NZ Manufacturer August 2014

August 2014

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COMPANY PROFILE

8

Bellamy & East.

PREVENTATIVE MAINTENANCE New inspection regime passes the test.

20

New opportunity for manufacturers Two Christchurch biotechnology companies, Olympic Biotec Ltd and Waitaki Biosciences, the trading division of PharmaZen Ltd, have pooled their expertise to produce the world’s first 100% krill powder.

The Rimfrost Pristine Krill Powder was recently in the spotlight at Vitafoods Europe, Europe’s largest nutraceutical show, held in Geneva.

Rimfrost Pristine is the first 100% krill powder to be developed internationally, offering a new opportunity for international manufacturers of nutraceuticals and health supplements to extend their range of health promoting omega-3

products – with potential benefits to cardiovascular and joint health among other uses.

The two local companies worked jointly on this project over the past 12-18 months, leveraging off their respective strengths – the high-quality krill raw material of Olympic Biotec, coupled with the acknowledged manufacturing and processing capabilites of PharmaZen.

market opportunity that was a bit of a reach technically. We had a very open dialogue, bouncing concepts back and forward between the companies until we had the product finalised.”

Early feedback from the market has been extremely positive and Olympic is now developing its global strategy to

Written in collaboration with Deloitte Touche Tohmatsu Limited, the study finds that the global manufacturing ecosystem is undergoing a dramatic transformation, with many emerging economies developing significant manufacturing and innovation

Olympic Biotec is one of the fastest growing companies in New Zealand’s biotechnology sector. It achieved sales of close to $10 million in 2012, its first year of operation and more than doubled that to well over $20 million by year end 2013.

John Cameron, managing director of Olympic Biotec Ltd, said it was extremely pleasing to reach this milestone after many months of research, development and refining the manufacturing process.

PharmaZen CEO Craig McIntosh was delighted with his company’s involvement. ”Olympic Biotec identified a significant

Skill shortages a major concern Talent, the ability to innovate and the strategic use of public policy will play a significant role in defining manufacturing sector competitiveness in developed and emerging economies going forward, finds The Future of Manufacturing, a report by the World Economic Forum.

meet this demand, Mr Cameron said.

capabilities, enabling them to produce increasingly complex products, leading to the globalisation of manufacturing supply chains.

Fading labour rate arbitrage, exposure to currency volatility, sovereign debt pressures and emerging protectionist policies will be countervailing forces to further globalisation of manufacturing value chains.

The report highlights the key trends that will define manufacturing competition over the next 20 years and which will require the attention and collaboration of policy-makers, civil society and business leaders.

With an estimated 10 million jobs with manufacturing organisations worldwide that cannot be filled today due to a growing skills gap, the report

identifies talent as one of the key differentiators that will define the future of the sector.

The other top differentiators identified in the report include the strategic use of public policy and the ability to innovate. The infrastructure necessary to enable manufacturing to flourish and contribute to job growth will grow in importance and sophistication and be challenging for countries to develop and maintain.

Growing materials resources competition and scarcity will fundamentally alter country and company resources strategies and competition, and serve as a catalyst to significant materials sciences breakthroughs.

10 million jobs with manufacturing organisations worldwide cannot be filled today due to a growing skills gap

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NZ Manufacturer August 2014

ORGANISED BY

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This is the trade show for New Zealand’s food, beverage, processing and packaging technology industries. Experience the latest technical advances first hand, talk to the experts, and connect with the products, services, and machinery you need to meet the demands of tomorrows market place.

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CONTENTS DEPARTMENTS STUDY 5 CASE Medial Plastics:

ADVISORS Larry Wiechern

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

Turning creative ideas into sustainable business.

6 ANALYSIS Collaborating to compete: A smarter way.

5

7 Delcam launches new PowerMILL CAM.

MANUFACTURING TECHNOLOGY

PROFILE 8 COMPANY Bellamy and East, Christchurch.

Craig Carlyle

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

Catherine Beard

PACKTECH 2014 9-19 FOODTECH PREVIEW

8

Complete packaging services on show.

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

Plastics Industry Awards.

Centra Forklifts on Stand 3129.

Easy palletising with Fuji robotics.

Brian Willoughby

Is president of the NZ Manufacturers and Exporters Association and managing director of Contex Engineers and Plinius Audio.

Foodtech Packtech ready to roll.

APC Technology: Providing industry focussed solutions.

Lewis Woodward

20 PREVENTATIVE MAINTENANCE

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.

New inspection regime passes the test.

22-24 PRODUCT NEWS

Cutting costs for resistance spot-welding light-alloy sheets.

Tool change speeded up.

12 26

Face mill features 16 cutting images.

26-28 THE FUTURE OF MANUFACTURING Building smarter manufacturing with the IoT. Army helicopter can fit in your pocket.

Universal track for robots.

VIEW 31 REAR Outside the silos.

28

Professor John Raine

Is Head of the School of Engineering and Pro Vice Chancellor – Innovation andEnterprise at the Auckland University of Technology.

Bruce Goldsworthy

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

See us on Stand 2001.

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NZ Manufacturer August 2014

EDITORIAL

We’re fast approaching

PUBLISHER

MANAGING EDITOR

an election…

CONTRIBUTORS

And what can I say but, business as usual.

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

Holly Green, Nick Inskip, John Walley Peter Carney, Sandra Lukey, Craig Carlyle.

ADVERTISING

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

DESIGN & PRODUCTION Kim Alves, KA Design T: + 64 6 879 5815 E: kim.alves@xtra.co.nz

WEB MASTER

Dan Browne E: dan@membrana.co.nz

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

DIGITAL SUBSCRIPTIONS E: info@nzmanufacturer.co.nz Free of Charge.

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

Vol.5 No. 7 August 2014 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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MANUFACTURING NEWS the

FactoryFloor www.nzmanufacturer.co.nz

None of the parties appear to have

policies which have business foaming at the mouth, waiting for voting to begin.

Any great ideas ought to be in place during the term of a government not as carrots to capture the punters vote.

For example, take Nationals housing policy, if it is so good for first-home buyers why wasn’t it introduced in the last year or so instead of being seen to be a carrot? People want to buy houses all the time – not just during an election year!

• Assistance for SME’s to keep manufacturing buoyant.

• Incentives to raise productivity in manufacturing. We know the economy is doing okay, slowing a bit, but doing okay.

High productivity is primarily carried through the food and timber industries and there is a need for high value manufacturing to step up like the All Blacks!

It all comes down to getting on with it. The technocrats in your company are as good as anyone at making the numbers stack up, at improving productivity and ensuring a thriving environment.

For businesses, we just put our head down and keep on doing the work because there are no incentives to make the workplace easier like: • Reduced power costs • Availability of tradespeople – lots of positions hard to fill.

Get Generation Z off their IPhones and into the EIT’s!

• The exchange rate for exporters – although a little (unavoidable) flexibility currently creeping through.

Manufacturers’ Trading Post

THE

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

Doug Green

NZ Manufacturer August 2014

Ability is what you’re capable of doing. Motivation determines what you do. Attitude determines how well you do it.

5

CASE STUDY

- Lou Holtz

Medical Plastics Turning creative ideas into sustainable business You could be forgiven for momentarily thinking you have been transported to an idyllic day in Milford Sound when you find yourself at the lights on the corner of Highbrook Drive and Cryers Road, facing the new Medical Plastics building, adorned with the glorious Mitre Peak.

This clean, pristine, and untouched imagery embodies much of what Medical Plastics is about: 100% New Zealand grass roots business, right down to the occasional meetings still held while standing in gumboots in grass paddocks and looking out over the nature beyond.

Established in late 2012, Medical Plastics is still a comparatively new player in the field of plastics manufacturing. However, the company brings with it decades of experience and knowledge from its parent company, Monaghan Plastics, established in 1975 and bought by John in 2006. Under this banner, John founded the Medical Plastics plant in Onehunga to allow the exploration of new niche markets and to infiltrate the rapidly growing market for technical medical plastic products. The recent addition of a second building in Highbrook in such a short time indicates that Medical Plastics is truly succeeding in their claims that they can get their customers’ products to market “quicker and more cost-effectively than our competitors”.

However, it hasn’t been the easiest road for John.

Creating the second office in Highbrook has meant he has had to step back from the manufacturing plant in Onehunga. “The hardest thing has been stepping away from the other manufacturing business. I’ve got some great people, but any business owner knows to

step back and run a business hands-off can be really tough.”

Medical Plastics specialises in “accelerated product development” and innovative ideas. Drawing from their pool of knowledge and expertise built up over many years in the industry, the company is able to offer “expert advice” on the production techniques, designs, and materials that will enable the customer to achieve the best quality result, while remaining cost-efficient and maintaining business sustainability. “If a company or individual has an idea and no clue how to get the product to market, we can help. We can shortcut the R&D phase and help create test market prototypes before major financial commitments need to be made.”

This approach is aimed at helping out “the little guy, or the small company that doesn’t have R&D facilities with limitless budgets” to take high-quality plastic goods to market quicker and with more customer focus.

“Traditional injection moulding requires a production tool that is hugely expensive, but in return the unit price is very cheap. The problem is that you don’t know what the final result is, or if it’s going to be desirable to you or to your customer before spending the money. What we’re doing is making prototype tooling, inexpensively creating a product that can be test-marketed or trialled in house to prove its Nautech building. commercial value.”

Medical Plastics specialises in small assembly items such as crutches with shock absorbers or medication dispensers for your favourite feline friend. They see the greatest opportunities for growth within the animal and health sectors. To John, this is partly because many of the simpler, “less attractive” sectors in plastic manufacturing, such as packaging, have already been dominated by China. As a result, the company has a particular focus on “high-end medical and food grade injection mould plastic manufacturing”. continued on page 31

Commercial & industrial growth

Employment growth

Economic output

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

getba

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Greater East Tamaki Business Association Inc.

