NZ Manufacturer April 2019 by Media Hawkes Bay Limited

April 2019

www.nzmanufacturer.co.nz

BUSINESS NEWS Consumers to pay more for tradespeople under proposed education reforms.

SOUTHMACH 2019 PREVIEW

SMART MANUFACTURING Safe and sound - Is your smart factory secure?

Professional 3D CAD Unbeatable value.

2018.2

Skills needed to remain competitive -Doug Green, Publisher

Every now and again we step outside the square and have a good, long look at what we are doing. So it should be with manufacturing. Specifically, to enhance the awareness of just what it is the modern New Zealand manufacturer does. Part of that, of course, is to recognise the contribution manufacturing brings to the New Zealand economy. The design, original concept processes that add so much to what is eventually made and finds its way on overseas markets. Manufacturers are modernising their technologies, equipment, systems and infrastructure consistently and applying that sophistication to their materials and production in an effort to create jobs and reduce energy costs.

The jobs themselves are changing too. New, modern ways of manufacturing require highly-skilled workers. The current Government, to this end, needs to sought out what kind of ITOs will be in place to skill the workforce to play a key role in competitiveness on local and world markets. Developing talent is a real challenge and the changing nature of manufacturing is making it harder for talent to keep up. Government needs to invest more in manufacturers, their suppliers and interested stakeholders to create workforce development programs that train and equip workers with the right skills to remain competitive.

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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 1

DEPARTMENTS PAGE ONE

ADVISORS

Skills needed to remain competitive.

4 5

EDITORIAL

BUSINESS NEWS MANUFACTURING TECHNOLOGY

The critical roll of IIOT in the future of food processing. Helicopter and security firms join forces to enhance safety.

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

It’s on the cards – fewer apprentices to be hired. Consumers to pay more for tradespeople.

Leeann Watson

SOUTHMACH 2019 PREVIEW Gumboot technology. Transforming the manufacturing industry with Internet of Things.

Dieter Adam

8 13

Kirk Hope

Apprenticeships vital to automated future.

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.

3D printing the next generation of machinery. Having trouble finding good design engineers?

SMART MANUFACTURING

Safe and sound: is your factory secure?

Lewis Woodward

Semcon increases focus on sustainable manufacturing. 200 Kilometres in 8 minutes: powering the e-mobility revolution.

SMART SECURITY

NEW PRODUCTS

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.

24/7 trade cycles lead to security risks. 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..

Rugged tablets ideal in hazardous industries. Time to take control. LWC lifting wedge ideal in restricted areas.

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.

FOOD MANUFACTURING Pure Bottling now BRC Certified. What do your motors really do?

SUPPLY CHAIN The warehouse of the future.

DEVELOPMENTS Government education reform consultation inadequate. New ENZ president to focus on diversity. New podcast series from HERA.

REAR VIEW Digitalisation and the food and beverage industry.

Craig Carlyle

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

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

– fewer apprentices to be hired

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

As Fiona Kingsford, Competenz chief

CONTRIBUTORS

before, it is vital that school leavers

executive says” now more than ever

Holly Green, Fi Kingsford, Ross Beal, Michael Cahill, Mike Russell, Ben Murton, Dr Don Clucas, Johnathan Wilkins

choose a pathway that equips them to learn new skills for jobs that don’t

ADVERTISING

yet exist in an automated future.”

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

And to do that they are currently dealing with a maze

DESIGN & PRODUCTION

of vocational education sector changes including the

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

replacement of regional polytechnics with a new, national training organisation – the NZ Institute of Skills and Technology.

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

So how does a school leaver, or a person wanting to undertake training, confidently go forward not knowing

PUBLISHING SERVICES

what system will be put in place? Not knowing what to

On-Line Publisher Media Hawke’s Bay Ltd

choose as a career when there are no processes in place? Garry Fissenden CEO of The Skills Organisation, New

DIGITAL SUBSCRIPTIONS

Zealand’s largest training organisation (ITO) which

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

represents 22 industries, 4,400 employers and over 10,000

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

apprentices, is critical not just of the proposed changes but the length of the consultation process offered to employers and the trade education sector. “The Government is currently spending longer consulting on raising the proportion of egg in imported mayonnaise and reviewing the current import standards for Asia zoo elephants coming in from Australia

Vol.10 No. 3 APRIL 2019

and Sri Lanka than on its total overhaul to the vocation education system!”

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

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Research

from

900

employers

found the majority will hire fewer apprentices if the proposal to move the managing of apprenticeships away from ITOs is implemented.

Doug Green

Success Through Innovation

EDITORIAL

If you want something you never had, you have to do something you’ve never done.

BUSINESS NEWS

-Thomas Jefferson

Consumers to pay more for tradespeople under proposed education reforms Kiwi consumers are set to pay 65% more for the services of electricians under new education reforms according to new data. The Government plans to replace regional polytechnics with the introduction of a new, national tertiary training organisation - the NZ Institute of Skills and Technology. The new entity would have responsibility for the arrangement and delivery of classroom and work-based learning programmes such as trade apprenticeships.

they are expected to take on the risk of employing them. “I believe the Government has actually forgotten employers are the drivers of industry at the moment and if they don’t create the training spaces for apprentices in employment you won’t need a training model anyway. “Under the new education reforms, the critical role of Industry Training Organisations (ITO) would be diminished and polytechs moved to take their place.

Ross Beal, chairman of Master Electricians New Zealand says the Government proposal is heavily flawed and is likely to have “horrific” consequences for the stability of the industry.

“In highly regulated industries such as our own, the introduction of a new barrier into the training model will result in a significant disruption to the supply of skilled labour over the coming years.

Beal says his organisation’s analysis of wage data from industry surveys shows that consumers could pay 65% more for the same service, if the reforms are implemented.

“The widening of the skills gap will increase the potential for Government deregulation of the electrical industry. This would have serious consequences for the value of a registration and downstream, negative impact on the amount of training undertaken in our industry.

“Our concern is that the cost of getting an electrician will one day be on par with that of a visit to the dentist,” he says. “We currently have a nimble, highly responsive training organisation which the Government plans to dramatically undermine with these new changes - it will set industry learning back a decade.”

“What has not been adequately recognised is that taking on an apprentice is already a high-risk investment for small businesses and many would simply stop training if the environment changed,” he says.

Beal says the proposed polytech based model focuses on quantity but doesn’t deliver a training outcome that employers have had any say in - yet

Beal says in the electrical industry even the most basic tasks need a staff member with a practicing licence, and to use unskilled labour would require

high levels of supervision to meet standards, as well as increase compliance costs. “If we remove apprentices from the equation this means that this function is filled by the next level up - the existing stock qualified electricians. “The issue at this point becomes one of job satisfaction as qualified electricians will eventually leave a role if they find themselves performing the work of an unskilled labourer on an ongoing basis - which will further exacerbate the supply shortage and lead to further price increases. Beal says that the electrical contracting industry is facing a “perfect storm” as large numbers of baby boomers are set to retire, there are not enough young people coming in and will face a declining number of training spaces as a result of the Government’s proposed reforms. “According to our analysis of industry wage data, if the number of apprentices being trained were to halve over the next decade, and the projected number of licensed electricians drops as the boomers move into retirement, we could see the charge out rate range increase from around $75 to $124 per hour in today’s terms,

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NZ Manufacturer April 2019

Great things never came from comfort zones.

MANUFACTURING TECHNOLOGY

-Neil Strauss

The critical role of IIoT in the future of food processing Michael Cahill, Rockwell MES Technical Consultant

As the old adage goes, an ounce of prevention is worth a pound of cure. New Zealand food companies, that often produce high value-add product that is exported around the globe, value their brand and reputation. Things are changing. Customer expectations for food safety and quality are unprecedented. Expectations from regulatory authorities are increasing to meet ever growing market regulation. Demand for high safe products is driving growth at an unprecedented rate. The reality is the number of food recalls has been steadily increasing over the last decade, according to FSANZ’s 2009-2018 reporting. The lack of visibility in the early stages of production is leading to an increased amount of inedible product and is posing serious food safety compliance risks. With headline after headline, product traceability from paddock to plate is becoming more and more important. Any deviation in quality in the product line will involve significant wastage and financial burden on the organisation. A sustainable approach to maintain the highest standard of production quality is sought to meet these customer, regulator and growth challenges. Connecting the dots The rise of the Industrial Internet of Things (IIoT) has emerged as a solution to this problem. IIoT platforms and advanced analytics now enable users to fuse multiple data sources to provide contextually relevant historical and real-time data. Add in AI and machine learning and food manufacturing is more predictive and intelligent than ever before, giving workers uncanny insight into how to solve issues and predict problems before they happen. The problem isn’t a lack of data but a lack of connectivity from food companies. IIoT has provided the tools to better verify quality, establish batch genealogy and capture meaningful processing data from beginning to end. It’s now the job of manufacturing plants and farms to embrace these

technologies. It awards us real-time operational visibility and the brilliance of predictive maintenance. Predictive maintenance is a technology that has grown tenfold in the manufacturing sector over the years, guided by major developments in AI, Big Data Analytics and IIoT collectively. As a tool it can trigger a work order before any downtime needs to occur and has an unprecedented ability to detect failure early. The software uses advanced analytics to effectively become a crystal ball, giving companies a predicted future and prescripted action simultaneously. Additionally, advancements in anomaly detection can identify the dips in performance that require immediate attention. Deploying technologies like this early in the production stage is exactly the kind of tool that could have prevented the salmonella outbreak in our supply of eggs. The food plant of the future is undeniably an interconnected one, empowering food processing facilities with access to real-time data that can effect real change and dramatically improve quality. It is an exciting time and many food manufacturers are still learning about these capabilities and what they can do with all of this new data at their fingertips. And it’s imperative that we do use this information. The food sector is a sector where in many cases something going wrong is not simply a problem but a calamity. Ignoring garbage-in is a timeless recipe to have garbage-out. Today’s advancements in IIoT technology and paperless manufacturing techniques can stop food recalls by preventing a faulty product from leaving the plant in the first place. Historically, a company may not know it has a bad batch until it is packaged because of the delays in manual reportage. Preventing recalls is critical for the health of the consumer, the company reputation and the bottom line.

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Add in AI and machine learning and food manufacturing is more predictive and intelligent than ever before. GRAPHICS

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SIGNAGE

CREATIVITY

Newsletters WEBSITES

Contact Kim on M 027542 7111 E kim.alves@xtra.co.nz

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Bringing Characters to Life with the Stratasys J750 “Being able to have a 3D printer like the J750 that’s repeatable and accurate with this full range of color and materials has afforded us the idea of being able to achieve this shot-by-shot customized animation.” Brian McLean, LAIKA

Learn more >> http://3dprintingsolutions.blogspot. com/2019/03/bringing-characters-to-life-with.html

Join industry experts from Objective3D, SolidWorks, Stratasys, Desktop Metal and Concept Laser for an opportunity to learn how leveraging 3D CAD and 3D Printing on the manufacturing floor can help you stay ahead of the competition. The Wellington event will include the launch of New Zealand’s first and only Stratasys J750, recently delivered to the Victoria University of Wellington. The Stratasys J750 is the world’s most advanced full-colour, multi-material 3D printer with 500,000+ colour combinations, highly accurate color-matching, transparent to opaque color gradients, and advanced clear material with texture bringing to life even the finest, most delicate details.

