonably strong start and finish for the sector, with the June 2018 quarter falling in comparison.

There are some really encouraging signs here, including the fact that the sub-sector with, arguably, the highest value-adding contribution showing the highest growth rates by a clear margin. Overall, manufacturing has had pretty steady growth over the last five years across most sub-sectors and while 2018 has largely continued this trend, there are some signs of weaker growth towards the end of the year. The core question is if this apparent slowdown of growth during the latter half of 2018 will extend to the coming year, or if this is just a temporary slowdown in growth. This may be related to a more general slowdown of the domestic economy, particularly

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related to some of the lower growth in the dairy and construction sectors. Time will tell if 2019 sees a bounce-back and continuing upward trends. In the face of Treasury in its latest HYEFU forecasting that Exports as per cent of GDP continuing to linger at well under 30% for years to come, we will continue to argue strongly that increasing the contribution of high-value-adding manufacturing to our economy is one of the few options we have to improve this embarrassingly poor economic statistic. h t t p s : / / w w w. t h e m a n u f a c t u r e r s network.org.nz/we-speak-up/ news-categories/articles-and-blog/ manufacturing-a-year-in-review.html

NZ Manufacturer December 2018

BUSINESS NEWS

Done is better than perfect.” -Sheryl Sandberg

Aurecon announces new CEO to drive global growth Global engineering and infrastructure advisory company Aurecon has announced the appointment of Managing Director Australia and New Zealand William Cox as its new Global Chief Executive Officer to lead the organisation’s rapid growth and continuing diversification across Digital, Advisory and Asia. Effective from 1 February 2019, William will be based in Sydney. His appointment marks the end of current Aurecon CEO Giam Swiegers’ successful fixed four-year term, which saw the company more than double its profits since 2015. William said: “This is a terrific opportunity to steer Aurecon during a time of significant growth and change for our industry. Incredible technologies are helping us plan and build infrastructure in a way never seen before, truly changing the way we engineer, design and advise.

“My focus areas for the immediate future are to consolidate and continue the growth trajectory in Digital, Advisory, and in Asia where we see immense potential in transport infrastructure, the built environment and fast-growing data centre sector.” As Aurecon Managing Director – Australia and New Zealand, William has a proven track record in building a financially successful, high performance culture with strong client engagement. William is a civil engineer with over 30 years’ experience in transport, aviation and infrastructure across Australia and the UK. William is also Aurecon’s Pay Equity Ambassador for the Workplace Gender Equality Agency (WGEA) and Aurecon’s representative for the Consult Australia Male Champions of Change. Under William’s leadership, Aurecon

implemented female representation targets in Australia. In 2016, there was 26 per cent female representation and a target of 30 per cent was set for 2020. That target was reached in early 2018 and now the aim is 40 per cent by 2020.

As a member of Aurecon’s Executive Committee, William has contributed to the company’s strategic direction, reporting directly to Giam Swiegers.

New managing director appointed at Hamilton engineering firm Long-time engineering manager Gerard O’Connor has been named as the new managing director (MD) of leading Hamilton-based global process and chemical engineering firm PDV Consultants. Mr O’Connor has been with the firm for the best part of 22 years and is well-regarded by colleagues, industry peers and clients. “I’m very excited and honoured,” says Mr O’Connor. “PDV has been my life for more than two decades and I feel very privileged to be now leading the company.” As PDV’s former engineering manager for the Asia-Pacific region, Mr O’Connor has successfully designed and managed many large scale client projects in New Zealand, Indonesia, the USA, the UK, Australia and China over the past two decades.