6

NZ Manufacturer August 2014

ANALYSIS

You’ve got to get up every morning with determination if you’re going to go to bed with satisfaction.

- George Lorimer

Collaborating to compete: A smarter way Peter Carney, global leader of supply chain advisory and analytics at Aurecon discusses how by collaborating, companies can improve performance and succeed.

For many decades competition has been strongly adversarial, with business practices based on free market behaviours and survival of the fittest. We have been trained to win at all costs, participating in business transactions as if they were a kind of zero sum game. Our win is someone else’s loss and most critically, someone else’s win is our loss. Sometimes this is true, but more often it’s not.

With improving technologies, the nature of businesses is changing and this inevitably impacts on the way they will need to act in future.

When thinking about traditional business models, we tend to think of a business as a highly vertically integrated set of functions. Traditional

There are many examples of organisations with market power that draw more value from the supply chain than they add to it. businesses typically maintained their own manufacturing and transport groups, IT, accounting and HR functions, and other departments.

They did this because the cost of coordinating between functions was high and it was simply more efficient than any alternative model.

Wind forward to today. In a large part due to new technologies and their reducing cost, the cost of coordinating between business elements has become very small. Email, messaging, telephone and video conferencing and internet based applications are readily and globally available. With these technologies, the rationale for companies to hold all functions within their walls has diminished.

Thinking then, we that does in-house,

about a modern business might think of a business not necessarily manufacture does not own its logistics

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assets and possibly outsources many of its functions. Numerous modern businesses have this form and the decisions about which functions to hold close, which to source from the broader market place and which to share are important ones.

In this environment a more nuanced relationship with competitors than a zero sum game would seem possible, appropriate and desirable.

When it comes to the supply chain, the notion of collaborating seems a natural way of operating. Supply chain managers have for many years been synchronising supply with demand along the supply chain between supplier and customers. Technology is making this easier over time, as it is possible to propagate demand signals to suppliers now virtually instantaneously.

More broadly however, companies have been poor collaborators. They have tended to act as distinct entities, and be measured on their discrete activities.

To act more collaboratively is an area of opportunity going forward. It requires companies to conceive of themselves as managers of skills and capabilities, some of which they hold in-house and some of which they source from elsewhere.

Collaborating companies create value when they add value to the web of suppliers and customers in which they operate. Quite obviously, companies that create value for their customers tend to stay in business.

In the logistics world, a collaborative model of business might therefore see businesses combining their freight tasks to achieve higher than individually possible utilisation of assets such as warehouses and trucks. They could achieve this by exploiting a backhaul opportunity or a cyclical opportunity, where one company may require the assets for the winter and another for the summer.

It is easiest to consider such a collaboration occurring for regionally located businesses, where critical mass might be difficult to achieve.

In this case, it is the companies that deliberately choose not to act as distinct entities driving value from discrete activities, that deliver the best value to themselves and the customers they serve.

It seems clear that companies might think about pursuing collaboration opportunities with some vigour.

Equally it is possible that collaboration

might occur between non-competing companies as well as competing companies.

Along the supply chain, the most common form of collaboration has been in action for years – the sharing of order books and forecasts. This could be characterised as essentially transactional.

A reason for success in New Zealand is perhaps the realisation that an individual organisation does not have all the skills, knowledge and resources it might need to be successful. In today’s complex world companies need a great range of skills and it is unlikely a single organisation can hold them all.

A more powerful model of collaboration is where a company shares more than the transactional.

Companies have knowledge, personnel, relationships, systems, facilities, suppliers, competitors and customers. How valued would the company be that can support its customers by providing knowledge, systems and facilities and services; or the one that can support a web of related businesses along a supply chain? And in turn, how efficient, effective and profitable might such a company be?

Technology improvements have significantly lowered the coordination costs between company functions, throwing into contention the capabilities that properly constitute a company. Similarly, due to technology, inter-company coordination costs are very low, and more than ever, the opportunity exists for companies to share some of their skills and capabilities and similarly to leverage those of other companies.

Good examples of elaborate collaboration are evident in food cooperatives. New Zealand has Fonterra and Australia has Murray Goulburn as examples of collaboration by farmers in marketing, milk production and milk product distribution.

The New Zealand fruit industry comprises companies that are mutually supportive.

They collaboratively conduct research and marketing and jointly use pack-houses and further distribution networks.

Two organisations that demonstrate this level of cooperation are Zespri, which in 2012 had sales revenues of NZD 1.6 billion and AVOCO, which recorded sales of NZD 130 million in the season ended 30 April 2014.

Zespri is a corporatized cooperative with origins in a single desk system established by the New Zealand Government.

The Zespri system, supported by all growers, is an integrated production and distribution system, underpinned by a history and practice of planning, scientific and technical research and practical developments.

The same technologies have brought global competition closer – this is the threat that drives a need for companies to get smart and collaborate.

The challenge for managers is to select the skills and capabilities they need to create sustained competitive advantage. They can achieve some of this with intuition, and some using mathematics to indicate where they might find efficiencies amongst the web of customers and suppliers in which they operate.

Drawing from Michael Porter, Professor at Harvard University, we would argue that to be sustainably successful, the nature of the collaboration chosen should be unique. The result will be an organisation that has access to sets of skills and capabilities that are difficult for competitors to replicate. Such an organisation is likely to maximise its efficiency, effectiveness and profitability over the long term.

To collaborate an organisation has to be a little bit socialist and many writers have written on the significance of industry clusters, particularly for manufacturing. continued on page 31

The New Zealand Avocado Company Ltd, which exports avocados under the AVOCO trademark, resulted from the coming together of the two biggest avocado exporters in New Zealand, Southern Produce Ltd, and Primor Produce Ltd. Peter Carney

NZ Manufacturer August 2014

Discipline is the bridge between goals and accomplishment.

- Jim Rohn

7

MANUFACTURING TECHNOLOGY

Delcam launches new PowerMILL CAM for five-axis machining Delcam has launched the 2015 version of its PowerMILL CAM system for high-speed and five-axis machining.

The new release includes improvements to the Vortex high-efficiency area-clearance strategy, improved collision checking to also cover near misses, and more efficient raster finishing.

The Vortex area-clearance strategy produces safe toolpaths with a much deeper cut by using a controlled engagement angle that maintains the optimum cutting conditions for the whole toolpath. As a result, higher feed rates and material-removal rates are possible, making the cutting time shorter by as much as 70%.

Previously, all entry moves had to be made by plunging onto the surface or by ramping into the material.

The second change allows an increased feed rate to be set for non-cutting moves. The default value is set at double the rate for the cutting moves but this can be altered as required for each machine tool. The extra time that can be saved depends on the shape of the part but an additional saving of around 20% should be expected above the earlier releases of Vortex.

In addition, cutting is undertaken at a more consistent volume-removal rate and at a near constant feedrate, so extending tool life and protecting the machine.

Another problem in previous versions of PowerMILL was that unnecessary lifts could be added to area-clearance toolpaths when the cutter moved outside the stock or close to its edge.

Changes to the roughing algorithm in PowerMILL 2015 have reduced the number of lifts per toolpath slice to the minimum needed and so made area clearance much more efficient.

Two enhancements in PowerMILL 2015 will give even greater reductions in machining time with Vortex compared to conventional roughing. The first change allows toolpaths to approach the part from outside the stock at the cutting height, both for open pockets and in areas where earlier cuts have made this possible.

Companies using PowerMILL for either positional or continuous five-axis machining can benefit from improvements to the collision checking within the software. Firstly, collision checking has been changed so that warnings can also be flagged for near misses. The user can now specify a clearance value and when the machine

tool comes within this value it will turn yellow in colour to highlight a near miss. Collisions are still be shown by a change of colour to red.

Secondly, the display showing the list of collisions, and now near misses as well, has been updated to be easier to read, making it simpler to extrapolate the coordinates at these points. For near misses, the clearance distance is shown in the display, with the distance shown as zero for collisions.

Another improvement will help companies using four- or five-axis machines with trunnions or similar tilting tables. Previous PowerMILL toolpaths could exhibit unwanted changes of azimuth as the cutting tool approached a position vertical to the part. This would slow down the machine, often to the extent that a witness mark would be left on the surface. New options are now available to specify the information used by PowerMILL to distribute the toolpath points so that the machine’s gimbal-lock position is avoided and a smoother motion results.

the part. In previous versions, the user had to select each area and specify the angle manually. The new option, which provides the same functionality that already existed for steep-and-shallow finishing and face milling, is most beneficial when finishing a series of pockets aligned in different directions.

A number of improvements have been made to the PowerMILL interface.

Most important is a clearer form for the strategy selector that makes navigation easier when choosing which strategy to use. It has also been made easier to create folders of strategies, for example, those most suitable for a particular machine tool, material or type of part, and to add and remove strategies from those folders.

Finally, three new curve-creation options have been added to the curve editor – ellipse, spiral and helix. These options can be used to create patterns or boundaries when generating toolpaths.

Raster finishing has also been improved in PowerMILL 2015, with the software now able to set automatically the most appropriate angle for each region of

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NZ Manufacturer August 2014

COMPANY PROFILE

Advice is like snow; the softer it falls, the longer it dwells upon, and deeper it sinks into the mind ~ Samuel Taylor

Bellamy and East Bellamy and East is a long-established company based in Christchurch, specialising in leaf and coil spring manufacture and repair. The joint input of owners Anton and Mary Van Tongeren has seen Bellamy and East change to a fully-computerised system within their workshop.