WHAT YOU WILL LEARN:

WHEN & WHERE: 16th April: Wellington 27th August: Auckland 29th August: Christchurch

• The Role of 3D Printing in Manufacturing • SolidWorks 2019- Where Possibility Takes Form • Designing for Additive Manufacturing (AM) with SolidWorks • Design-to-3D Printing for Anyone, Anytime and Anywhere • Updates on Desktop Metal including an Overview of FABRICATE - pre-process 3D CAD models and deliver a flawless workflow. • How Metal 3D Printing is Transforming Metal Fabrication • Strong as Steel – Carbon-Filled AM Technology • Stratasys reinvents 3D printing. Again. Launch of the Stratasys J750 (Wellington event) • Customer Presentation on use of AM (Auckland & Christchurch events) • Panel Discussion: Leveraging CAD and 3D Printing on the Manufacturing Floor

Places are limited. Please book early to avoid any disappointment.

TIME:

1.00pm - 5.00pm

COST: FREE WHO SHOULD ATTEND: Business Owners Corporate Executives Educators, R&D Professionals Product Designers / Managers Design Engineers / Managers Engineering Managers Anyone who is interested in AM

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NZ Manufacturer April 2019

MANUFACTURING TECHNOLOGY

The first step toward creating an improved future is developing the ability to envision it. - Anonymous

Leading helicopter and software firms join forces to enhance safety A leading global helicopter operator and an innovative software firm are teaming up to deliver real-time risk management tools that will lift the bar on helicopter safety. PHI International, formerly HNZ, the international operating division of PHI Inc, is partnering with Ideagen, a UK-based, global, software developer, to implement Ideagen’s Coruson software across PHI’s international business. Coruson is an enterprise cloud-based system that enables real-time control, visibility and reporting of risks. By deploying Coruson, PHI International will extensively enhance its safety, risk and compliance oversight. The project also sees PHI International become the first in the helicopter industry to combine comprehensive bow-tie risk models with aspects of safety reporting and auditing. “We fly helicopters in extreme environments all over the world from offshore Western Australia to the ice shelves of Antarctica, every day of the year, and our absolute, number one priority is keeping people safe,” said Robert Cavers, Safety and Quality Director at PHI International. “Many places we fly to have dynamic and fast-changing operating conditions and it is critical that we have the best possible systems in place to help us manage any risks as they emerge. Coruson is a game-changing software system that will help us do that as it gives us real-time monitoring of hazards

and risks in every location.” Robert continued: “For example, if a pilot is on an offshore marine pilot transfer flight and observes a hazard, he or she can report that back to us immediately by inputting it to Coruson. We can then start tracking the risk factors and making the necessary safety adjustments straight away. It is a great tool to add to our industry-leading safety systems.” By combining bow-tie risk models with all aspects of its safety reporting and auditing functions within Coruson, PHI International has enhanced its efficiency and oversight to enable continuous improvement of key safety controls. Ross McLarnon, Ideagen’s Product Manager for Coruson, said: “PHI International is a well-established and globally renowned helicopter operator with a very strong focus on safety and quality. We are pleased to be partnering with them to integrate Coruson as part of their safety and risk management tools. “More than 5,000 organisations use Ideagen’s products, including seven of the top 10 UK accounting firms, all of the top aerospace and defence companies along with 75% of the world’s

leading pharmaceutical firms, so we look forward to a close and successful future together with PHI International.” PHI International operates a fleet of more than 20 single and twin-engine helicopters in New Zealand, Australia, Africa, South East Asia and Antarctica. It is growing its international operating footprint and Coruson will be a key enabler of safe and sustainable growth as it enters new markets. Ideagen provides software and services to organisations operating within highly regulated industries such as aviation, banking and finance and life science, healthcare and manufacturing with its main operational premises spread throughout the UK, EU, US, Middle East and SE Asia. Its Coruson software is a mainstay in its portfolio of governance, risk and compliance applications, with many high-profile customers using the software including Jaguar Land Rover, Haeco, Johnson Matthey, Air Asia, British Airways, Ryanair and Telefonica.

Valiant performs advanced milling operations Valiant is the new Ficep drilling line to perform advanced and high-performing milling operations, beside the scribing operations, as a stand-alone line or combined with a saw line or robot. An extra value that assures higher performances and reduced cycle times. Ficep is appearing on Stand 154 at SouthMACH 2019. Valiant inherits all the strengths from the Ficep drilling range, with additional technological improvements. The line has an electro welded steel structure that guarantees solidity and stability, resulting in the same time agile enough to ensure highly dynamic performances.

Compared to the existing models, one of the numerous innovations is the advanced clamping system of the piece, the new blocking system and two independent handling cylinders that process all the operations on the top and bottom of the beam. Valiant is a generously dimensioned machine, able to handle pieces that are usually processed in the civil and industrial constructions. The spindles are designed by Ficep and suit perfectly in terms of strength and available torque, to process the requested operations. Other strengths are the auxiliary axes per each operating head, which allow to process, without moving the beam, numerous operations like special milling and “rat holes”. These kinds of operations are usually processed with other technologies like oxy-cutting or other machines. Now instead the same can be realised through chip removal with

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specifically shaped tools and with specific software cycles already integrated in the machine. Being able to position the beam and process all the operations without moving it again, gains time and precision due to the simultaneity of the processing operations. Moreover, Valiant can be equipped with automatic tools storage with up to 14 positions for each head. This is a significant increase of the availability of tools that complete all the necessary operations on the beam (drilling, milling, scribing, etc.). All this means higher performances and considerable reduction of the working cycles.

Also, thanks to the use of technological solutions and innovations, a numerical control that gives numerous advantages. The main one is the possibility to customise the machine capabilities and to add specific programs. Moreover, the firmware is common to all Ficep lines and only certain functions are activated based on the operations that must be processed. Valiant is another industry first example of superior technology from Ficep, the world’s largest manufacturer of automated systems for the steel construction industry.

Learn to say ‘no’ to the good so you can say ‘yes’ to the best. -anon

MANUFACTURING TECHNOLOGY

Guardian Angel Security’s lone worker solutions a winning formula ecentre startup continues run of success with prestigious SheEO win Guardian Angel Security, a solutions provider for lone and remote workers, has won a share of up to $500,000 for a five year interest free loan from global female entrepreneur network SheEO. The company was one of five New Zealand businesses selected by 500 women (SheEO Activators) who contributed $1100 each to support early stage female entrepreneurs. This is the second year SheEO New Zealand, led by businesswoman Theresa Gattung, has backed ventures via their unique ‘Act of Radical Generosity’ crowd funding model. The win continues a successful run for Guardian’s Angel Security’s founder and CEO Petra Hakansson who in February was selected through a competitive application process for the Sprint Global programme run by ecentre, the business incubator hosted at Massey University, to help startup founders accelerate their garage-to-global journey. Hakansson set up Guardian Angel Security in 2014 to deliver solutions that deliver safety and protection for lone and remote workers, after seeing a gap in the market for technology solutions that provided 100% connectivity with immediate response and support for this growing group of workers. “We take our guardian role very seriously and bridge the gap between people and technology to keep them safe,” says Hakansson. “We were first to market with complete technology, training and monitoring solutions for lone and remote workers in New Zealand, and the success with ecentre and now SheEO provides important validation for our business.” The fast growing lone worker market is estimated at around 500,000 in New Zealand and 1.9 million in Australia. Recent Health and Safety law changes have put the onus on companies to protect high risk workers with panic button pendants – if staff spend time out of cell cover an alternate means to communicate must be provided. 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

Guardian Angel Security solutions integrate the best personal GPS panic button solutions from around the world with signals that link directly to their response software in NZ to ensure fast reliable delivery of the SOS, with 24/7 monitoring. Solutions circumvent the 111 process to speed up an emergency response, and to ensure connectivity even when cell coverage is unavailable. “We’re going after a really big market with enormous potential – from transport operators and manufacturing to Local Government and District Health Boards,” says Hakansson. “Our solutions make a dramatic difference to people in vulnerable situations. Recently one of our animal control officer clients went to uplift an aggressive dog and became trapped. He was able to push the panic button he was wearing which automatically dialled into an emergency line into our control room. “Our operator quickly dispatched the appropriate emergency backup support and was able to stay connected to our client until help had arrived.”

Guardian’s Angel Security’s founder and CEO Petra Hakansson.

“It’s extremely powerful being able to tap into the accumulated wisdom and experiences of others who have built businesses before. It gives a whole new level of confidence when it comes to making growth decisions for my company.”

Jackie Young, CEO of ecentre, says: “Guardian Angel Security really stood out as a high growth potential business when we were selecting businesses for our Sprint Global programme.

“We’re going after a really big market with enormous potential – from transport operators and manufacturing.”

“By keeping pace with rapidly changing communication and monitoring technologies, Guardian Angel is delivering robust and innovative end to end safety solutions to meet the changing needs of remote and mobile workers, and to meet the legislative requirements of employers. “By clearly identifying a niche and achieving a market leader position Guardian Angel Security is on a high growth path.” Hakansson says the timing could not be better for our business to have secured support and mentoring from the ecentre and the funding, mentoring and ongoing Activator support from SheEO.

NZ MANUFACTURER • May 2019 Issue • Features

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SUPPLY CHAIN

COMPANY PROFILE

DISRUPTIVE TEHNOLOGIES

BUILDNZ PREVIEW

ADDITIVE MANUFACTURING Advertising Booking Deadline – 10 May 2019

Editorial material to be sent to :

Advertising Copy Deadline – 10 May 2019

Doug Green,

Editorial Copy Deadline – 10 May 2019 Advertising – For bookings and further information contact: Doug Green, P O Box 1109, Hastings 4156, Hawke’s Bay Email: publisher@xtra.co.nz

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

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

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

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NZ Manufacturer April 2019

SOUTHMACH 2019 PREVIEW

If you want something you never had, you have to do something you’ve never done. -Thomas Jefferson

Gumboot technology You are starting a manufacturing company. You are considering making rockets, yachts, gumboots or rubbish bins. So, you visit SouthMACH, the leading South Island trade show for manufacturers in the know and for aspiring manufacturers who are looking for the best in technology and equipment to help get their business going. The show this year is being held during Techweek 2019. In our highly competitive business world, it is imperative that trade shows such as SouthMACH exist. They are a celebration of the best that can be and highlight the go ahead attributes and attitudes of exhibitors and visitors alike. To have a magical event that brings decisionmakers together can only be for the good; to benefit the fortunes going forward of people committed to enhancing their products and improving their levels of productivity. New Zealand is an innovative country, renowned for ground-breaking developments which succeed on world markets. An example of this is the robot apple picker currently at use on orchards in Hawkes Bay. Or the innovation from Dr Matthew Jones of Christchurch which recently won an Australian award – automated technology that reduces food waste. These two examples support ‘land-based industries’ very well, as this is where seventy three percent of what we manufacturer comes from. And to manufacture and develop these products there is a need for the latest and best in technology and

this mess out, to work with companies, ITO’s and industry groups to provide the very best of outcomes to keep our economy going forward.