PDV Consultants is a global expert in food processing technologies and systems design, headquartered in Hamilton, New Zealand, with an office in Belfast, Northern Ireland. Many of their projects for global food manufacturers involve spray dryer and evaporation technology. The company was founded 28 years by David and Anne Platts. The couple have announced their retirement from the firm at the end of November. Mr Platts is stepping down as MD, a role Mr O’Connor will take over on 30th November. “I’m really pleased that Gerard will be taking on the role,” says Mr Platts. “Gerard is very experienced and knows our business well. Under his leadership it’ll be business-as-usual.” Since opening in 1990, PDV has grown from two to 25 staff – including

21 in the firm’s Alexandra Street headquarters and four international staff based in Ireland. PDV’s team of highly qualified chemical, process and mechanical engineers have delivered projects for clients including Fonterra, Tatua, the Dairy Goat Cooperative, Danone, Glanbia (Ireland and USA), Dairconcepts (USA), First Milk (UK), South West Cheese and more. Mr O’Connor says that PDV Consulting is a New Zealand success story. “Anne and David have built PDV Consultants – or Platts Drievap Engineering as it was then known – from small beginnings. Today it is a multimillion dollar international consultancy that delivers significant projects to international food and nutraceutical processing industries. It’s an amazing achievement, and one they should be proud of.” He says the there is a high level of expertise at the company. “We know that clients trust our ability to design innovative, safe and hygienic systems that are tailored to client and plant requirements. I’m proud of the knowledge, skills, experience and integrity at PDV,” says Mr O’Connor. He says the potential for growth in the industry is exciting. “The New Zealand dairy industry is the global leader and the rest of the world looks to us for the latest technical solutions and systems, which is something PDV delivers on.” Mr O’Connor is a chartered chemical and materials engineer and has also

NZ Manufacturer December 2018 /

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previously worked in the United Kingdom for Novartis and Zeneca Pharmaceuticals after starting his career at Naclo NZ. He qualified from Auckland University and is originally from the Waikato where he was raised on a dairy farm. He has been a shareholder director in PDV alongside David, Anne and engineering managers Steve Lowe (Engineering Manager – Design and Drafting) and Rodney Lucas (Engineering Manager of Europe). “We have a strong, collaborative leadership team at PDV,” says Mr O’Connor. “I intend to carry on the vision for the company that David and Anne created. PDV has a reputation for excellence, and as a team we will continue to deliver that to clients and honour PDV’s core values.” Mr O’Connor said that the company will continue to focus on its core values: teamwork, innovation, fun, integrity and excellence. In addition, the leadership team has been strengthened by the appointment of Lynn Waters, former group financial controller at Livingstone Building, who has been named PDV’s new business manager. Prior to joining PDV, Mrs Waters was group financial controller at Livingstone Building for more than 10 years. Before that she work at Norris Ward McKinnon as a finance manager. Her daughter Grace Waters works at PDV as an engineer.

REAR VIEW

I’m not a businessman, I’m a business, man! - Jay-Z

New technologies can

meaningful jobs

create huge numbers of

Augmented reality can play a pivotal role in removing labour inefficiencies. In the US, recent jobs reports have generally been met with enthusiasm and positivity. Unemployment continues to drop to 10-year lows and most economists believe America is approaching “full employment.” Wage growth remains in positive territory. And yet, people are angry. Blue-collar manufacturing jobs have disappeared. Income inequality is increasing, and the once-steadfast middle class is being hollowed out. Their anger arises from a sense of economic insecurity and it is the idea that weaves together Brexit, Trump’s takeover of the Republican party, and Le Pen’s National Front. The acute disconnect is alarming. How can the US be at full employment and yet harbour such profound socioeconomic discontent?

The Dignity of Work A reporter for the New York Times recently rode with a number of truck drivers to learn about their job. Truck drivers spoke at length about the low pay and health issues the job entailed. The title of the article was “Alone on the Open Road: Truckers feel like ‘Throwaway People.’” Much has been made of the looming devastation that self-driving technology will have on the 3.5 million truck drivers in the US, as well as how these millions of newly unemployed individuals will add fuel to the populist flames. The concern is misdirected. Digging deeper into the data clarifies this disconnect further. Many are in part-time jobs or are underemployed for their experience and skillset. Only 62% of Americans are even participating in the labour market, and a growing number of people in their prime working years have given up on trying to find a job. The populist language of modern politicians confirms this thesis. Americans are being “left behind.” Workers in the Rust Belt have become a “forgotten people.”