They took over the business in 1999 and employ seven full-time staff, who

between them have over 65 years of experience in the industry.

Anton Van Tongeren talks to NZ Manufacturer.

NZM: How long have you been in business?

Anton: Over 15 years.

NZM: What got you started?

Anton: We were young (in our 30s) with a small family and looking to become self employed. We spent around four years looking and missed out on another opportunity and took this one.

NZM: As a New Zealand manufacturer, how do your products compete with overseas products?

Anton: Our products are sold alongside imported products and we also repair, which overseas producers do not do.

NZM: Is research and development important for your company?

Anton: Ours is an old trade and not much has changed in the process over 50 years for our local market.

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NZM: How often do you need to upgrade your equipment?

Anton: It is difficult to find new equipment so we must fix our existing and source used machinery where possible.

NZM: What equipment do you use?

Anton: Large, heavy, old machinery as well as custom built new machines.

Mix with like minded people and ask plenty of questions.

Anton: One of our business premises was affected and is in the process of being rebuilt. We were lucky enough to continue manufacturing throughout the time with minimal downtime.

NZM: Do you export?

Anton: No NZM: Favourite business quote?

Anton: “Treat others as you would have them treat you” NZM: What inspires you?

Anton: Like minded people.

NZM: How are you finding business conditions in New Zealand now?

NZM: If you were starting out in business today what would you do?

Anton: Due to the nature of our business as a repairer as well as a manufacturer we are finding ourselves adequately busy.

Anton: Mix with like minded people and ask plenty of questions.

NZM: How did things change for your business after the Christchurch earthquake?

the

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NZ Manufacturer August 2014

FOODTECH PACKTECH 2014 Centra Forklifts on Stand 3129 Centra Forklifts has been the exclusive NZ agent for Mitsubishi forklifts for over 30 years. It operates from 6 sites around the country - complimented by a national dealer network.

It provides for all material handling requirements – including sales, parts, rental and service. Centra is also the exclusive NZ agent for the JCB Teletruk and Zowell warehouse equipment range.

Centra represents a different business from the pre-GFC version. According to NZFMDA data, material handling companies had to contend with almost 50% reduction in the volume of new forklift sales between 2008 and 2009.

This represented approximately 900 new units, and changed the shape of the industry for a period of time.

The NZ market for new forklift sales can be characterised as follows: a small

increment in the amount of annual units; a large and increasing range of brands being supplied; highly price competitiveness; an eroding degree of brand loyalty and a lack of incentive to invest in new forklifts (either driven by false economy or in some cases caused by genuine product quality and longevity).

Despite this situation the market has recently recovered to volumes that were last experienced during 2008, and furthermore Centra have managed to report record sales and market share results. The source of this success lies in several key areas: • Its people - our family-owned culture delivers superior customer service and a focus on customer demands • Diversification – a renewed focus on strengthening its range of services to its forklift customers • Its products – Mitsubishi have offered new model equipment right across the range and with a refined supply chain pricing is very competitive. In this quality line-up

when

reliability is everything!

Plastics Industry Awards entrants to feature Plastics New Zealand, the Industry Association for the Plastics Manufacturing Industry in New Zealand, will feature this year’s entrants to the New Zealand Plastics Industry Biennial Design Awards on their stand at FoodTech PackTech 2014.

range of products and applications from Food & Beverage, Primary & Industrial, Consumer and Environmental Categories, through to new processing Technologies and Material Development that have been commercialised in the past 2 years.

The 2014 New Zealand Plastics Industry Awards acknowledge and promote excellence in the creation, design, production, manufacture, and marketing of plastic products or components.

Plastics New Zealand, in conjunction with Competenz, will display all entries at the Industry Awards Showcase Evening and Gala Dinner on Friday 3rd October 2014 in Auckland. Dr Mary Quinn, CEO of Callaghan Innovation will be in attendance as our honoured guest.

These Awards are an opportunity to showcase an Industry; renowned for its innovation and entrepreneurial ability. Entries are judged not only on concept, design, commercial performance and export potential, but to an increasing extent, on sustainable design and manufacturing practices considering the full life cycle of products.

This

year’s

entrants

cover

a

proactive improvemeNt reduce risk

“We saw that the Enviro-Mark certification would provide us with everything we were looking for.”

“The Enviro-Mark Platinum accreditation removes the confusion for the consumer.”

New ZealaNd’s leadiNg eNviroNmeNtal maNagemeNt certificatioN provider

You’ve achieved Enviro-Mark Platinum certification now. Tell us about some of the improvements you have made along the way.

We now separate all our rubbish into their various streams: steel, plastic, cardboard which has led to a 60% reduction in waste going to landfill. We schedule all our production so that the primary driver is to minimise our energy use and reduce our water consumption. An example of how we have taken our EMS to the smallest level: we wash & sanitise all our own toilet handtowels, factory cleaning cloths & overalls internally. Re-using all our cleaning cloths over and over is better for the environment. We use environmentally-friendly cleaning detergents – made by us - in the process.

Any other benefits apart from cost savings?

A large number of our staff have told me that through what they have seen at work, they have improved their own recycling habits at home. They are also mentioning how they are influencing their friends’ recycling habits. In short our EMS programme is spreading beyond our own four walls into the wider community, which is fantastic to be a part of.

What are the environmental challenges of operating a manufacturing facility?

To be the leader in their field ecostore has committed to a very progressive research and development programme. ecostore is expanding domestically and internationally, and continually developing new products. For us as their manufacturing facility it is very important we continually review our processes and procedures to ensure our EMS is keeping pace. We need to be very dynamic, as does our EMS. What challenges to implementing an EMS have you encountered along the way?

As one example: when we were attempting to track where stormwater goes from our car park. We had to communicate with government departments and local councils. This turned what we thought would be a simple process into a rabbit warren! The ‘system’ sometimes doesn’t make it easy to be good. We got there in the end.

What has been the key to your success?

The most important thing was that we knew exactly what we were heading into. We had 100% commitment from our Board members and management. We resourced ourselves appropriately,

0508 FORKIT (367 548) info@centrafork.co.nz www.centrafork.co.nz www.nzmanufacturer.co.nz

Stand # 3129

o8oo eNmark

w w w.eNviro-mark.com

NZ Manufacturer August 2014

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FOODTECH PACKTECH 2014 Moving goods around the world The Gavan Group commenced business in 1988 when the Directors, Gavin Condon and Andrew Corstorphine, perceived the need for a company to supply all parts and accessories required by Intermodal marine transport equipment operators, hence the formation of Gavan Container Products.

Since this time the Gavan Group of Companies has expanded through the network of branches to become the world’s largest supplier of Shipping Container related products. With eighteen (18) warehouse and office operations in nine (9) countries throughout Australasia, New Zealand, the Pacific Rim, South East Asia and Mainland China they will continue to expand their operation throughout Asia, providing a professional and efficient equipment service.

Gavan has over 24 years expanded the product range from Shipping Container repair spare parts and accessories to include a wide range of Transport, Cargo Care / Protection products, Lifting and Safety Products, Marine Lashing, Rail and Rolling Stock Lashing systems, Military Lashing Systems, Light Engineering and Manufacturing, as well as a Plastic Pallet division.

Supplying quality products sourced locally and from around the world at competitive prices Gavan Container Products use a sophisticated computer controlled stock inventory, dispatch and accounts systems providing customer tailored billing to ensure customer satisfaction.

and range of products. They have formed new companies with the Gavan Group such as Gavan Container Products, Secure A Load, The Plastic Pallet Company, The Intermodal Equipment Alliance and GavanKR to name but a few.

In 1998 Gavan formed a strategic alliance with two major container parts suppliers one based in Europe and one based in America; this then led to the formation of the “Intermodal Equipment Alliance” which gives the Gavan Group a truly global reach and coverage.

Intermodal Repair Products:-Supply products used in the repair and manufacture of ISO Shipping Containers, including Dry Freight container, Refrigerated containers, ISO Tank container and specialized Shipping containers and domestic office/ house containers.

Gavan Container Products staff has a unique blend of experience and skills in the international container/ shipping, transport industry and rigging industries. This experience is invaluable when ensuring the correct parts and accessories, are supplied.

The commitment of the management and staff will ensure the organizations continued growth and development as the premier transport parts and accessories service company.

Transport Products:-The Truck Body Parts division has a comprehensive range of products used in Load securing and lifting equipment including Tiedowns, Load Binders, chains and fittings, shoring bars, Twistlocks for truck decks, container ramps, connecting links, corner boards (plastic and cardboard), cargo hoop sets, F-Track, door hardware, Furniture Blankets, security seals and of course Door Locking Systems, Lashing rings, Aluminum and Stainless sheet.

All staff are dedicated to providing excellence in their technical approach and service to customer requirements.

After being in business almost quarter of a century the Gavan Group continues to expand in both geographical areas, and continues to expand their quality

General Business Area

Cargo Care Products:- The Cargo Care Division has a comprehensive range of protection products not only for shipping but inland transport and storage protection products such as; Dunnage Bags, with appropriate

inflation equipment (Air Guns), plastic container liners, slip sheets, Shoring Products (Jacking Bars), insulation blankets, In-transit temperature recorders, antiskid pallet connectors, dangerous goods labels, moisture control in various packaging types (Moisture poles, Blankets, Silca gel pellets) Lifting and Safety Products:- Lifting Slings, both Round and Flat Web Slings, Lifting G80 Chain, Leather Gloves, Foot ware, Eye protection and Safety Decals Marine Products:- Ship Lashing, Transfer and Securing Systems are an important part of the Gavan Product range, We are able to supply complete Lashing Rods, Turnbuckles, Stacking Cones and a full range of Automatic & Manual Twistlocks to choose from, as well as dovetail, U-frame, semi-automatic, bottom, single stackers, bridge fittings, deck fittings, lifting slings and of course wire rope.