equipment to be available. The world waits for no one and there is no catch up – only a competitor who steals the march on the market you had all lined up to succeed in. Another important role of the trade fair is to provide a meeting place for apprentices and those entering the work force who are seeking inspiration and a direction for their future. There is debate underway these days as to whether going to university is such a big plus when gaining an apprenticeship and obtaining a trade may well be the better option. Less student debt to pay off and a guaranteed and successful future by choosing a trade that will always be in demand. Who doesn’t need a plumber or an electrician or a builder? Currently, Government’s plans to reform the vocational education sector and merge ITO’s and polytechnics is causing a headwind. Real concerns exist about these changes undermining critical workplace and apprenticeship training. New Zealand has a skills shortage and Government needs to sort

There is a lot to see, do and listen to at SouthMACH 2019. Take Additive Manufacturing. A 2-day workshop is being presented by Professor of Additive Manufacturing and Head of the Creative Design and Additive Manufacturing Lab at the University of Auckland, Olaf Diegel. There is an Entrepreneurs Development Hub where Motovated Design and Analysis and Brush Technology, amongst others, have created a unique environment for creativity and information sharing. Then there is The Lab, an incubator for Kiwi technology start ups to present their work to engineers, manufacturers and investors. Twelve start-ups will display their designs during the show and get advice from professionals. And The Innovation Quarter where the latest in technology for manufacturers and engineers will be on display. So being in this rich environment of creativity for manufacturers ought to be enough to inspire any manufacturer looking to go forward with his business. You may have heard of the book’ Move Fast and Break Things’ and of the definition Disruptive Technology. Think of these when you are wandering around the show. Look for where the opportunities are for your company. Treat these titles in a positive way because within them may well lay the future for your company going forward. - Doug Green, publisher, NZ Manufacturer

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SOUTHMACH 2019 PREVIEW

Transforming the manufacturing industry with Internet of Things Mike Russell, COO, Central Innovation In a highly competitive global marketplace, businesses are searching for and adopting revolutionary technology and processes to stay relevant. According to the latest IDC Worldwide semiannual Internet of Things Spending Guide , New Zealand shares the second highest position with Australia in APAC region when it comes to the IoT spenders per capita. The report further highlights that the top three industries spending most on IoT solutions in 2018 were discrete manufacturing ($43.9 billion), process manufacturing ($33.2 billion) and utilities ($20.1 billion). With the advent of automation and analytics, manufacturing is moving from mass production to mass customisation. The immense growth of IoT in the industry has resulted in factories being able to extract critical data on operations. By using big data and machine learning they are achieving more efficiency in their workplace as well as enhancing customer experience. Without a doubt, IoT is a clear investment area for the manufacturing industry particularly in the Asia Pacific Region which is among the world’s top regions for IoT adoption and usage . To effectively work with new technologies, businesses must be prepared to think differently, adapt and invest to remain competitive. According to the MBIE report , Industry 4.0 is seen both as a threat and an opportunity for New Zealand manufacturers. The ministry believes that Industry 4.0 technologies have the potential to make a type of short run, customised production that will enable more specialisation to become efficient and profitable. This would be especially important for the manufacturing industry where it currently accounts for 12 per cent of New Zealand’s GDP value. This means there is untapped potential for New Zealand businesses to stand out from their competitors in the race to transform their businesses.

Business productivity The bottom-line when adopting new technology is that it will increase overall productivity of the workplace. The integration of IoT into smart devices enables industrialists to autonomously manage manufacturing and distribution operations. IoT

also allows manufacturers, and their customers, to access critical, real-time data, which can be used to improve productivity and system performance and give customers data on the status of their product delivery. The consistent information derived from processes of IoT can be used for preventative or predictive maintenance, resulting in reduced downtime by making more informed and targeted upkeep of equipment. Increased connectivity between pieces of equipment and machinery means improved collaboration and integration amongst stakeholders throughout the manufacturing value chain, which is crucial for the success of implementation. Furthermore, IoT will continue to drive the future of factories. In the automotive industry, smart manufacturing will interconnect and better harmonise the individual stages of manufacturing production in order to advance plant-wide efficiency. From an engineering cycle standpoint, this means that manufacturers will be able to get new products to the market sooner and meet consumer demands more responsively. For example, medical device manufacturers can also leverage IoT to improve customer experiences and monitor patients more closely by managing everything from dosage through to the use and efficacy of devices. Regardless of industry, IoT will be beneficial to all businesses looking to improve their products and services amongst their competitors. Renewed business models: Servitisation Greater investment in IoT gives manufacturers an opportunity to diversify their services sector. The

new buzzword in the manufacturing industry is ‘servitisation’ that refers to the aftermarket service work and is a huge growth area for the industry players. This is driven by the data retrieved from IoT. The key advantage of adopting a full servitised model is in the continual relationship with the customer. A manufacturer delivers a piece of equipment as a service and is billed on basis of usage or through a revenue sharing model. By focusing on customer retention and loyalty through servitisation, manufacturers can stand out in the crowd with an enhanced customer experience. According to IMCRC, less than 30 per cent of manufacturers are in the business of selling services, which implies there is a huge scope to use IoT to its advantage . By introducing service offerings in addition to the sale of goods, IoT can give organisations competitive advantage in the saturated one-off market by increasing value differentiation. To remain competitive and increase the market share in the highly competitive manufacturing industry, IoT adoption is key. As we head towards a hyper-personalised world, customer experience will be paramount to the success of a business. Staying relevant will come from rethinking revenue and business models. Servitisation reflects changing customer expectations, with consumers no longer satisfied with one-off purchases. Ultimately, the right investments in IoT will enable businesses to tap into the potential of digital transformation that awaits. Whether it is through automatic retrieval of performance data, delivery tracking or equipment performance monitoring, an enhanced customer experience is supported by IoT and, in turn, increased competitiveness is delivered.

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NZ Manufacturer April 2019

SOUTHMACH 2019 PREVIEW

We did not come to fear the future. We came here to shape it. -Barack Obama

Apprenticeships vital to automated future Now, more than ever before, it’s vital that school leavers choose a pathway that equips them to learn new skills for jobs that don’t yet exist in an automated future. And despite what many people think, automation is not a jobs killer – it’s creating new jobs and opportunity, says Competenz chief executive Fiona Kingsford. “Human jobs won’t disappear, they will change. The World Economic Forum predicts 75 million jobs will be lost in the next four years as companies automate, but at the same time, 133 million jobs will be created. “As parents and teachers, we are natural guides for our young people. But we need to accept the world of employment is undergoing a massive shift, and it’s happening right now. Our children must be equipped with the skills they need to meet change, and to find relevant, rewarding and adaptable jobs.” Outmoded thinking of what workplace learning and apprenticeships can deliver is an ongoing battle for Competenz, New Zealand’s industry training organisation for manufacturing and engineering. Modern food and beverage manufacturing plants, engineering workshops and other trades-based workplaces demand a high level of technical skill. Mechanical engineering apprentices are using artificial intelligence and robotics to facilitate the automation of a growing number of “doing”’ tasks. Today’s AI-enabled, information-rich tools are increasingly able to handle jobs that in the past have

been exclusively done by people. “These shifts will produce massive disruptions to employment and, if we are going to meet this disruption and prosper from it, we need to address it now by helping our children choose the right learning pathway,” Kingsford says. The people needed for those 133 million new jobs will be responsible for gleaning insight and intelligence from the machines, fixing and maintaining them as well as quality assurance, among other things. “Various organisations have identified the top soft skills that will be an absolute given in 2020 – skills our young people will need to thrive. These are collaboration, empathy, complex problem solving, critical thinking, creativity and people management. In our opinion, the best place to learn these skills is on-the-job.” As an industry training organisation, the businesses Competenz works with employ more than 20,000 people completing apprenticeships or on-the-job training. They are committing to the future by growing their workforce’s competencies or work-related skills for a world of lifelong learning, rather than the “three or four years and you’re done” university system. These businesses are future-proofing their people, right now.

“We have to collaborate and help our children develop the range of skills they will need to succeed in this brave new world of work,” Kingsford says. “Although disruptive, these shifts are exciting and are opening new pathways for our young people. We think their life-long learning begins now, on-the-job, for the best head start for their careers.” Talk to Competenz at SouthMACH 2019 Talk to the Competenz team about apprenticeships and on-the-job training at SouthMACH Stand 54 in the Employment and Training Hub. Looking for your next apprentice or entry-level employee? Meet jobseekers at SouthMACH via the Competenz SpeedMeet, a quick-fire series of job interviews with local high school students who are ready and willing to start a career in engineering or manufacturing. Register for SpeedMeet via the Employment and Training Hub page at www. southmach.co.nz or email marketing@competenz. org.nz.

EXCALIBUR Automatic CNC single spindle drilling line

The Excalibur is the latest development in FICEP family of CNC drills where the drilling unit positions along a support table while the part to be processed remains stationary. The line is equipped with complementary axes that enable scribing and milling operations. Thanks to its exclusive features, the Excalibur is an exceptionally versatile and brilliant solution for small and midsize companies. Excalibur is another industry first example of superior technology from Ficep, the world’s largest manufacturer of automated systems for the steel construction industry.

Ficep Headquarters 21045 Gazzada Schianno Varese - Italy - Via Matteotti, 21 Tel. +39 0332 876111 - Fax +39 0332 462459 E-mail: ficep@ficep.it • www.ficepgroup.com

NZ Manufacturer April 2019 /

Ficep New Zealand 10E Maurice Road, Penrose Aukland - 1642 - New Zeeland Tel. +64 9 525 6907 E-mail: francis@ficep.co.nz • www.aoteamachinery.co.nz

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Great things are not accomplished by those who yield to trends and fads and popular opinion. -Jack Kerouac

SOUTHMACH 2019 PREVIEW

3D printing the next generation of machinery While metal 3D printing is regularly used for components such as brackets, rocket parts and turbine fuel nozzles, it is rarely used as the major manufacturing process for an entire mechanical system. In a world first, students from the University of Canterbury developed an operational 3D printed titanium ethanol fuel injected internal combustion engine, showcasing the possibilities and limitations for the process. The team took their engine to Singapore and won the innovation award at the Shell Eco-Marathon event, a global competition on for students to compete with highly efficient vehicles. This was all done in one academic year, so a highly accelerated design process was required. To test and visualise ideas quickly, concepts were modelled and refined using cheaper and easier to post-process polymer 3D printing. The titanium parts that were optimised for efficiency, not machining constraints, were then printed and post-processed. Post processing proved to be the biggest headache. It is often said that 3D printing can create anything, but in reality it has its limitations and drawbacks. An

example is the almost organic shape of the cylinder head that required little post processing, while the rather basic cylinder required complex support material. Using a laser sintering process that melts and fuses layers of very fine titanium powder has its complications. Thermal contraction of thin features would distort the part, much like MIG welding distorts steel, so support material is required. Removing the support required many hours EDM wire cutting, machining, and finally sand blasting. Before and after cutting the part off the build plate, thermal stress relief was required. Good Design for Additive Manufacture, DfAM, was essential to avoid or reduce the support material, ease support material removal, and reduce distortion. The raw titanium powder is a collection of very small diameter beads at micron scale. When a part comes directly off the printer the body of material has a uniform homogeneous structure. The surface,

A world first! Students from the University of Canterbury developed an operational 3D printed titanium internal combustion engine.

however, is coated with partially fused powder. This is not a concern for machined surfaces, but on the inside of the crankcase, where the raw surface encounters hot engine oil, these particles can break off and cause havoc between moving surfaces such as piston and cylinder walls. With careful sandblasting and ultrasonic cleaning before assembly this issue is eliminated. Good DfAM therefore must include access for a sandblaster or other post processing into internal cavities if complete removal of powder is required.