People may have jobs, but they’re not the jobs they want. They lack the purpose, stability, and opportunity for advancement that give their work meaning and dignity. Any approach to this issue should focus on two key issues. The first is to create new jobs that are accessible to broader geographies and demographics. The second is to provide these workers with the retraining in the skills they need for those jobs.

An engine for job creation Cities have always been durable hubs of economic progress and job creation because of the concentrated networks of specialized talent they create. For knowledge workers, technology has weakened this geographical stranglehold.

work, health systems have struggled to centralise and standardise these administrative services, and have placed the majority of the documentation burden upon the most expensive and highly trained resources in healthcare: the doctors. Augmedix is one example of how augmented reality is creating thousands of jobs and entire new industries by unlocking labour inefficiencies.

With the right infrastructure, a digital marketer, visual designer, or Android developer can be as prolific working from a cabin in Montana as they are in the offices of a technology company in San Francisco.

By equipping doctors with augmented reality wearables like Google Glass to stream the real time audio and video of the patient encounter to a highly trained remote scribe, Augmedix can offload the three to four hours per day of documentation from the doctor to their remote scribe.

However, this emerging flexibility for knowledge workers has yet to impact the more traditional secondary and service sectors such as manufacturing, healthcare, and retail.

By enabling the doctor to operate at the top of their licence, Augmedix reduces the cost of care, improves the patient experience, reduces medical errors, and reduces physician burnout.

Through services like ODesk, a software developer based in Akron, Ohio can provide their services to thousands of companies across the world. The same cannot be said of the very physical skills of a healthcare worker or an automotive plant worker.

In addition, the location-agnostic nature of these augmented reality jobs helps to redistribute skilled labour from highly concentrated and affluent urban areas to lower cost areas more in need of job creation.

This fundamental and global labour inefficiency is the keystone to the value of augmented reality technologies unlocks for modern economies.

Redistributing skilled labour As an example, many medical clinics struggle to hire the qualified mid-level staff – medical assistants, nurses, back office administrators – to support the growing piles of documentation and paperwork necessary to operate in the American healthcare system. Because of the real-time and context-dependent nature of this

Faster retraining in a fast-moving world In addition to unlocking new opportunities for underserved areas of the labour market, augmented reality technologies are playing an increasingly pivotal role in retraining employees to handle these rapid shifts in the labour markets. According to the World Economic Forum’s The Future of Jobs report, more employers are focused on retraining employees – 65% – than any other strategy. Upskill, an augmented reality company in the manufacturing and field services sectors, uses wearable technologies to provide step-by-step

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instructions to industrial workers. In a side-by-side comparison presented in the Harvard Business Review, providing this real-time instruction improved the performance of a GE technician by 34% on the first try. With the pace of technological progress only accelerating, and with increasing specialisation becoming the norm in every industry, reducing the time necessary to retrain workers is pivotal to maintaining the competitiveness of industrialised economies.

What the future holds for augmented reality and jobs Meaningful employment remains the cornerstone of economic and political stability, and focus must be allocated to ensuring not just that there is employment, but that it is meaningful. This means that businesses and governments should focus on not just employment rates, but on the metrics that measure the quality of the jobs being created – part-time workers, rapid job turnover, contract labour, and wage growth stagnation, to name a few. Solutions like Augmedix and Upskill can unlock opportunities and improve prospects for underemployed workers in low-growth regions. Most importantly, businesses and governments should recognize that, when it comes to the future of work, technology is a double-edged sword. Technology is a force that has the potential to eliminate entire industries through robotics and automation, and for that we should be concerned. But it also continues to be a catalyst for the creation of entirely new industries and opportunities, as well as a way for the economy to unlock inefficiencies in the market and create win-win opportunities for employers and employees alike.

NZ Manufacturer December 2018

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