Rail Securement Products:- Rail Twistlocks and refurbishment of Rail operators existing Rail Twistlocks, Cargo Protection products for cargo on and in rail wagons.

Stand 2112

ICS provides on-site design facilities for machinery and conveyor systems.

We have a wide range of specialist expertise and can design a customised system for your requirements.

Design

Simulation Commissioned

Applications / Industries: · Concept To Commissioning · High Quality Systems · Plant Up-Grades · Customer Satisfaction · Simulation · Project Management · Design · Plastic Modular Belts

· Thermodrive Belting · Flexmove Conveyors · Modular Systems · Niko Overhead Conveyors · ARB & DARB Technology · Box Handling · Dairy Industry · Cheese Processing Machinery

· Red Meat · Chicken · Fish · Bakery · Packaging · Vegetables / Fruit · Snack Foods · Robotic / Automation

Innovative Conveyor Systems Ltd

I_1976

Secureaload, a member of The Gavan Group of companies, is appearing at Foodtech Packtech on Stand 3057.

Phone: 07 850 4299 • Fax: 07 850 4298 • Mobile: 027 273 4907 • 23 Sheffield Street, Te Rapa, Hamilton, NZ • PO Box 20-363, Hamilton, NZ www.ics-conveyors.co.nz

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NZ Manufacturer August 2014

FOODTECH PACKTECH 2014 Complete packaging services on show Packaging House, a major distributor of foodservice packaging, cleaning, hygiene and industrial consumables in New Zealand, is appearing on Stand 3131 at FoodTech PackTech being held at ASB Showgrounds, Auckland from 23-25 September 2014.

It’s a great opportunity to find out the different ways Packaging House can work with the food industry - and to see their exciting new machinery range.

Packaging House actually delivers more products, to more industries, through more branches, than anyone else.

Whether they’re supplying coffee cups for cafes or latex gloves for surgeries, Packaging House take care of the everyday essentials needed to keep business running smoothly and efficiently.

Their wide-ranging expertise also extends to the food processing industry – and Packaging House can deliver a healthy menu of options to ensure food production is safe and risk-free.

This includes the ability to supply you with the expertise needed to make HACCP part of your business.

Serving Up Food Processing Expertise In addition to HACCP compliant hygiene consumables, to compliment and complete your Risk Management Programme, Packaging House now have new ranges available: a full range of food processor brushware, metal detectable tools and hygiene consumables, a personal safety range and a complete stretch film, tape and strap machinery, and consumables range.

They also have a choice of finance options available, from outright purchase, to lease, lease to own and amortisation.

The Right Solutions No one knows a business like the person who runs it, that’s why a specialist from Packaging House takes the time to get to know your business and discover what it needs to operate day to day.

Armed with this knowledge, they can get to work and deliver solutions to help your business run like a well-oiled machine.

Collective Buying Power Thanks to Packaging House’s collective buying power, they can deliver better prices across the widest range of products. Combine this with the lower administration costs of dealing with one supplier, and your procurement costs will come down quickly.

Better still, Packaging House can supply you with just one invoice - so your time won’t be taken up dealing with multiple orders from a range of suppliers.

Procurement Made Easy Everyday ordering has become a breeze, thanks to Packaging House’s website and Electronic Data Interchange (EDI) /connections capability. It’s there 24/7, allowing you the freedom to place orders or access information whenever you need to. And it’s loaded with features designed to make procurement simple and efficient, such as compliance to preferred product lines, and detailed tracking and reporting.

Once orders have been placed, efficiency remains a priority. That’s why Packaging House offers the choice of pick-up or fast delivery from any of its warehouses across the country. This means your business is less likely to be slowed down by a lack of supplies.

All this delivers you with more time to focus on your core business.

Local Knowledge, Global Efficiency Packaging House understands the importance of keeping informed about global trends and developments. That’s why they’re always on the lookout for new products to make life easier for customers.

The Packaging House global sourcing office in Shanghai has developed a strong network of global suppliers across all their product categories.

They can also ensure the quality and performance of all globally sourced products, so customers can have confidence in all aspects of the supply chain. www.nzmanufacturer.co.nz

NZ Manufacturer August 2014

13

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

– Voltaire

YOU SUPPLY THE FOOD, WE’LL ENSURE HACCP IS ON THE MENU.

At Packaging House, we can help you ensure your food production is safe and risk-free. That’s because our team can supply you with the expertise needed to make HACCP part of your business.

We’re also experts in sourcing and delivering everyday business essentials – something we’ve been doing for over 40 years. We can supply you with stretch film and strap, workplace cleaning products, safety, kitchen and cafeteria products, and more. And with nationwide warehouses, you won’t be slowed down by lack of supplies.

All this gives you more time to focus on your core business.

Better still, our One Source model makes procurement simpler and can significantly reduce your costs through reduced vendors, consolidated Your Company Coded Zones invoicing and Colour collective for HACCP buying power.

Request your FREE onsite appraisal from a Packaging House specialist by emailing your name and contact details to marketing@packaginghouse.co.nz

Your Company Colour Coded Zones for HACCP

DELIVERING MORE expertise Visit us at Foodtech Packtech, Hall 3, Stand 3131, ASB Showgrounds Auckland, September 23-25, 2014. www.nzmanufacturer.co.nz

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NZ Manufacturer August 2014

FOODTECH PACKTECH 2014 High capacity, easy palletising with Fuji robotics Fuji Ace have been developing, supplying and improving palletising technology for nearly 40 years. In 1982 Fuji recognised the changing market and met the demands of the palletising industry by developing the first Robotic Palletiser.

They have since perfected the mechanical and electrical aspects of robotic operation to match the needs of virtually every palletising application currently available, with over 10000 installations in operation.

Aurora is excited to announce the addition of the Fuji range of Robotic Palletising systems to its extensive range of process equipment on offer. Aurora have for many years provided superior machinery for the Bulk Materials Handling industry and as solution providers we are able to combine modular type equipment for materials handling plants large and small. The addition of the Fuji range of Robotic Palletisers means Aurora offers its clients the choice of a high capacity, economical solution to handling bags and boxes on their packaging lines.

As a specifically designed palletising robot the Fuji-Ace system provides many benefits over conventional robotic arm alternatives. The Fuji-Ace Palletiser reduces space and power requirements, provides the highest capacity cycle available, and is easily programmed and adjusted from the specific palletising controller, removing the previously time consuming task of programming the robot. Up to 30 stacking patterns can be programmed

into the robots memory.

Fuji also utilises a point to point control system that further reduces and simplifies programming time, with only the pick and drop points needing to be programmed for the first two layers.

Aurora provides full automation and pallet transfer systems, specified to suit whatever application within all production environments. At Aurora we stand close behind our product and our industry leading brands are backed by expert advice, premium product, installation and scheduled servicing, that is second to none. All this is ultimately designed to make your next decision an easy one. No matter what stage of your process you’re at right now, make Aurora your process equipment partner.

To view a demonstration of the Fuji Robot visit our stand #3078 at the Foodtech Packtech Exhibition, held at the ASB Showgrounds Auckland, 25th – 27th of September 2014.

SE

PALLETISING,

AURORA CAN HANDLE IT

E ON A F OU UJ R IR ST OB AN O D TD #3 E 07 MO 8

With over 10,000 Robotic Palletisers installed worldwide Fuji is unmatched in palletising technology.

Experience, focus and dedication to the industry have enabled Fuji to provide the best solution to your palletising needs. > No1 Palletising Robot worldwide > High speed palletising & energy savings acheived simultaneously

> Up to 1800 cycles per hour > Pallet Dispenser, pallet wrapper and transfer accumulation options

CALL US AND EXPERIENCE OUR QUALITY SERVICE TODAY 0800 55 77 33 | www.aurora-nz.com www.nzmanufacturer.co.nz

NZ Manufacturer August 2014

15

FOODTECH PACKTECH 2014 LineView takes automated production line monitoring to the next level Workflow Ltd is pleased to launch their latest production line-monitoring tool, LineView, into Australia and New Zealand, to compliment and build on the success of the existing XL Visual Productivity Appliance.

LineView is a web based and automated advanced line monitoring system that is modular and scalable from one machine to a multi machine production line, making it a cost effective option for many manufacturing operations.

LineView identifies the effect of downtime on the overall line output without the need for any operator intervention. It provides real time and historical information in an easy to read format, enabling the Production teams to focus their efforts on taking action to reduce the losses rather than spend time interpreting the data.

The system has been designed by Operational Experts.

LineView is built on the iView ‘black box’ solution, which provides a platform for manufacturing data and incorporates a unique advanced true causal loss logic engine.

To identify the root cause of your machine stoppages LineView provides high resolution automated trending of PLC fault codes on each machine.

This unique feature enables you to see the causes of your downtime and their effect on the line.

Key features of LineView include: • Automatic data capture including uptime, downtime, rejects and planned stops • Gives you an overview of the entire factory as well as each production line and machine.

• Genuine causal downtime • Real time 6 Loss Analysis on your bottleneck machine

• Full historical analysis • Web based interface • Live machine trending and Efficiency Figures for every machine • User configurable reports

screens

and

• Visual System - Graphic overlay of your line. Instantly see the state of every machine • Operator comment entry • Inbuilt tactical review process

Workflow Ltd specialise in assisting manufacturing companies improve their productivity through supplying cutting edge production monitoring solutions, along with training and coaching to implement structured communication, data review and continuous improvement processes to get the most from the data collected.

Data is only of value when it is used in the correct way, Workflow assists you get results from your data.