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SOUTHMACH 2019 PREVIEW

In order to attain the impossible, one must attempt the absurd. -Miguel de Cervantes

Having trouble finding good design engineers? When clients contact us for the first time, this is often the complaint they have: they can’t find good design engineers. After they’ve used our service, the response is “what’s your secret?” “Cailber have nailed the selection and vetting of great talent”. Mark Robotham, CEO, Stackflo

A new approach to project resourcing Caliber Design is a mechanical design consultancy that provides project-based design engineering services. Our team of highly skilled and experienced engineers are based in Auckland, Hamilton, and Christchurch. Our engineers work with clients on a project-by-project basis … this means our clients can upsize their team with the exact skills they need, when they need them.

What IS the secret? We have a great team, with a breadth and depth of engineering experience that is hard to beat. Our team experience spans multiple industries, including aerospace, materials and food handling, packaging, marine, agriculture, and medical. It’s a big ask for engineers to move between project and industries. That’s why Caliber employs engineers who have great “soft skills” as well as top technical ability. Our team is agile, adaptable, and brings innovative design thinking to every project. We have a rigorous recruitment process, thorough induction, solid processes, ongoing training, and robust values that underpin everything that we do.

What’s the benefit of project-based resource? By using project-based resource, our clients find they can make more efficient use of their resource, reduce their costs, reduce their overheads, and get their projects completed on time. Clients appreciate that our engineers work on site, as part of their team. And the fact that we can supply the hardware and software they need too! It takes the HR hassle out of the equation. They get the resource they need, when they need it. We handle the rest.

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We’re seeing rocketing demand for our service, with some of New Zealand’s most well-known and successful businesses enjoying having Caliber engineers assist them with their design work: Stabicraft, Fonterra, Trimble, Shotover Camera Systems, Sanitarium, Scott Automation, Tip Top, AIM Altitude, to name a few. If you have a looming deadline, a shortage of resource, or a tricky engineering problem you’re trying to solve … give the team at Caliber Design a call.

Don’t let what you cannot do interfere with what you can do.

SOUTHMACH 2019 PREVIEW

-John Wooden

TechRentals at SouthMACH again on Stand 25 After attending SouthMach, for the first time in 2016, it was an easy decision to sign up again. Whilst TechRentals have many South Island Customers their ability to have a rental instrument delivered early the next day was not widely known. Using a nationwide overnight courier service makes this possible.

here so check out our website www.techrentals. co.nz.

This service, combined with skilled Application Engineers, ensures you have the right instrument in your hands, tomorrow, ready for your use.

The general areas Calibration services are offered for are electrical, medical, pressure, light, air flow, mass flow, temperature, humidity and vibration. Standard turnaround time is 3 to 5 days from an agreed booking date.

Call TechRentals and describe your application and what you are trying to achieve and they can describe the instrument(s) that would best suit your application. TechRentals carry an extremely diverse range of instruments from electrical power analysers, endoscopes, thermal imagers, sound level meters, air flow and air quality meters, environmental, health and safety…really it’s too broad a range to describe

They also offer Calibration services for your own electronic instruments and are an IANZ accredited Calibration Laboratory offering both IANZ endorsed and traceable calibrations.

Again, by using overnight couriers TechRentals minimise the time you are without your instrument. Simply email or call them the make and model of your instrument and they will reply confirming if they can calibrate it and provide a quote. calibration@techrentals.co.nz

Supply Services on Stand 130 Supply Services Limited, appearing on Stand 130, is a privately-owned New Zealand business and since 1980 has been servicing a wide-range of primary industries and manufacturing sectors. The company is committed to being the leading performance engineering product supplier in New Zealand, stocking only superior products, backed by qualified staff who are dedicated to providing exceptional service. Supply Services hold substantial inventory of

engineering plastic materials, conveyor and drive chains, sprockets and attachments locally in New Zealand. They offer in-house CAD design, draughting and reverse engineering capabilities, which are fully supported by their own conventional and CNC machine shops. Welding and fabrication services are also available. Supply Services utilises the latest coordinate measuring machines and laser scanning technologies

to 3D digitise machine geometries, allowing them to design and manufacture accurate, machine matched change parts for bottle filling machines used in the food, beverage, pharmaceutical and industrial manufacturing industries. For complete New Zealand coverage, they are located in Auckland, Mt Maunganui and Christchurch. It takes a lot of chain and plastic to keep NZ industry moving!

Trotec lasers for marking In mechanical engineering, many machine components must be marked with data matrix codes for optimal part tracking and traceability.

Trotec offers a wide range of both flatbed lasers and galvo lasers which are ideal for laser marking many materials and parts of all sizes.

In addition, serial numbers, timestamps and company logos are often also added through labelling. The lettering must be durable and resistant to mechanical and chemical stress. When marking workpieces, labelling speed is particularly important, so a fast method such as laser marking is ideal for this task.

Developed and built in Austria and Germany, Trotec sets new standards in terms of quality and user friendliness.

In special mechanical engineering and plant construction, a large number of informational, hazard and type plates are required, which can be engraved quickly and flexibly with the laser.

The flatbed lasers in the Speedy series can be used for the production of information signs. The laser materials – also available from Trotec – can be engraved and cut to size in one step. Trotec also offers galvo laser workstations in all sizes. The software that controls the laser is particularly

unique. Thanks to the SpeedMark marking software, all marking requirements that might come up in industrial production can be simply and intuitively fulfilled. The software is particularly suitable for automated marking processes and covers all processing steps from importing data and graphics to serialisation and right up to the generation of codes (data matrix codes, barcodes, etc.). Visit Trotec on Stand 42 at SouthMach and see how a Trotec laser system can make your business more profitable.

SEE US AT SOUTHMACH

STAND 42

Developed in Austria = Austrian Engineering Manufactured in Austria & Germany = Quality and Reliability Direct support in New Zealand = Experience and Assurance

www.troteclaser.com www.nzmanufacturer.co.nz

NZ Manufacturer April 2019

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The shortest way to do many things is to do only one thing at once. -Samuel Smiles

22-23 May 2019 www.southmach.co.nz

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If you want to live a happy life, tie it to a goal, not to people or things.

HEADING

- Albert Einstein

2019 Exhibitors 3D Printing Systems Ara Mechanical Engineering* Aspex Balluff New Zealand Ltd Barcode Products Baskiville.com Ltd BOC Brush Technology* CAD Central Cadpro Systems Ltd Caliber Design Carrel-Electrade Central Innovation Challenge Partners Cigweld PTY Ltd Competenz Control Devices New Zealand Ltd Design Energy Limited ECI Software Solutions Engineering Compressor Services

85 110 8 116 175 12 69 110 190 112 150 189 146 95 40 54 1 66 94 110

HP Jet Fusion 3D HTC Tooling Kreon Technologies Leap Australia Linak New Zealand Ltd Lincoln Electric Co (NZ) Ltd Machinery House MDH Mardag MESNZ Maintenace Engineering Society of NZ Motovated Design & Analysis*

147 24 147 7 87 55 88 45 138 110

FICEP Genesis Industrial Fasteners Global Communications Haas Factory Outlet

154 157 156 61

National Springs & Wire

132

Omron Electronics Photoetch P L Berry & Associates

135 93 173

NZ Engineering News NZ Safety Blackwoods NZ Welder Supplies Nitto Kohki Australia The Manufacturers Network

194 62 44 155 52

Portable Analytical Solutions Power Tool People (Hindin Marquip) Precision Waterjet Ltd Professional CAD Systems RAM 3D Re-Generate Revolution Precision Machinery Ricoh Rivtec Roadrunner Manufacturing NZ Ltd Saito Scott Machinery Limited SICK NZ LTD SigmaTek Sprockets New Zealand Supply Services Ltd Synergy Electronics Ltd TechRentals The Ministry of Awesome* TiTeNZ Trotec Laser University of Canterbury Viking Weldworx Worksafe NZ

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ADVISORS Mike Shatford

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.

Sandra Lukey

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.

Matt Minio

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 April 2019

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If you are free, you need to free somebody else. If you have some power, then your job is to empower somebody else. -Toni Morrison

Safe and sound Is your smart factory secure? Alarms, cameras, locks and fences are all commonly recommended to keep burglars out of homes. Obtaining clear guidance for securing your smart factory isnâ&#x20AC;&#x2122;t quite as easy to come by. Here Jonathan Wilkins, marketing director at obsolete industrial equipment supplier, EU Automation, discusses smart factory security and what manufacturers should consider when protecting their facility. In a connected factory, manufacturers have access to a constant data stream from the shop floor, commercial operations and supply. The Internet of Things (IoT) generates a huge amount of data, gathered from machines and components, which can be accessed and analysed remotely. Though it brings a facility a number of advantages, connectivity also introduces a vulnerability in terms of cyber-security. With information technology (IT) and operational technology (OT) more closely connected than ever, systems are more vulnerable to attackers. The risk is increased by remote access or third-party access. According to Dark Reading magazine, the second most cyber-attacked industry after healthcare is manufacturing. With high profile ransomware attacks such as WannaCry disrupting large companies such as Honda, manufacturers know they must be vigilant. In the manufacturing industry, cyber-crime is

usually a type of data theft, ransomware or data manipulation. Hackers can modify procedures to disrupt production processes, gain access to private patent data or cause system downtime, all of which can cause serious losses to a company.

collect and store. When updating or upgrading your system, the entire footprint must be considered. This includes accounting for any personal devices such as smartphones, tablets and laptops that are authorised to be in your network.

Engineering businesses must ensure that their operations, data and valuable intellectual property (IP) are protected. Businesses need to understand the limitations of their own capabilities and systems to form a well-rounded cyber-security strategy.

Manufacturing businesses must take a proactive approach to cyber security. This includes having a firewall, but also involves network monitoring. By closely looking at activity in the network, any unusual activity can be marked as suspicious, helping you to identify risks more quickly.

For example, legacy equipment can be a target for cyber-criminals. Old equipment was not designed to be connected to the internet, which means that cyber security was not a priority during its design. Industrial control systems as well as programmable logic controllers (PLCs) have become targets as a result.

Securing operations The first step to cyber security is to assess your digital footprint, understanding what data you

Companies should also consider segmenting their networks, limiting access to the network unless necessary. The more connection points, the greater the risk, so a segmented network can limit the damage done in the case of a data breach. Itâ&#x20AC;&#x2122;s not as simple as securing your home from burglary but securing your smart factory from cyber-criminals is just as important in keeping operations safe.

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NZ Manufacturer April 2019

Always do your best. What you plant now, you will harvest later. -Og Mandino

Semcon increases focus on sustainable manufacturing Demand for digitisation in the manufacturing industry is ever-increasing. Besides creating sustainable production, there are major streamlining benefits and savings to be made. Semcon is now aiming to significantly increase its presence in the industry with a unique mix of digital expertise and extensive experience in production optimisation. “Accelerating our growth in the manufacturing industry is a natural step. We are in the midst of a development that is making new demands of those of us on the boundary between technology and IT – requirements that we are capable of handling here

at Semcon, thanks to our unique mix of expertise and the opportunity to transfer competence between industries. Semcon has extensive experience of robotisation and automation. Adding new technology such as AI presents fantastic opportunities for the manufacturing industry,” says Markus Granlund, President and CEO at Semcon.

Unique conditions Achieving production that is more cost-effective and sustainable requires an understanding of the entire production process and how it can be optimised. Adding expertise in UX, software development and IoT projects into the mix creates unique conditions for future production. “For us, it is all about allowing people to do the things we are best at and allow robots to do what they do best. Always working based on human needs is what allows us to develop technology that really makes a difference. This creates smarter, more efficient and more sustainable solutions,” says Markus Granlund.

A futureproof offering Investments in the manufacturing industry are expected to increase over the next few years so that market demands can be met in a sustainable, cost-effective way. According to a report by PwC industrial sectors worldwide plan to invest USD 900

billion in Industry 4.0 each year. There is a major need for consultancy and analysis in several industries in order to enhance all or parts of the production process, such as life science and the food industry.

Production environment of the future What will happen with production in the future? And what does digitisation mean as regards how production developers work? There are lots of answers, of course, but some of the advantages of Industry 4.0 are: • Streamlining through automation and AI. • Sustainability gains for both humans and the environment. Less waste, cleaner production environments. Less stress, safer and more qualified jobs for people working in production when robots take over some of the work. • Collecting large amounts of data and information in real time leads to improved, proactive maintenance, and digital twins provide control over the entire product life cycle. • Used correctly, this new technology will add benefits for customers and result in new business models.

Your next press release will not be written by a robot Fears that automation will take our jobs are rife but press officers need not feel threatened by new tools that translate technical research into lay summaries.

A robot did not write this article. Copyright: ktsdesign/123rf By Ruth Francis

I recently attended a seminar that looked at tools we can use to help promote research. One of the panelists, Sabine Louët of Science Pod, sparked a discussion I had afterwards with two other press

NZ Manufacturer April 2019

officers about the value we bring compared to what can be automated.

simply straight translations, not in-depth analyses or stories that we and journalists write.

Louët showed examples of news content that was written by Natural Language Processing, a sub-discipline of artificial intelligence. For example, in 2014, the first news article reporting a small earthquake in Los Angeles, California was generated in this way, and others were created from crawling data on street crime or climatic events.

A good press release should do much more than simply translate a research article. We can and should engage the reader and persuade them to find out more. We do this by adding detail gleaned by talking to the researchers, finding out why they did the work and what it adds to the field and beyond.

For those of us who struggle with headline writing, A*STAR and Singapore Press Holdings in Singapore may be able to help: they are using AI to make headlines more engaging without resorting to pure clickbait.

Our ability to improve prose to clarify research, to tell stories, use metaphor and simile, add context and memorable quotes, all differentiate our releases from these summaries. Louët concludes, and I agree, that Natural Language Processing offers an efficient tool for press officers and media to understand research quickly, but the resulting summaries are just a first step. They leave the door wide open for us to create more informative and engaging content.

At Science Pod, they have software that can augment the work of a press officer by automatically creating a lay summary of a research article. In this way, it demystifies the original research much like a press release. Although next-generation summaries should be good enough to publish with little human intervention, press officers need not worry. These summaries are

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As is the case with much artificial intelligence, some aspects of our work could be alleviated, leaving us freer to be more creative with the time we gain.

You have to risk going too far to discover just how far you can really go. – Jim Rohn

200 kilometres in eight minutes: powering the e-mobility revolution

What started as a small start-up in one of ABB’s business units almost a decade ago is now an integral part of the company’s innovative push for sustainable mobility. One innovation after another is coming from ABB developments in electric-vehicle (EV) chargers. The Terra HP is the world’s fastest EV-charger, adding up to 200 kilometres of range to an electric vehicle in just eight minutes. With the number of electric vehicles on the road rising, the global demand for powerful and energy efficient vehicle charging stations is ever increasing. ABB EV-chargers, like the Terra High Power charger, are the driving force behind the efforts of nations to reach sustainability targets and charges have become a critical part of sustainability policies. With more than 7,000 DC fast charging stations installed in 60 countries, ABB is a global leader in that segment. The technology behind e-mobility is truly coming of age, which is also shown in ABB’s partnership with the ABB FIA Formula E Championship. ABB is bringing its name, innovation and technology leadership to the first fully electric motor sport series.

for 20 percent of overall energy usage, the Icelandic government has put in place a state-financed incentive program to increase the use of electric vehicles. It is already having an impact—today there are more than 6,000 e-cars, compared to a scant 90 in 2014. To power these e-cars, more than 20 ABB fast charging stations have been installed along Iceland’s famous Route 1, the 1,300+ kilometre road that’s the country’s main highway and its logistical backbone. ABB has also delivered six 350kW fast chargers in Switzerland, the first with liquid-cooled cables in Europe, as part of the IONITY initiative to open highway “fuel” stations of the future at 400 sites across Europe by mid-2019.

ABB Ability technology guarantees that the chargers are operational 24/7. Remote digital connectivity enables continuous monitoring of the device from any location. This gives access to data in real time for the remote monitoring and proactive control of the operational and technical status of the charging stations. ABB’s fast-chargers help to pave the way for a quick adoption of electric vehicles, which are increasingly becoming more attractive and less expensive to buy and maintain. As policy makers across the world promote sustainable transport solutions ABB will continue to be at the forefront to develop a greener future for all.

The ABB FIA Formula E Championship perfectly supports ABB’s belief that we can run the world without consuming the earth. The series’ next race will be in Zurich on June 10. The ascendance of sustainable mobility and the charging infrastructure required to keep electric vehicles moving is evident by the increasing number of ABB EV charging projects around the world. German energy supplier EnBW alone has 185 EV fast chargers on German motorways and in April, ABB was selected to supply its Terra HP charging stations as part of the biggest electric vehicle infrastructure project to date in the United States. The chargers were selected for deployment by Electrify America, which plans to place hundreds of charging stations within and around 17 metropolitan areas and along multiple nationwide highway corridors. The chargers are an important element, for example, in Iceland’s ambitious plan to increase the adoption of renewable energy. While fossil fuels still account

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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SMART SECURITY

Anything I come across that feels impossible, I probably need to take a second look. -Joe Gebbia (Co-founder AirBnb)

Industrial, logistics and data centres face security risks with moves to 24/7 trade cycles Security of access to industrial, logistics and data facilities is a growing issue in New Zealand as the country moves to 24/7 trading cycles and criminals target activity hotspots for theft, commercial data penetration and trafficking of illegal goods and substances. Global entry solutions leader Boon Edam says the full gamut of industrial production, warehousing, data, distribution and export facilities (including port, road, rail and air facilities) need to be increasingly aware of site security as industry in Australasia follows global trends toward 24/7 responsiveness to world markets.

Its latest products also cover top security facilities, such as data and financial centres, where the highest level of entrance tailgating protection is achieved

using the latest in camera detection systems to help prevent unwanted physical access by visitors tagging along behind authorized personnel.

Boon Edam – which works throughout NZ in partnership with leading access control specialists, HTS Group – says good business risk management practices mean local companies should ensure now that industry facilities are prepared for new security issues arising from the expanding flow of visits to company facilities at different times of the day and night. HTS Managing Director Noel Maharaj says that, as 24/7 business practices expand, more people need access at different times to sensitive areas of company operations, including goods handling, data centres, dispatch, financial and proprietary information across facilities that may be working multiple shifts. In response to the need to provide high security even at times when security staff are scarce, Boon Edam’s latest Turnlock, Lifeline, Tourlock and Circlelock ranges of security entrance products are designed for areas ranging from outdoor company perimeters, through to building entrances and sensitive interior areas.

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Tourlock security entrance technology for industry’s sensitive facilities.

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Ever tried. Ever failed. No matter. Try again. Fail again. Fail better.

SMART SECURITY

-Samuel Beckett

HTS partner the Managing Director of Boon Edam Australia Managing Director Michael Fisher, says business owners frequently and rightly focus on online threats to data facilities, “but there is also another more forgotten dimension to cyber security – and that is protection of physical facilities from unwanted visitors, including industrial intelligence thieves and even sometimes disgruntled former employees,” says Mr Fisher. Boon Edam globally provides entrance security for scores of Fortune 500 companies, as well as banks, data centres, legislatures, government agencies, resource development sites, airports, hospitals and educational and scientific facilities subject to unwanted attention. HTS Group partners Boon Edam in providing security access technologies to these industries while also providing a complete design, system integration, installation and maintenance package to the transportation, traffic engineering and parking industries in Australia and New Zealand. The latest version of Boon Edam’s Tourlock 180+90 revolving door system is designed for access hotspots such as the entrances to company HQs and data and financial centres that might be subject to physical penetration from people seeking to penetrate or damage data facilities vital to trading companies “This latest Tourlock 180+90 system is a 24/7 solution offering high volume capabilities (20 people each way per door a minute) proven by some of the world’s largest companies and government agencies. It is a superbly flexible, non-intrusive way to control physical access and prevent problems arising from unauthorised access to sensitive facilities and areas. It is also an outstandingly cost-effective and reliable way to overcome the problems inherent in expensive manned security systems,” said Mr Fisher. In addition to the latest BoonConnect software to configure the system to individual users’ needs, the

system can be specified to include StereoVision “time of flight” camera systems which create extremely accurate 3D images of the person in the door to determine whether they are alone. StereoVision is even capable of discerning between a person and a briefcase or bag.

Case study Boon Edam installed Turnlock 100 full height turnstiles at a multipurpose Pacific Rim shipping terminal (which cannot be named for security reasons) as part of a large-scale physical security plan to protect one of the largest marine terminals in the region from criminal activity. A.P. Moller Maersk was awarded management of this particular terminal for a period of 30 years. At that time, all entry control and registration activities were performed manually by security staff, which detracted from the effectiveness of procedures and controls. As part of a continuous improvement program, the terminal invested in new access control equipment designed to modernise visitor and employee application processing and auditing standards for objectivity and efficiency.

The system operates 24/7/365 in order to service the high level of traffic. “The product families involved – which have been proven globally with distribution extending over 27 countries – are engineered to provide a cost-efficient way to regulate access to a facility without having to employ an army of security people or to construct facilities that look like a fortress,” says Mr Fisher. “This is particularly true of businesses such as logistics facilities that are part of globally fast-moving industries that have to be able to provide immediate access to people who are entitled to have it – but to exclude unwanted visitors posing threats to physical and cyber security,” he says. Boon Edam security solutions are designed to blend security with corporate aesthetics to provide individually engineered, world-class entry solutions of a quality already in service with dozens of Fortune 500 companies including some of the world’s largest firms. Boon Edam already has more than 100 installations in Australasia of its architectural revolving doors and security entrance systems.

The terminal selected Boon Edam’s Turnlock full height turnstiles to achieve these objectives, for their robust barrier construction and ability to efficiently control the flow of visitors and staff to the facility, who are recorded also via security cameras during entry. In addition to the full height turnstiles, the terminal installed biometric access control systems, electronic barriers for vehicle access, a module to manage visitors, software to register and control personnel access with capabilities such as automatic locks and anti-passback capabilities (a user can only exit if his/ her access has been logged in the system), among others.