LineView (developed by LineView Solutions Ltd) has been in use for the last 12 years with some of the most recognisable names in manufacturing in the UK and Europe, and Workflow is pleased to now be able to offer this to Australian and New Zealand manufacturing companies.

Workflow will be demonstrating LineView at the Foodtech Packtech 2014. 23-25 September on Stand 3044.

Improve your Manufacturing Productivity Workflow Ltd helps you see how your plant is really performing with the XL Productivity Appliance • Visual plant floor display • Automated tracking 100 KPI’s • Real Time • Accurate • Downtime, OEE, speed • Changeovers, • Planned downtime • Web interface access • Built in reports • Historical trend charts • Top 5 loss focus • Bolt-on, Self install • Simple

90 Day Trials available Not sure?

See for yourself how good it really is

Workflow Ltd

Ph: 03 579 2999 Visit us at Foodtech Packtech Stand 3044

www.wflow.co.nz

www.nzmanufacturer.co.nz

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NZ Manufacturer August 2014

FOODTECH PACKTECH

Foodtech Packtech 2014 ready to roll The event that food, packaging and technology professionals have been waiting for is just about here. Held once only every two years, trade-only Foodtech Packtech 2014 will be bigger and better than ever.

It attracts the cream of the crop because it’s the only place where those in the industry can network with their peers and get up close and hands on with the newest and best technology from around the world.

on whole birds while scanning the product for contaminants.

The Pack 550 PRO delivers reliable and precise contaminant detection required for compliance with stringent HACCP protocols and retailer food safety requirements.

Additional inspection modes including mass measurement, component count, fill level, and seal inspection ensure product integrity, maximising your return on investment.”

eliminated.”

Innovation is the keyword everywhere at Foodtech Packtech, even for the humble jerry can. “In addition to our cube style Fortress Jerry cans, the market told us that they wanted a premium style for agricultural and horticultural based products that would make their product stand out when placed alongside their competitors’ in a retail environment,” explains Heather Allen of ES Plastics. “From this requirement comes the Swing Handle family of Jerry Cans. There was also the need to make these jerry cans compatible with plastic recycling programmes such as Agrecovery and Plasback where the containers need to be triple rinsed.

“The Swing Handle Jerry Cans all feature the same fitting, as well as base dimensions. It is only the height that varies offering 10 and 20 Litre capacities (Dangerous Goods approved) with a 15 Litre option pending. There are lots of other innovative features that visitors will discover at Foodtech Packtech. All in all, the new Swing Handle range of Jerry Cans is the new generation of containers for all markets where you want to be offering your customers the best package!”

One global problem will have a new solution revealed at Foodtech Packtech.

Eriez Magnetics will introduce a new product that’s been called ‘The Extreme Metal Detector’. All new from the ground up, with feature packed controls, Eriez’s new Xtreme Metal Detector sets the standard for best in class performance and offers the greatest dollar-for-dollar value of any detector on the market.

This feature-rich, multi-frequency unit is designed to achieve the highest levels of sensitivity to detect small ferrous, non-ferrous and stainless steel metal contaminants in sanitary and non-sanitary environments, and particularly suited to the food industry.

The value of attending Foodtech Packtech is proven when you consider that metal and contaminant solutions are also a feature on another stand – in one place on one day you can compare solutions and talk to the experts from each supplier.

“The Eagle Pack 550 PRO delivers superior contaminant detection and quality measurements for large and varied sized packages,” notes Tania Carey of Food Processing Equipment.

“It’s ideal for packaged chicken with its ability to ignore ‘aluminium’ clips www.nzmanufacturer.co.nz

in material handling. UniGripper is the most effective and universal vacuum tool on the market. UniGripper project engineers have a long and wide experience solving the most difficult applications and use their knowledge to customise the UniGripper to fit your needs.”

The ‘big picture’ is covered at Foodtech Packtech as well. The Clean Water accord is vital to New Zealand’s status as an environmentally responsible country, says Tony Rumbold of Scanz Technologies. “The large Dutch company and international supplier Aqua Industrial Water Treatment B.V. will have a presence on our stand.

We’ll be highlighting the technologies that are available for treatment of the waste water exiting our primary industries, as well as other types of food processing. Our solutions will allow treatment to standards required by the EU and other jurisdictions, and secure New Zealand’s position as a responsible exporter. This is vital, and a reason why we’ve an expert from Europe in attendance.”

There is more to Foodtech Packtech than suppliers showing the latest and greatest – with many also offering

Business solutions to other problems are also a feature, including comprehensive conveyance solutions that create significant economic value, such as those offered by Intralox.

“With more than 40 years’ experience, we continue to lead the way,” says Brandon Campo.

“We pushed past the boundaries of traditional conveying systems with the revolutionary invention of modular plastic belting, and continue to move beyond industry standards with new products, equipment, solutions, and services. Intralox’s commitment to innovation has led to over 700 patents currently in force around the world. If our customers have a need, we invent smart solutions to solve them.

“Just one example is the Intralox DirectDrive System which advances spiral conveyance by eliminating the most common issues related to product migration, belt tensioning and sanitation. This new technology is ideal for applications where product orientation, belt life, and grease/oil buildup are concerns.

DirectDrive simplifies spiral operation compared with conventional systems – overdrive and associated controls are no longer needed, while surging is

Another stand that will offer plenty to see – and a hands on experience – is Romheld Automation with its UniGripper intelligent vacuum grippers, which visitors will be able to try on different products. “When Tepro Machine & Pac System launched the UniGripper in 1997, little did they know that it could be used in so many different applications,” says Peter Hope. “Today it’s become new standard

show-only specials. This is a complete business event and includes seminars,

NZ Manufacturer August 2014

networking opportunities and valuable presentations and displays. One not to miss is the exhibition of the Pride In Print Award winners.

“The great innovative winning work will be on display at Foodtech Packtech to both showcase the expertise available and spark ideas,” notes Sue Archibald.

“The winning work always attracts a wide audience as it has appeal across several sections of industry from customers through designers to manufacturers looking for a point of difference for their products. The Awards is not affiliated to any one company so the appeal to view this work is often enormous because of its neutrality.”

Foodtech Packtech is 23-25 September 2014 at the ASB Showgrounds, Greenlane, Auckland.

17

ATTENTION

All Health And Safety Officers Slippery floors are a serious safety hazard and one of the greatest causes of workplace accidents. Colourgrip® eliminates this overnight and brings them up to Code. Our incredibly robust resin and aggregate system boasts nearly 20 years’ experience, saving lives on roading networks around the World.

Visit the event website - www.foodtechpacktech.co.nz

With Colourgrip® now available to NZ industry, if you need to stop your fork hoists from skidding, create highly visible and grippy staff walkways, line marking that won’t wear off, and have a Best Value mind-set then you need to talk to us.

Phone 09 274 42 84 Mobile 022056 7799 www.colourgripsurfacing.co.nz enquiries@colourgrip.co.nz Visit us on Stand 2015

Auckland 23-25 September

Goodman Fielder upgrade milk factory to meet Asian demand Goodman Fielder, the Australian food ingredients maker, will spend $27 million to expand its Christchurch ultra heat treated milk plant, giving it additional capacity to meet increased demand for its Meadow Fresh brand in Asia.

of traditional pastoral farms to dairying. Higher payouts are enticing farmers to increase milk production, and dairy factories are having to step up production capacity to cope with the surge.

Work to extend the existing UHT building and install a new pasteurising, sterilising and palletising line as well as a new 250ml high-speed filler is expected to be completed by October 2015 and will boost production at the site by 50 percent, enabling it to process an extra 32 million litres a year, Sydney-based Goodman Fielder said in a statement.

“The premium UHT category in Asia Pacific is anticipated to grow by around 50 percent over the next five years,” Goodman Fielder chief executive Chris Delaney said. “We are investing now to meet that demand and also plan for future growth.”

Increased demand for milk powder from China, driven by an expanding and wealthier population that is embracing western foods, has pushed dairy cooperative payouts to farmers to a record high and underpinned the conversion

Construction of the new building and production line will require 40 full-time equivalent roles for the 8-month construction period and the increased production will also require 12 new roles, the company said.

www.nzmanufacturer.co.nz

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NZ Manufacturer August 2014

FOODTECH PACKTECH APC Technology Providing Industry Focused Solutions - Designed for Food & Beverage Production Environments, Abattoirs & Meatworks Since 1984, APC Technology has designed and manufactured specialist computer solutions for use in some of the most severe environments on earth.

APC Technology’s Food and Pharmaceutical solutions are ideal for a range of environments including production & assembly lines, hose down areas, food production and livestock management applications within abattoirs & meatworks & pharmaceutical manufacturing environments.

With many established clients across the food processing /manufacturing sectors, APC Technology has an extensive understanding of the industry and enjoys a proven reputation as a comprehensive, reliable solutions provider who meets the evolving needs of their clients.

APC Technology has recently launched a range of ruggedised stainless steel cabinets designed for use in F&B environments where high pressure hosing is required. The enclosure size can be customised to house a range of equipment as specified by the client or fit the APC Technology range of panel PCs and displays.

APC Research, the design group within APC Technology, worked with a leading food producer in South Australia to create a design which would meet the high standards demanded within an F&B environment. This includes a fully sealed unit which water cannot penetrate, corrosive resistance to chemical cleaning agents and a streamline design eliminating gaps and collection points with a specific focus on the base. The design allows water to be sprayed under

the pedestal to dislodge any food products.

Scott Begbie, Managing Director at APC Technology commented, “As a company we strive to meet the needs of our clients, so to this end our cabinets are designed to meet the demands of a production area whilst also offering a range of customisations. If a client needs a certain size or height cabinet, we can meet their demands. If they need a range of input options we can do that too. We offer computing solutions which are cost effective but also designed for a company’s requirements.”