Turnlock 100 exterior access system, left, and Turnlock 200 interior system, right.

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NZ Manufacturer April 2019

Extreme people get extreme results.

NEW PRODUCTS

-Sam Altman

Rugged tablets ideal in hazardous industries Getac has announced the launch of its new K120-ANSI and K120-Ex fully-rugged tablets, set to deliver unparalleled levels of safety and performance to personnel operating in hazardous working environments. Digital transformation in the industrial sector has seen traditional paper-based systems replaced with mobile devices that feature integrated RFID readers and barcode scanners, making data collection and management much more efficient.

K120-Ex

However, the presence of flammable gases and dust in many industrial facilities creates volatile atmospheres where a single spark from an electrical device may cause a significant explosion. In order to work safely in such environments, specialist notebooks and tablets that limit electrical and thermal energy output to below dangerous levels and eliminate the risk of sparks should be utilised.

Combining power and safety The K120-ANSI and K120-Ex combine the features of Getac’s popular K120 tablet with anti-explosive, intrinsic safety technology that fully complies with stringent US and EU regulations that govern certification of products for hazardous locations. The K120-ANSI is fully certified for use in all C1D2 hazardous areas (US) while the K120-Ex is fully certified for use in all Zone 2/22 hazardous areas (EU). K120-Ex is also IECEx certified, which is accepted in a number of countries in Asia Pacific including Australia, New Zealand, Singapore and India. The results are two versatile new tablets that can be used to perform key tasks in a wide range of challenging and hazardous environments around the world.

Powerful and versatile in all conditions The K120-ANSI and K120-Ex feature an 8th generation Intel Core i5 and i7 Quad-core CPU for maximum performance, even when using multiple applications simultaneously. A 12.5” full HD widescreen display offers ultimate versatility, while LumiBond sunlight readable technology with rain and glove touch capability ensures screen visibility (1200nits of brightness) and productivity in even the most extreme conditions. Built rugged from the ground up

As digital transformation continues to drive major changes throughout sectors such as oil and gas, petrochemicals and pharmaceuticals, the need for devices that can operate efficiently in every corner of the plant, rig, refinery or factory is becoming increasingly important.

Industrial facilities are tough on equipment, which is why the K120-ANSI and K120-Ex meet MIL-STD-810G military durability standard and IP65 for water and dust resistance. In addition, they boast drop resistance of up to 1.8 meters (six feet) and remain fully operational in temperatures ranging from -21°C to +63°C.

most popular vending devices. SupplyBay is engineered for industrial environments to deliver reliable high-volume dispensing for a wide range of tools and supplies. Its large dispensing door gives easy access to load and refill.

functions to distribute, rent, return for regrinding or reserve products for up to 30 days. SaveRent is a locker-type tool renting and monitoring system. It allows the storing, distribution and return of valuable, frequently used tools and items. Each transaction is saved and recorded when each user accesses an item.

Time to take control Tool inventory and management can be a costly and time-consuming process for any manufacturer. Having greater control over what cutting tools are on-site, how many are available, who is using them and when to re-order, offers significant support and accountability. Dormer Pramet’s ProLog vending system provides such assistance to hundreds of companies in numerous countries, offering individual compartment control in a standard shop floor cabinet at Point-of-Use. In addition to the standard check-in/check-out features, added business rules and reports are available to provide detailed analysis of performance. In addition, users can automatically “age” and lock-down tools based on specific criteria, set-up alert notifications when a tool has reached a defined setting and a full audit history by asset and user. SupplyBay and SmartDrawer are Dormer Pramet’s

The versatile SmartDrawer allows users to choose the best level of access for each application. It can be a stand-alone unit or combined with other devices for a tailored solution, offering a mix of compartment options between 2 - 128 positions in each drawer. To enhance its vending offer, Dormer Pramet has launched several new machines, giving even greater choice to suit individual requirements. The new additions include SaveRing, SaveBin and SaveRent. All the systems help companies move away from peg-board or open access methods. SaveRing is a versatile vending machine which stores and distributes up to 540 unique items. It has four key

With SaveBin employees return used or contaminated items, with the unit taking a photo of the product and logging the transaction to the employee. The system automatically alerts if waste levels reach a pre-defined number. All machines are supported by industry leading data management software. It’s intelligence engine drives all devices, connects with distributor information, integrates with customer-based ERP systems and enables access to real-time information and administration on any web-enabled device.

Lubrication systems enhance reliability Hydraulink mobile service brings its expertise on-site or through a network of well-equipped branches extending throughout New Zealand Ensuring fixed plant and mobile machinery is properly lubricated keeps money in the pocket of owners and operators, as under-lubrication is a

major cause of machine unreliability and downtime due to bearing damage and failure. Ensuring the best and correct systematic application of grease can sometimes be a challenge when the machinery in question is required to be available 24/7 and worked continuously on remote, difficult sites with few breaks. One answer to this issue is automatic centralised grease lubrication systems from Hydraulink, which is New Zealand agent for high quality Lincoln Lubrication pumps and components. Hydraulink’s many branches throughout NZ are experts at installing these handy controllers that enable automatic systems to meet all applications requirements. Hydraulink is ideally placed to provide guidance

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on best industry practice in lubrication through its 24/7 network - with hundreds of service points throughout the country, including both mobile units and Hydraulink regional branches throughout the country. Key industries locally now drawing on Hydraulink services include agriculture, construction and infrastructure, civil engineering, forestry, farming and primary industry, public works, manufacturing, mining, machinery transport and machinery OEM and rental and other industries. These industries depend on Hydraulink’s prompt, expert service coupled with strong supply of quality branded hydraulic hoses, fittings, adaptors and accessories vital to optimising machinery reliability and safety while avoiding costly downtime.

A bad attitude is like a flat tyre, you can’t get very far until you change it. – Unknown

NEW PRODUCTS

Qenos now offers a direct channel to New Zealand manufacturers Qenos - Australia’s sole manufacturer of polyethylene – is extending its specialty polymer distribution group, eXsource into New Zealand. The arrival of eXsource opens a direct channel to New Zealand manufacturers, with a new and expanded product range of local and international specialty polymers. A pioneer in the Australian polymer market, Qenos has been supplying polyethylene to the manufacturing and processing industries for over 60 years. The launch of the New Zealand arm of eXsource means the group now provides the very best product, service and supply to the New Zealand market.

Qenos’ ongoing commitment to the manufacturing and processing industries across the region means New Zealand customers will benefit from the significant investment and ongoing technological advances of the group. With the coverage and scale of Qenos logistics, eXsource customers will enjoy fast lead times, an extended product range and improved service. The new eXsource channel will: • Provide a wide range of polymers from manufacturers such as Qenos, Bluestar, LyondellBasell and others • Offer a broad product range of polymers and additives that are used in flexible packaging films, injection moulding, blow-moulding,

hot-melt adhesive applications, polymer and wax modification, pipe and cable, bitumen modification and other polymer conversion

eGX electrified power unit for commercial-grade work equipment The Honda eGX, an electrified power unit Honda is for commercial-grade work equipment. Honda is currently developing the eGX as an advanced zero-emission electrified power unit without compromising the high reliability and excellent installation compatibility of their GX Series general-purpose engines, which are popular among a broad range of industries as the world standard of a power source for various types of commercial-grade work equipment. The eGX is an advanced electrified power unit which accommodates the needs of the construction machinery market to enable their equipment to be more compatible with usage environments,

considered difficult for engine-powered machines, such as underground tunnels and nighttime construction work near residential areas. While utilising know-how in the areas of durability and reliability amassed through the long history of developing the GX Series, Honda is pursuing the development of this particular eGX prototype on the basis of being installed to construction machineries with high vibration, such as a rammer and plate compactor. Moreover, the motor for the eGX is equipped with a three-phase brushless DC motor, which was developed exclusively for this model, and realises high-efficiency and high-power through outstanding insulation

technology and winding technology for the alternator that Honda amassed through a long history of developing generators. Furthermore, the convenience and operational efficiency of the eGX were pursued through the adoption of a detachable lithium-ion battery pack.

LWC16 lifting wedge handles jobs with restricted access

Each LWC16 unit comes in a custom fitted, blow-moulded case for easy storage and greater portability across multiple job sites.

A powerful new vertical lifting and lowering wedge with integrated handpump has been announced by Enerpac for loads up to 16 tons with very small access gaps down to 10mm. The compact, powerful and portable (10kg) high-pressure (700 bar) LWC16 Integral Pump Lifting Wedge is an extension of the LW-Series family of lifting tools designed to safely lift and lower heavy equipment during operations such as machine maintenance and alignment, and machinery installation and disassembly. LWC16’s integrated hand pump, offers greater

manoeuvrability, operator convenience and safety on more constrained application spaces, says Enerpac National Sales Manager Darryl Lange. The lifting stroke of 21mm (tip clearance 10mm/maximum spread 81.5mm) is ideal for floor level lifts, such as those encountered in industries such as mining and energy, oil and gas, electrical distribution and government utility (including water and waste water and maintenance) as well as transport and industrial workshop mechanical maintenance, manufacturing, and infrastructure and construction engineering tasks. “This integral, sealed single-acting, spring-return hydraulic unit is a convenient lifting solution with quick configuration and set up, which saves time by eliminating the need to make or break hydraulic connections,” says Mr Lange. Enerpac’s LWC16 (top) is part of the broader Enerpac vertical lifting wedge family with safety block (bottom). Other members of the LW family (centre) are compatible with Enerpac RC cylinders and P392 hand pumps

• Each step can be spread under full load • Unique interlocking wedge design with no first step bending or risk of slipping out • Includes safety block SB2 Enerpac’s new LWC16 Integral Pump Lifting Wedge complements the global high pressure hydraulics market leader’s comprehensive ranges of lifting cylinders, pumps, pullers, presses, control technologies and professional bolting technologies widely used throughout Australia, New Zealand and Papua New Guinea. All Enerpac products are backed nationally by its extensive service, sales and technical support networks, optimising their uptime and safety in service even in aggressive conditions and remote locations.

Features of the LW series include:

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NZ Manufacturer April 2019

FOOD MANUFACTURING

Be yourself; everyone else is already taken. -Oscar Wilde

Pure Bottling now BRC Certified Pure Bottling New Zealand from Tauranga has recently added the Global Quality Standard of BRC (British Retail Consortium) to its list of Certifications. This puts Pure Bottling in the unique position of being the only BRC Certified Contract Beverage Packer in New Zealand outside of the wineries. “Gaining a Globally recognised Food Safety benchmark like BRC is an important part of us becoming a world class operation and also allows our customers to gain access to many export markets” Pure Bottling General Manager Craig Ayres noted. “It was a big effort by all of the team to achieve the Double AA Audit result and the benefits can now flow through to our customers” BRC, now in its eigth issue provides a framework to manage product safety, integrity, legality and quality, and the operational controls for these criteria in the food and food ingredient manufacturing, processing and packing industry.

Pure Bottling is a 4 year old organisation started by Group CEO Hamish Gordon and has rapidly grown to become a Production Partner of choice for some of New Zealand’s leading brands and retailers. They are passionate about working with brands that stand for something and want to work together to take quality NZ products throughout New Zealand and Internationally. Now with three production lines in operation across Glass & PET, Pure Bottling is ideally placed to be both a flexible and efficient Co-Packing partner. The Capabilities stretch across Soft Drinks, Juice, Kombucha, Alcohol, Liqueur & more.

What do your motors really do? In 1969, the first home security system was born, consisting of four peepholes and a camera that could be moved to look through any of them, broadcasting the images to a monitor. Nowadays, we can now stream and view a feed of our home security cameras on our mobiles, giving homeowners greater piece of mind. Here, Markus Brettschneider, of ABB’s food and beverage program, explains how food plant managers can add a similar level of connectivity to retrofit most motors with smart sensors to bring their plants to the digital age. Industry as a whole is utilising technologies and solutions enabled through the industrial internet of things (IIoT). Gartner predicts that 25 billion devices will be connected to the internet of things by 2020, with some agencies predicting even double this amount. This presents plant managers with a conundrum. Most food manufacturing and processing plants currently have motors powering essential equipment such as mixers, conveyors and packaging machines.

These motors are just motors and do not play in the same league as the other intelligent devices in their factories. With years of service often left in the motors, it’s difficult for plant managers to justify replacing motors that work effectively for the sake of an upgrade with any smart features. However, there are alternatives to a complete overhaul in order to connect motors to the IIoT. Instead of investing in new, more intelligent or smart

equipment, plant managers should invest in sensors that provide similar functionality to connected devices. For example, ABB offers smart sensors, which can be fitted to almost any standard low voltage induction motor. The pocket-sized sensor, dubbed ABB Ability Smart Sensor, is directly attached in a couple minutes to the motor’s frame, without wiring. By using sensors that feed performance data to the cloud through a smartphone or gateway solution to a secure server, plant managers can bring their motors up to date with the IIoT. This data gives plant managers a full picture — even on mobile devices — of how their motors are working, without having to carry out dangerous hands-on monitoring. Plant managers can then carry out condition based or predictive maintenance, rather than periodic maintenance. Using the right method to monitor motor condition, enables plant managers to reduce unplanned downtime by up to 70 per cent. This is particularly important in the food and beverage industry, where even a short downtime can be extremely costly. Infrastructure failures in this industry cost up to $75,000 per hour and have a serious impact on seasonally produced items such as sugar. This is a cost that plant managers can avoid by using the right performance insight and awareness. An increased awareness of the condition of any motor also leads to a better awareness of how an entire system is performing. For example, a motor overheating or burning out may indicate a problem elsewhere in the production line, such as a line moving too fast and producing waste. Eliminating this problem could improve energy efficiency by up to ten per cent. Motors, the heart of the food and beverage plant, don’t have to be left behind in the age of the IIoT. Just like a home security camera being connected to your mobile phone, a smart sensor could give a motor a new lease of life, making it perform as an integral part of the data-rich factory and providing all the additional benefits that this creates.

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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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Adversity reveals genius, prosperity conceals it.

SUPPLY CHAIN

-Horace

The warehouse of the future Consumers expect a lot when they shop online, frequently opting for next day delivery. In 2017, one Amazon customer was impressed when a product was delivered in under 15 minutes. As consumers expect more from delivery services, manufacturers need to streamline their warehouse logistics. Here, Jonathan Wilkins, marketing director at obsolete industrial parts supplier, EU Automation, explains how manufacturers can invest in automation to improve warehouse logistics.

The UK Cards Association found that UK shoppers spent around ÂŁ154 billion on online purchases in 2016. Companies do not have to deliver all these products in 15 minutes, but they need to offer fast delivery to remain competitive. Rapid technological advances are improving services across the supply chain and is increasing productivity in manufacturing facilities. Manufacturers invest in this equipment to meet the ever-changing demand of consumers that want more customised products. As consumers want more from the products themselves, they also expect more from services,

particularly delivery. Many online sites now offer one day delivery and, occasionally, even less. Warehouse logistics managers must look to new methods to meet demand. The quicker the journey from buy to deliver, the better.

Adding value When warehouse managers look to introduce more technology to the warehouse, they should choose it based on how the technology will increase efficiency, save money and add value to the business. For example, warehouse managers can install a wireless network because many processes are wireless. However, unless they use devices, like smart glasses, the network will not add any value to the business. Warehouses are also full of products, so manufacturers need to be careful to ensure the facility is easy for humans to manoeuvre around the facility and work with the technology.

Machines helping humans With so much going on in a warehouse facility, humans are at risk of injury from handling heavy goods, picking objects from high shelves and having to operate around large infrastructure. Some technology in the warehouse will change

how humans interact with packaging. For example, Automated Guided Vehicles (AGVs) can carry heavy loads, that would not be manageable for humans. This allows human workers to concentrate on other tasks that require a more creative approach. Wearables are also changing how employees can complete their work in the warehouse. Smart glasses did not prove popular for consumer applications, but now, employees wear them to receive information about the task at hand, allowing them to complete it more quickly and accurately. Smart glasses can show employees information on the screen, freeing up both hands to complete the work quickly and efficiently. Hands-free, wearable devices also allow workers to easily move around the warehouse, streamlining their interactions with products and access information from any location.

Smart monitoring As more products enter the warehouse, plant managers need to more to make sure they can accurately track every product on its journey to the customer. Radio frequency identification (RFID) tags are not a new technology, but they are being introduced to the supply chain to improve delivery services. Employees will have real-time data showing the exact location of any product at any time. Some companies are also looking to more advanced technologies, such as drones, for faster deliveries. Technology may not reduce delivery time to 15 minutes for every customer, but it will streamline processes in the warehouse to optimise deliveries in the growing consumer market.

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The secret of getting ahead is getting started.

DEVELOPMENTS

-Mark Twain

Australia and New Zealand receive standardisation for oral fluid drug testing • Standard adds process and technology guidelines for workplace testing The Drug Detection Agency (TDDA) welcomes the new standards for oral fluid testing processes and technologies. TDDA has long believed that oral fluid testing technology and processes required reviewing and to become a joint Australian and New Zealand standard. The AS/NZS 4760:2019 (CH-039 Detection of Drugs in Oral Fluids) Oral Fluid testing standard by Standards Australia and Standards New Zealand dictates consistency around testing methodology, the quality of devices required, and how labs manage test samples. “The new standardisation delivers value to employees and employers alike. It provides a framework and guidelines to ensure that oral fluid testing is carried out in a way that will deliver accurate, reliable results,” says Kirk Hardy, CEO, TDDA. TDDA is on track to be the first to achieve cross Tasman accreditation and provide independent and reliable externally audited oral fluid drug testing collection service to International Standards Organisation (ISO) standards. TDDA-Omega laboratories is also seeking accreditation to AS/NZS 4760: 2019 for the provision of laboratory confirmation services.

“If a drug tester follows the standard, they’ll use a process that ensures the testing carried out meets the requirements of the AS/NZS 4760:2019, giving it more scientific rigour to withstand legal challenges. We’re also in the process of verifying a device to meet the criteria of the new standard” says Hardy.

about oral testing are ‘will this type of test lead to a personal grievance’, ‘will it comply with health and safety’, and ‘will it stand up in court’. Any testing is better than none, but managers should have a discussion with their provider if they’re thinking about changing testing methodologies,” says Hardy.

Even with standardisation improvements with collection, Hardy warns that oral fluid testing isn’t a catch-all testing product, and not all workplace testers are accredited or will follow the standard.

TDDA recommends testing trial periods of up to a year to determine a testing technology matrix that includes oral fluid testing, and measuring metrics such as:

“Businesses who care about compliance and the Health and Safety at Work Act 2015 need to make sure they’re using an independent, accredited, certified tester that follows the new standard. But companies also need to understand it’s not a one size fits all test,” says Hardy.

• Detection rate increases and decreases • Accident rate increases or decreases • Employee wellness • Employee attendance and attrition rates • Subjective surveying of employees and their opinions In developing the standard, Rod Dale, Group Technical Manager, TDDA and Armin Kiani, Chief Toxicologist, TDDA-Omega Laboratories were part of the New Zealand, Australian standards committee that updated AS/NZS 4760-2006 to the new 2019 version. The pair worked with other committee members to create a standard that has been approved by Standards New Zealand and Standards Australia as a published standard.

TDDA recommends utilising a range of different testing methods, such as a mixture of oral fluid, urine and hair testing. All tests have their advantages and disadvantages. Businesses should utilise testing methods to fit the needs of their workplace, and should consider all forms of testing based on what the testing outcomes desired. Hardy says TDDA has been conducting oral fluid testing for companies for nearly two decades. “The most common questions I hear from employers

Government education reform consultation inadequate With the closure of the six week vocational education sector consultation period, a key industry leader has called the process inadequate with dire consequences for the economy. The Government’s proposed changes include the replacement of regional polytechnics with a new, national tertiary training organisation - the NZ Institute of Skills and Technology. The responsibility for the arrangement of training and work-based learning, such as trade apprenticeships, would no longer be delivered by industry owned Industry Training Organisations. Garry Fissenden CEO of The Skills Organisation, New Zealand’s largest Industry Training Organisation (ITO) which represents 22 industries, 4,400 employers and over 10,000 apprentices, is critical not just of the proposed changes but the length of the

consultation process offered to employers and the trade education sector. “The Government is currently spending longer consulting on raising the proportion of egg in imported mayonnaise and reviewing the current import standards for Asian zoo elephants coming in from Australia and Sri Lanka than on its total overhaul to the vocational education system! “We are concerned that so little time has been dedicated to better understanding industry needs and reservations about the proposed changes - which would have a dramatic effect on the career prospects of the next generation of young New Zealanders as well as having an immediate impact on business. “Despite seeing the results of research from more than 900 employers which found the majority say they will hire fewer apprentices if the proposal to

move the managing of apprentices away from ITOs is implemented, the Government remains resolute in its desire to fast track this reform through,” he says. According to latest statistics, apprenticeships are a key employment pathway for Maori - who make up around 17% of all industry apprentices/trainees. In contrast, Maori make up just under 15% of the general population which suggests they will be disproportionately more affected by the proposed changes. “New Zealand businesses need greater access to more affordable training, an increase in the number of trade apprenticeships and better incentives for businesses to take on trainees,” says Fissenden.

Leuze electronic again listed in world market leader index Leuze electronic was included in the world market leader index (WMF index) of the University of St. Gallen as the champion in the field of optical sensors for the first time in 2016. To qualify for the champions category, a company must have an annual turnover of more than €50 million and earnings through exports of at least 50%. Additional requirements are that the company must have its headquarters based in the DACH area (representing the regions and countries with German as their official language), must be active on at least three continents and must also be the market leader in its relevant segment.

They employ around 6 million people worldwide and generate a turnover of 1.5 trillion euros. Leuze electronic has its headquarters in Owen/Teck. The WMF index is generated through objective research and transparently presents world market leaders in the DACH area. The selection criteria and the values determined are disclosed and the entire index is made accessible to the public. The creation and scientific direction of the project is in the hands of Prof. Dr. Christoph Müller of the HBM School of Entrepreneurs, which is part of the Executive School of Management, Technology & Law of the University of St. Gallen. \

Academy of German World Market Leaders and the weekly business news magazine “Wirtschaftswoche”, who once again organised the annual summit conference of world market leaders which took place in Schwäbisch Hall at the beginning of February. In reply to the question as to how a company becomes a world market leader, Ulrich Balbach (managing director at Leuze electronic) explains: “The entire Leuze electronic company pursues a consistent focusing and differentiation policy – in other words, concentration and focusing on the industries intralogistics, packaging industry, machine tools, automotive industry and lab automation.”