Additional features include manufacturing options of 304 stainless steel or 316; adjustable stainless steel hinges designed to pivot in a range of directions as specified by the client; integration of the Roxtec gland

system with optional I/O configuration and a slide out tray for easy access to equipment.

APC Technology will be showcasing a range of panel PCs, displays, fanless computers and mobile devices during FoodTech PackTech. If you need a dedicated stand-alone workstation or a fully integrated production system, APC Technology can provide a qualified, turnkey solution to meet requirements.

See APC Technology on Stand 3142 or visit www.apctechnology.com.au.

Computing Solutions for Tough Conditions Celebrating 30 years designing & manufacturing

state of the art computer/control technology packages for defence & industrial businesses.

Solutions designed specifically for farming and food processing industries Engineered to survive shock, vibration, extreme temperatures & environments Customisation options to meet the clients needs including I/Os, user interface & mounting

Built to Last

See us on

Stand 3142

www.nzmanufacturer.co.nz

Waterproof

Sunlight Readable

www.apctechnology.com.au Tel: +61 (0)8 8363 0400

Fully Sealed

Introducing

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

– Voltaire

NZ Manufacturer August 2014

19

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

Developed by AsureQuality, inSight™ provides shoppers with independently verified information about the products they are about to buy.

After a successful application process, producers can place the inSight™ logo and a QR code on their product packaging.

When shoppers scan the QR code at the point of sale they can access information about the product, including: • • • • •

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

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

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

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NZ Manufacturer August 2014

PREVENTATIVE MAINTENANCE

There is nothing impossible to him who will try.

- Alexander III

New inspection regime passes the test Ever since the announcement of a complete overhaul of New Zealand’s health and safety system there has been no denying that the government agencies have worked hard to heed the clarion call for change.

The feedback of SME’s was very clear during the discovery phase of change; health and safety is confusing, complicated and turning to the official experts (the old DOL) for advice could be career limiting. The solution was to provide a one-stop shop that provided pathways to all the information businesses need to stay safe and compliant.

The challenge is for the health and safety consulting group is to step up and change its delivery.

improvement notices, 19 prohibition notices and 5 written warnings. Metal manufacturing made up 37% of the visits and 45% of the notices, yet food and beverage and woodworking sectors were cut from a relatively similar cloth. While MESNZ advocates more carrot and less stick, it must be said that these results indicate an endemic level of complacency or lack of knowledge.

Worksafe NZ reported an initial hurdle of “brand”; businesses confused about who Worksafe NZ is. The problem cuts deeper than this though; MESNZ has collated reports from a number of sources of at least one private health and safety company playing on its brand name to further confuse business owners and get a foot in the door. Business owners be warned, WorkSafe NZ is the ONLY brand that officially represents health and safety.

Meanwhile the inspection results are clear; machine guarding in the Metal sector is the most common hazard area found, followed by “Other Hazards” and then noise. Inspectors found a mix of good and bad sites, but generally found larger companies more aware of their responsibilities.

for solutions, but Worksafe NZ has delivered on its promise to deliver web based information, the inspectorate has been (and continues to be) abundantly clear on its inspection content and there have been NO reports of draconian inspection results.

Where there IS a problem, is the gap between Worksafe NZ and business, a vacuum filled by health and safety consultants. While the government has put the solutions into the public domain, making sense of it is still daunting and confusing to the uninitiated.

Such businesses need confidence and simplicity if they are to embed health and safety management into their other business management.

The challenge is for the health and safety consulting group is to step up and change its delivery. One thing for sure, the scaremongering and overcomplicated approach employed in the previous 20 years failed everybody except the consultants.

It may still have a bureaucratic flavour but WorkSafe NZ must be credited with stepping up to the plate with its new (and still developing) website and inspection regime.

However, far too many companies were unaware of their responsibilities and did not understand the hazard identification and management processes.

Inspectors reported businesses are “thirsty for knowledge” and don’t have an issue with making improvements.

As an example, MESNZ has researched the gap between the actual inspection results and recent guarding consultant’s recommendations. It found that companies are being fed recommendations that are out of step with the inspectorate and in some cases are putting directors at more risk by imposing guarding solutions that will fail over the working life of the plant.

The first round ‘pilot’ inspections across Auckland, New Plymouth and Tauranga have been completed and the results published. From 62 inspections, WorkSafe NZ issued 90

MESNZ believes the government has made a good fist of its efforts in the best manner that you could expect from bureaucracy. Ok, it is not (yet) the easiest website to navigate

MESNZ has not seen any guarding recommendations that focus on safe systems of work, yet this was identified by inspectors – “guarding removed”.

Unlike an automated machining

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 www.nzmanufacturer.co.nz Manufacturing Processes

centre, a jobbing machine guard that can cope with the full potential of jobs and still allow safe operator input is often not feasible from the tradesman’s experience.

Take the full swing of a centre lathe over the complete length of the bed.

Add any toolpost attachments (other than a conventional turning tool) and their span as well as any projections from the rear of the headstock.

We have all seen them and they are a reality over the lifespan of many machines. This is what safe systems of work are designed for, coping with the impossible.

Safe systems of work allow the business to guard for the obvious and predictable, but come up with a safe and repeatable process for the extreme situations or the man-machine interface. What they then need to become expert in is their safety processes, no different to manufacturing sites coping with hot work permits, lock out procedures etc.

If the gap between businesses with their heads in the sand and ‘safe’ workplaces is to be closed, then finding solutions that are people-centric rather than drilled down, cover-your-butt exercises would be a great place for the health and safety industry to start.

NZ MANUFACTURER • SEPTEMBER 2014 Issue • Features

www.nzmanufacturer.co.nz

The Future of Manufacturing Workshop Tools Food Manufacturing Contract Manufacturing Advertising Booking Deadline –18 September 2014 Advertising Copy Deadline – 18 September 2014 Editorial Copy Deadline – 18 September 2014 Advertising – For bookings and further information contact: Doug Green, P O Box 1109, Hastings 4156, Hawke’s Bay Email: publisher@xtra.co.nz

Editorial material to be sent to : Doug Green, P O Box 1109, Hastings 4156, Hawke’s Bay Email: publisher@xtra.co.nz Tel: 06 870 9029 Fax: 06 878 8150

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.

2014 NZ Manufacturer August 2014

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

– Voltaire

21

Kingsgate Hotel, Hamilton 12th - 13th NOVEMBER

2 Day Con ference $6 Bring a m 80 + gst ate and it’ s $440 + g st each!

E

xhibition s pace from : $800 + gs t

Register O

nline Toda y: www.m esnz.org.n Email: info z/nmec @ a dminonca Phone: Le l l.co.nz anne Pow ley (09) 29 6 1333

TAKING KNOWLEDGE BACK TO THE WORKPLACE! Information, Inspiration & Interactive Displays

Get in early to reserve your place And maximize your exposure... www.nzmanufacturer.co.nz Free public trade expo, Tuesday 11th November 2014

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NZ Manufacturer August 2014

PRODUCT NEWS Tool change speeded up The new rapid clamping system “Quick Tool Unlock” for tube bending machines allows quick change of the bending formers without tools and therefore reduces set-up time noticeably.

The rapid clamping system is comprised of a split tension rod with clamping lever as well as a swivel device.

While in customary models the continuous tension rod to the swivel cross arm needs to be unscrewed at the top of the bending former for a tool change, the procedure is much simpler with the Quick Tool Unlock.

Here, only the clamping lever is actuated and therefore the connection

to the swivel cross arm disengaged.

The swivel device can subsequently be opened so that the bending former is exposed to the top. In interaction with the automatic tool clamping, the bending former can be removed without any difficulty.

There is no longer any need for the previously necessary unscrewing of the bending former. The work-saving technology is absolutely self-explanatory and quick. Another plus of Quick Tool Unlock: All connections from static to rotating parts are carried out via rolling bearings which contribute to the durability of the machine.

When a man has put a limit on what he will do, he has put a limit on what he can do.

- Charles M. Schwab

Pendant control stations to suit your need With that in mind, the Mike pendant station range from TER serves as the perfect complement to the existing Charlie range of ergonomic, hand-held pendants.

The Mike pendant station range is ideal if there is a requirement for several machines to be controlled using one pendant or for other auxiliary commands to be sent such as slew left/right, with the capability to facilitate up to 14 buttons in a single row. A comprehensive range of operator symbol inserts and label/symbol sheets are available to describe every combination of functionality required.

The contact arrangement has also been simplified in the new Mike range of pendant stations with

dual speed operation achieved via the pushbutton actuation rather than multiple versions of contact blocks (early make, etc).

A reliable and efficient method for the auxiliary control of lifting elevators, hoists, conveyors, and many other industrial lifting and motion applications, the Mike range of pendant stations ensures minimum machine downtime and most importantly, peace of mind.

Double Octomill High Feed optimises roughing operations Designed to increase metal removal rates in steel and cast iron applications, the new Seco Double Octomill High Feed face mill features 16 cutting edges per insert and brings versatility, productivity and economy to roughing operations.

The “Quick Tool Unlock” System from Schwarze Robitec simplifies tool change and is easily understood.

SCREW

MANUFACTURER Buy NZ Made

Prompt Delivery • Self Tappers • Wood • Machine • Thread Cutters InSteel, Stainless & Brass Ex stock & made to order

Screw Productions Ltd

07 348 8050

W www.screwproductions.co.nz E info@screwprodutions.co.nz Postal & Factory - 12 Davies St, Rotorua www.nzmanufacturer.co.nz

While traditional face mills typically use inserts with four edges, the Double Octomill High Feed, available in diameters from 80 mm to 160 mm, incorporates insert pockets with a negative axial angle that allows for double-sided inserts with a total of 16 cutting edges. The inserts themselves use a positive rake angle to minimise power consumption while achieving higher cutting speeds for a significant increase in productivity.