Cooperation partners of the project include the

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NZ Manufacturer April 2019

A goal should scare you a little and excite you a lot.

DEVELOPMENTS

- Joe Vitale

Small company wins design award for a rubbish idea Hideaways Bins is the winner of a prestigious international Red Dot design award for its innovative kitchen bin design. Their winning product, called Concelo, is a kitchen waste bin designed to overcome common issues – including grime and odours - associated with the most-used but least-thought-about kitchen appliance. The New Zealand-designed and manufactured Concelo bin was one of more than 6,300 entries submitted from 59 countries for the highly-regarded international design competition based in Essen, Germany. Entries are judged by an international jury panel of 40 experts who only award the sought-after Red Dot seal of quality to products that feature an outstanding design. Past jurors include noted shoe designer Jimmy Choo. The Silverdale-based Hideaway Bins, run by daughter and father team Jamie and Allen Bertelsen, won a coveted Red Dot Award in the Product Design category for household appliances and household accessories. The recognition for Hideaway Bins puts it in good company - other notable New Zealand winners have included Air New Zealand for their SkyCouch design and Fisher & Paykel for their Gas on Glass cooktop and its 60cm Built-In oven. International brands who have received Red Dot awards include Apple, Bulgari, Porsche, Volkswagen, Montblanc, Sony and 3M. Jamie says the goal was to design the best bin possible for the home owner. “We set about this task after applying for and receiving a Callaghan Innovation grant towards research and development costs. It took seven years of research, development and testing but the result is a paradigm shift for a kitchen appliance that is used 20 to 30 times a day

on average.” The company’s investment in R&D has been a crucial part of their success. “We couldn’t have made this fabulous design without the hard work and commitment of our small R&D team. We also used a small focus group of cabinet makers and kitchen designers who gave their time to provide feedback on our early designs. Dad and I accept this award on behalf of our hardworking team and all the people who gave their time to help us turn this idea into a reality. We believe Concelo will ultimately change the way the kitchen design industry will look at rubbish management in the kitchen - a bucket in a drawer will no longer be good enough, as homeowners are far more aware of the need to deal with waste in a smart way,” she says. Concelo is an integrated kitchen waste solution for rubbish and recycling that is clean in both its design and functionality. It exceeds the basic requirements of looking and running like a kitchen drawer, by considering the homeowner’s needs and requirements. Above all, Concelo overcomes two common issues of waste bins –- grime and odours. A key feature of the bin’s award-winning design is its self-closing Active Lid, which is hidden from sight inside the cabinet, helping to control odours. The lid is a game-changer as it is now a true hands-free operation meaning the lid is synchronised with the

opening and closing of the bin. The lid is cleverly designed and can be removed simply for cleaning with the push of a button! The clever Clip ’n’ Clean trays, buckets and liner holders are made from stain-resistant polypropylene. They can be removed effortlessly for cleaning and clip back into position in seconds, eliminating potential dirt traps in difficult spaces. Concelo boasts specially-designed and customised smooth over-extension synchronised runners. Concelo is the first premium waste bin that integrates concealed runners into its design, making it possible for the bin to be mounted at bench height for easy use for the homeowner (no more bending inside cupboards), whilst allowing the back bucket to be removed independent of the front bucket.

New Engineering New Zealand President to focus on diversity Engineering New Zealand’s new President Ben Holland says diversity and inclusion will be a strong theme of his tenure. A Wellington-based civil engineer who is Head of Commercial and Major Projects Governance at WSP Opus, Ben says he is determined to make the engineering profession more welcoming and accepting of all people.

by 2021.

He is a strong supporter of the Diversity Agenda, a collaboration between Engineering New Zealand and the Institute of Architects that’s set a target of 20% more women in engineering and architecture

“I also want to keep broadening Engineering New Zealand’s membership outside our traditional civil and structural spheres, into fields like software and medical-device engineering.

“I want to see the Diversity Agenda ramping up and pushing our industries to embrace all forms of diversity, including diversity of ethnicity, religion and sexuality.

“Together, we are stronger voice for engineers and the critical work they do for New Zealand.” Engineering New Zealand currently has 22,700 members, up from 15,000 four years ago. Ben succeeds Dean Kimpton in the role, which has a one-year term.

New podcast series from HERA New Zealand metals-based industry organisation HERA is solidifying its reputation as a future-focused thought leader with the launch of its bi-weekly podcast series, Stirring the Pot. The free podcast has launched with three episodes on subjects as diverse as the future of manufacturing in New Zealand, innovation as a driver of the global economy and what’s required to build a thriving metals industry. HERA CEO Troy Coyle will faciliate most of the half-hour long discussions, which promise to take on the big issues facing the metals industry. She says, “There are many challenges facing our industry and, equally, many opinions on how we should tackle them. Stirring the Pot is a forum to discuss and challenge viewpoints with leaders, experts and influencers who are shaping the metals

NZ Manufacturer April 2019 /

industry here and around the world. We’re going to be talking the tough stuff – the things that keep us metalheads up at night.” In episode one Ms Coyle talks with globally renowned industrial transformationalist Goran Roos about the potential of manufacturing to transform the New Zealand economy. In the second episode, Ms Coyle talks with Ross Pearce from Callaghan Innovation about artificial intelligence, robotics and blockchain as both disruptors and opportunities, and about how companies like Team Emirates and Rocket Lab have harnessed innovation to take on the world.

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In episode three, she joins a panel of metal industry leaders including Metals NZ Chief Executive Nick Collins and Steel Construction NZ Manager Darren O’Riley to talk about sustainability, advocacy and how to improve productivity across the entire New Zealand metals sector. Future episodes feature conversations with Rowan Larsen from the Human Resources Project about how to retain an organisation’s top performers, and with Application Development Engineer Emily Allison on gaining maximum value from additive manufacturing.

Your big opportunity may be right where you are now.

REAR VIEW

-Napoleon Hill

Digitalisation and the food and beverage industry Wikipedia, the world’s largest free-content encyclopedia, now has over 41,000,000 articles in 294 languages. If printed, the English articles alone would form an impressive, but unrealistic 2,512 volumes. Without digitalization and the widespread use of computers, this amazing wealth of knowledge would be impossible. Here, Robert Glass, global food and beverage communications manager at ABB, explains the opportunities digitalisation presents for the food and beverage industry. Digitalisation encompasses a transformation in the way industrial environments work. For the food and beverage industry, this means companies can better comply with legislation through a transformation in areas including connectivity, smart sensors, traceability, cloud computing and monitoring. The shift toward digitalisation is a natural continuation for leading food and beverage manufacturers, as the president of the Grocery Manufacturers Association in the USA, Pamela Baily explained. Baily said “food, beverage and consumer products manufacturers are leveraging innovation to optimise service to consumers and trading partners.”

Legislation The Centre for Disease Control and Prevention (CDC) estimates that one in six Americans suffer with a food-borne disease each year, and 3,000 deaths are attributed to food-borne illness. When people’s lives are at stake there is no room for error. Therefore, one of the largest concerns for the food and beverage industry is using technology to find the best method to keep well maintained traceability records, which show the journey of food from farm to fork. Similarly, in the EU, the General Food Law Regulation (EC) 2002 requires business operators to keep detailed records of food they supply to others and food they receive from suppliers. Digitalisation aids this process by automatically collecting data such as food temperatures throughout production.

Smart Sensors Well-kept traceability records and sensor data can increase transparency between businesses, producers and consumers. This allows plant managers to respond faster in emergencies and use evidence to rebuild public trust following recalls.

such as Regulation (EC) 852/2004. A similar product, self-chilling beverage cans, produced by collaboration between Crown Cork & Seal and Tempra Technologies are paving the way. As the costs of connectivity reduce, all-in-one products such as this are likely to become common across multiple industries.

Connectivity For the first time in 2016, over half of the world’s developing population had internet access. As internet access widens and the price of networked devices drops, the volume of network traffic will rise. Alongside this, the falling cost of producing devices such as WiFi-enabled temperature sensors mean they will become ubiquitous in industrial environments. However, more sensors lead to more raw data. This higher rate of data production presents issues of how to store and use the data. WiFi connected versions of motion and temperature sensors themselves, when combined with cloud based storage may solve the problem of data capacity. Vast amounts of data can be instantly communicated, stored and even analyzed in the cloud, supplying useful information about traceability, production costs and predictions.

Cloud Although almost sixty per cent of US food and beverage manufacturers use the Internet of Things (IoT) to track and trace ingredients, less than half are using the advanced analytics the IoT makes possible. Cloud analytics, real-time monitoring, virtual commissioning and digital twinning — the ability to recreate the plant virtually — are just some of the techniques now helping plant managers in the food

sector reduce unplanned downtime, improve safety and mitigate food emergencies. Crucially, plant managers can use cloud to adapt to seasonal changes in demand, flexibly altering production setups, factory layouts and even reassigning staff without causing wider disruption.

Monitoring The huge amount of data produced by the connected factory can be used for many purposes in the food and beverage sector. For example, understanding why one machine is running hotter than another, or why one is not picking as many products, can help operators understand the efficiencies of each machine, data that can be used to improve plant maintenance. Many plants are using their own mobile networks to take monitoring to the next level. For example, on farms, sensors are used to monitor soil conditions, using the data to predict when animals are in heat and text the farmer with the information. “In the future, agricultural machinery will work as rolling data centers and sensor technology will provide all the important information in real time” predict PwC advisors. “The challenge for farmers will lie in intelligently networking the technology and managing the data.” Further down the production line, food retailers such as Ocado have built their own high speed 4G networks to communicate with thousands of robots. Raw technical data has its uses, but these are greatly enhanced when the sensor data is combined with maintenance management or financial data. It is this consolidation that allows the information to come into its own and be useful for prediction, past analysis and optimization. Although many businesses will be wary of the perceived complexity of undergoing digital transformation, it can bring about a true competitive advantage. Plant managers of the future should not only recognise the trend toward digitalisation, but they should embrace the opportunities it brings, just as approximately 70,000 active contributors have wholeheartedly adopted Wikipedia, an opportunity produced by consumer digitalisation.

The processed and raw data can be stored and recalled if there are any issues further along in production. Cloud technology has made it easy to store and analyze data, removing any potential for human error by raising alerts and red flags immediately. Sensors can aid traceability in two ways: they improve the accuracy of automated processes and they can track and store a variety of manufacturing data. Time-temperature history, physical shocks and other important credentials can be continuously measured and synchronised across the factory thanks to the IIoT. Sensors used during food production can monitor products throughout the manufacturing and distribution supply chain. Sensors can form part of a device such as a smart container, or act standalone, depending on the needs and conditions of the manufacturing process. In the future, smart containers may be able to self-diagnose and correct, for example by self-heating the container so that it remains above a threshold set out by health and safety guidelines

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NZ Manufacturer April 2019

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