Seco has further enhanced the cutter’s performance by grinding location grooves on the inserts to ensure precise and stable positioning in relation to the edge and seat of each insert pocket, which allows very tight tolerances to be held. Each pocket incorporates a strong centre lock screw and axial and radial high speed steel (HSS) location pins that mesh with the insert grooves.

These pins increase tool life because the pockets do not wear out as fast when compared with a traditional face mill. Additionally, the Double Octomill High Feed cutter body features a hard HV 700 coating that protects the tool from wear and prevents chips from welding onto the cutter.

Seco offers a comprehensive ON09 insert range for the Double Octomill High Feed, with three first-choice insert geometries (M12, M14 and MD16) and four first-choice grades (MP1500, MP2500, MK1500 and MK2050). This range of inserts allows the cutter to be successfully applied across a wide range of steel and cast iron applications. The Double Octomill High Feed is available in normal pitch versions.

In terms of machining parameters, manufacturers can combine a shallow depth of cut with high feed per tooth and use the Double Octomill High Feed to achieve higher metal removal rates and increased part production.

Such parameters also increase process stability and tool life by directing the cutting forces axially, which reduces the risk of vibration.

the

FactoryFloor

NZ Manufacturer August 2014

Habits are safer than rules; you don’t have to watch them.

And you don’t have to keep them, either. They keep you.

-Frank Crane

23

PRODUCT NEWS

Cutting costs for resistance spot-welding light-alloy sheets Welding technology specialist Fronius International has further evolved the pincer guns used in its acclaimed resistance spot-welding process DeltaSpot.

Now available, this second generation of pincer-gun improves both the serviceability and the technology of the system, leading to shorter production downtimes at customers’. A further benefit of these improvements has been to lower operating costs still further, allowing light-alloy sheets to be joined even more economically and with consistently superior quality.

Among the outstanding features of these pincer guns are their extremely rugged build and straightforward interface- and maintenance concept.

This clears the way for widespread introduction of this innovative resistance spot-welding process in large-scale series production.

Users can look forward to working with a new generation of pincer-guns that has been designed – right down to the last detail – for deployment in large-scale production.

The core elements of the second generation of pincer-gun are its reshaped carrier body and the fundamental redesign of the pincer-gun arms and drive motors.

Unlike in the previous generation, where the process-tape reeling and unreeling devices, the arm adjustment mechanism and the servo-electric main drive were all integrated within the pincer gun, these components are now located directly on the carrier body.

By ‘decoupling’ the components in this way, the Fronius engineers have made the construction of the pincer-gun arms both simpler and stronger, which is an absolute ‘must’ in aluminium spot-welding. Even in the standard

version, the pincer guns now come with a powerful MFDC transformer that runs at 1000 Hz. Another result of this is that the system readjusts once every millisecond during welding, in order to achieve perfect results. The transformer and the rectifiers have also been moved closer to the electrodes so as to reduce transmission losses.

As part of the overhaul given to the mechanical design, Fronius also restructured the interface between the carrier body and the pincer-gun arms, to make it even more modular. This means that far less design work and equipment are needed when the pincer gun has to be individually adapted to a particular welding task. It also provides greater flexibility regarding the pincer-gun geometry and the ‘window’ between the arms.

The new pincer guns are much quicker to maintain and service, as assemblies such as the transformer, the motor control box, the tape drives and the main drive now feature high-quality plug-in connectors and can be changed in just a few simple steps when needed.

Fronius have also made it even easier to replace the process tape, with no change in the principle underlying the welding process itself: In this, a specially coated metal tape is guided between each of the electrodes and the weldpiece, protecting the surface of the electrode from soiling. It moves on to the next position after every weld-spot, with the result that unlike in

conventional resistance spot-welding systems, the electrode contact surface always remains clean, and exactly the same initial situation is ensured for every single weld-spot.

This leads to significantly lower soiling of the electrodes and ensures consistently high-quality weld-spots, up to 10,000 times per tape, with no need to clean the electrodes using complicated electrode milling cutters.

The process-tape mechanism has been overhauled on the basis of insights gained from the first generation of DeltaSpot machines. The tape feed has been redesigned for even greater robustness, and the reeling and unreeling device has been amalgamated into a single compact unit.

As well as the standard 12 mm wide process tapes, it is now also possible to use optional 16 mm wide versions.

This new feature broadens DeltaSpot’s range of application still further.

The drives of the new generation of pincer-gun are also equipped with a fail-safe brake. One of the advantages of this for the system operator is that the time-consuming reference cycle is no longer necessary after an automatic pincer-gun changeover, meaning that production can be restarted more quickly.

These innovations give users of the DeltaSpot process a new generation of pincer-guns that has been designed – right down to the last detail – for deployment in large-scale production.

In conjunction with the cutting-edge graphical control software ‘Fronius Xplorer’, DeltaSpot provides an optimally tailored solution for spatter-free resistance spot-welding of light alloys, with consistently high joining quality.

The hassle free apprenticeship service Apprentice Training New Zealand recruits, employs and manages apprentices to train in your business.

0800 526 1800 www.atnz.org.nz www.nzmanufacturer.co.nz

24

NZ Manufacturer August 2014

PRODUCT NEWS

Most successful men have not achieved their distinction by having some new talent or opportunity presented to them. They have developed the opportunity that was at hand.

- Bruce Barton

SCENE 5.3 laser scanning software scan registration without targets Faro’s SCENE 5.3 software, for use with the Laser Scanner Focus3D X Series, delivers scan registration by eliminating artificial targets, such as spheres and checkerboards.

Users can choose from two available registration methods: Top View Based or Cloud to Cloud.

Top View Based registration allows for targetless positioning of scans.

In interiors and in built-up areas without reliable GPS positioning of the individual scans, targetless positioning represents a highly efficient and largely automated method of scanning.

The second method, Cloud to Cloud registration, opens up new opportunities for the user to position scans quickly and accurately, even under difficult conditions. In exterior locations with good positioning of the scans by means of the integrated GPS receiver of the Laser Scanner Focus3D X Series, Cloud to Cloud is the method of choice for targetless registration.

New D curve and 100mA din-safe RBOS

variety of project requirements. For instance, Correspondence Split View matches similar areas in neighbouring scans to resolve any missing positioning information, and Layout Image Overlay allows users to place scan data in a geographical context using image files, CAD drawings, or maps.

New D curve and 100mA din-safe RBOS Complementing the highly popular DIN-Safe long body RCBOs (DSRCBH series),is the D curve trip characteristic and 100mA RCD sensitivity options.

Common features of the DSRCBH series include its compliance to AS/NZS 61009, single module width of 18mm, 10kA short circuit breaking capacity in C curve, Type ‘A’ RCD with 10mA or 30mA trip sensitivity and neutral and earth (PE) flying leads, perfect for installation in NHP’s Concept Panelboards.

SCENE 5.3 is the ideal tool for processing laser scanning projects.

Faro’s cloud-based hosting solution, SCENE WebShare Cloud, allows scan projects to be published and shared worldwide via the Internet. The collective upgrades to FARO’s laser scanning software solution, SCENE 5.3 and WebShare Cloud 1.5, make even complex 3D documentation projects faster, more efficient, and more effective.

The D curve trip characteristic complements these existing features and is suitable for high inrush current loads whilst 100mA RCD sensitivity is suitable for installation/equipment protection purposes where 30mA sensitivity is not required.

This expanded range means there are D curve and/or 100mA options to suit varied application requirements.

In addition, the software also offers various new processes that enable the user to flexibly respond to a wide

Power source three independent phases in one device The 6003A Three Phase Electrical Power Source is a cost-effective instrument that provides the superior accuracy and performance of three independent phases in one compact device.

The 6003A is accurate enough for calibration laboratories, with specifications of plus-or-minus 0.038 per cent for power and plus-or-minus 0.01 degree for phase.

Its compact form factor also makes it easy to transport and maintain in manufacturing companies, electric utility meter shops, and other organisations that manufacture, maintain, and calibrate power

meters, energy meters, power quality analysers, and similar tools.

The 6003A delivers the accuracy and features found in more expensive three-phase systems. It provides three independent phases of precise voltage and current. It also sources power quality phenomena, including harmonics, interharmonics, and dip/swell variations. It includes measurement capabilities for dc voltage, dc resistance, and frequency for measuring outputs from power and energy transducers.

Because it’s a single instrument, the 6003A is easier to transport to test workloads in situ, takes up less

bench space, and is more cost effective to maintain than multi-piece units. Its graphical user interface enables users to set up complex harmonic signals quickly and easily. It also makes the instrument remarkably easy to learn and use, so new users become productive quickly.

Specialised capabilities can be added, including an energy option, which adds a pulse counter and pulse output; a power quality option that enables the 6003A to calibrate power quality instrumentation by generating up to 63 harmonics, an interharmonic,

modulation (flicker), and dips and swells on all three channels; and a 90 A adapter with high-current leads that generates up to 90 A from a single current phase to manage high-current workloads.

Are you a Kiwi manufacturer who is NOT appearing in NZ Manufacturer?

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B&B Electronics Improves Work spares us from three evils: boredom, vice, and need.

Efficiency at Baked Goods Plant

NZ Manufacturer August 2014

25

– Voltaire

Industry: Industrial Automation and Manufacturing Product: Ethernet to Serial Server

• The Challenge A contract manufacturer for baked goods had recently installed a new packaging line. The upgrade introduced an industrial Ethernet network to the plant and was very successful. The process engineer wanted to use this new technology to optimize the efficiency of baking ovens on the baking line. But the thermometers, level sensors, scales, and conveyer system all communicated via RS-485. None of this equipment was near its end-of-life and it represented a huge capital investment. Replacement was out of the question. The company needed a costeffective way to link the packaging line to the Ethernet.

• The Solution B&B Electronics provided an Ethernet serial server. Designed for industrial applications, the serial server was rugged enough to take its place on a factory floor while connecting the RS-485 ports to the new Ethernet network. Suddenly the entire line could be monitored and controlled from the factory control room.

• Why B&B Electronics?

The product was easy to set up and integrate into the existing system. The Ethernet pass through port allowed the product to be daisy chained without purchasing additional switches. The company preserved its legacy equipment investment and increased plant floor productivity at the same time.

• The Product Vlinx™ Model VESR922T – Ethernet to Serial Server • Expansive serial, fiber combinations • Wide temperature and power ratings • Slim, industrial DIN rail mount enclosure • Web-based management • Optional second Ethernet pass-through port

Model VESR922T

USA and International Headquarters p: 815.433.5100 f: 815.433.5109 url: www.bb-elec.com Europe, Africa, Middle East p: 353.91.792444 f: 353.91.792445 url: www.bb-europe.com 2912

Represented in New Zealand by Connection Technologies Ltd P.O.Box 39340, Te Puni Mail Centre, Lower Hutt Tel. 04 5665 345 Fax. 04 5665 347 Lewis@connectors.co.nz www.connectors.co.nz

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26

NZ Manufacturer August 2014

THE FUTURE OF MANUFACTURING Building Smarter Manufacturing with the Internet of Things (IoT) Since the Industrial Revolution, manufacturing has been transformative for countries and companies. In 2012, the World Economic Forum published a research report titled ‚The future of manufacturing: Opportunities to drive economic growth.

The research stated manufacturing has been immensely important to the prosperity of nations, with over 70% of the income variations of 128 nations explained by differences in manufactured product export data alone.

In 2012, The Economist claimed we are entering the third industrial revolution, which is based on the digitization of manufacturing. Others refer to this as ‘Smarter Manufacturing’.

According to a December 2013 survey by the American Society for Quality (ASQ), only 13 percent of the manufacturers surveyed said they use smart manufacturing within their organisation.

Of those organisations that claim to have implemented smart manufacturing, 82 percent say they have experienced increased efficiency, 49 percent experienced fewer product defects and 45 percent experienced increased customer satisfaction.

The development and adoption of the Internet of Things (IoT) is a critical element of smarter manufacturing.

Though manufacturing companies have been implementing sensors

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and computerized automation for decades, the sensors, Programmable Logic Controllers (PLC) and PC-based controllers and management systems are largely disconnected from IT and operational systems.

These systems are organised in hierarchical fashion within individual data silos and often lack connections to internal systems. There are several reasons for these legacy structures, including significant security issues.

These legacy structures differ from the open, highly connected IP network structures that play such a large role in the value propositions of IoT. While the transition to more open network architectures and data sharing of IoT poses challenges in manufacturing and industrial markets, the combination of IoT, Big Data, and M2M optimization will bring profound opportunities.

IoT describes a system where items in the physical world, and sensors within or attached to these items, are connected to the Internet via wireless and wired network connections. The Internet of Things will connect and share data from inanimate objects. IoT will also gather and transmit data from sensors connected to living objects such as people, animals and plants. IoT will connect everything from industrial equipment to everyday objects that range from medical devices to automobiles. IoT can share this data with systems and with people. z In the case of manufacturing, high

value production equipment has been heavily instrumented for some time in a closed, hard-wired network environment. Industrial standard sensors, controllers and networks are expensive and upgrade projects in existing facilities are not easy.

The growth of IoT on the consumer side has driven cost reductions in sensors, controllers, and communications through high volume semiconductor manufacturing. However, industrial standard equipment is constrained by a huge installed base of legacy equipment and standards.

As costs of industrial standard ‘smart’ sensors with IP communications and embedded controls falls, these solutions will be implemented across the whole range of manufacturing equipment and in new areas that have not seen the investment in automation, such as Balance of Plant (BoP) equipment and supply chain logistics.

IoT will benefit manufacturing companies by collecting data from these sensors and communicating that data to factory floor workers, plant managers, software systems and many aspects of the supply chain.

Where’s The Value in IoT for Manufacturing?

Bosch, a German manufacturer of consumer and industrial products, refers to the next wave of manufacturing with IoT-enabled systems as Industry 4.0. Stefan Ferber, Director for business development of

the IoT at Bosch Software Innovations, said ‚”Industry 1.0 was the invention of mechanical help, Industry 2.0 was mass production, pioneered by Henry Ford, Industry 3.0 brought electronics and control systems to the shop floor, and Industry 4.0 is peer-to-peer communication between products, systems and machines.”

The basic principle of Industry 4.0 is the essence of IoT and smart manufacturing.

By connecting machines, a manufacturer can create intelligent networks along the entire value chain that communicate and control each other autonomously with significantly reduced intervention by operators. Bosch, GE and Johnson Controls describe an IoT-enabled vision where machines predict failure and trigger maintenance processes autonomously rather than relying on unreliable monitoring by maintenance personnel.

Another IoT example is self-organised logistics that react to unexpected changes in production, such as materials shortages and bottlenecks.

Manufacturers will use technology to deliver dynamic, efficient, and automated manufacturing processes.

IoT delivers new value by connecting: People Connected sensors will provide an unprecedented level of visibility into the factory operations and supply chain flow in a much broader range of manufacturing than just the

NZ Manufacturer August 2014

27

Take chances, make mistakes. That’s how you grow. Pain nourishes your courage.

You have to fail in order to practice being brave.

- Mary Tyler Moore

very high value processes currently enabled. Iota in manufacturing will improve business by connecting people to the right information, over the right device at the point of need and cross company boundaries to include suppliers, maintenance partners, and distribution chains.

New mobile-ready software will allow plant managers to have access to data such as equipment efficiency, line efficiency, data visualization tools and alerts from any location at much lower costs than previous custom systems.

Process In the first phases of IoT deployments, manufacturers will seek visibility into specific visibility and supply problems.

Manufacturers may deploy these systems of use third party managed solutions to get started.

As IoT becomes more pervasive, manufacturers will enable faster information flow, faster decisions, and greater market responsiveness by connecting devices into both operational and business software processes. Machine to machine (M2M) communications will enable new levels of automation. For example, GM uses sensor data to decide if it’s too humid to paint an automobile.

If the system defines the conditions are unfavourable, the automobile will be routed to another area of the manufacturing process, reducing repainting and maximizing plant uptime. This change alone saved the company millions of dollars.

Data Mobility and the IoT will change the types of devices that connect into a company’s systems and these newly connected devices will produce new types of data. IoT will connect physical items such as sensors, actuators, video cameras and RFID readers, to the Internet and to each other.

Big data processing and analytics, either on-premise or in the cloud, will collect and analyse data from IoT-enabled devices. These solutions will turn data into context that can be used to help people and machines make more relevant and valuable decisions.

IoT impacts every business, but has the ability to radically transform industrial businesses such as manufacturing, utilities and aviation. There will be an exponential number of machines and devices that will transmit both large and small amounts of data.

Smart manufacturing companies will use analytics to enact smarter decisions

and more efficient operations. IoT, big data analysis and IP networks will help manufacturers prolong their asset lifespan while simultaneously optimising efficiency and minimizing energy consumption.

Smart manufacturing systems will link production and business domains such as Material Requirements Planning (MRP), Manufacturing Resource Planning (MRPII) and Manufacturing Execution Systems (MES). There are many potential business use cases for IoT in manufacturing. Several examples of process improvements that IoT can impact include: Factory visibility IoT data and IP networks will connect what’s happening on the factory floor to enterprise-based systems and decision makers. IoT will provide production line information to decision makers and improve factory efficiency.

For example, a plant manager walking the production floor could also use IoT and visibility tools to access the efficiency of each machine, view production from any location, and reduce the time to decision and action.

For example, GE mobile-enabled SCADA applications allow tablets to display performance data and status updates traditionally available only on PCs. Instead of being chained to a control room, facilities managers and production personnel will have easy access to real-time information and collaborate more effectively. When you equip people with mobile technology, you can dramatically shrink the delta between when a problem occurs and when it’s acted upon. If there’s a quality control problem in a production line, they can shut down the line before it continues to create products that will all be waste.

The benefits of visibility will extend beyond the enterprise to a wide range of suppliers and third party providers of services, consumables and capital goods. IoT systems will enable extensive involvement by third party suppliers in the direct operations and maintenance of manufacturing plants with new service and supply business models based on increased visibility and remote monitoring.

Suppliers of capital equipment may now be able to offer business models that involve production based revenue rather than capital equipment sales if equipment can be monitored sufficiently for both output and maintenance status.

Parts, services and consumables suppliers within Maintenance, Repair and Operations (MRO) will use IoT to monitor distributed inventories, tank levels of process fluids, wear parts conditions, and production rates. This will create entirely new and very closely linked business relationships between manufacturers and their suppliers.

Automation Plant networks have been isolated from each other and from local and distant business networks. Today, we can use IoT and IP Networks to connect everything within a plant and provide connectivity and information sharing across multiple locations and business networks.

Once machinery and systems are connected within the plant, manufacturers can use this information to automate workflows to maintain and optimize production systems without human intervention.

One example of this is Harley-Davidson’s use of IoT in its motorcycle plant. The company installed software that keeps a record of how different equipment is performing, such as the speed of fans in the painting booth.

The software can automatically adjust the machinery if it detects that a measurement, such as fan speed, temperature, or humidity, has deviated from acceptable ranges.

Energy management In many industries, energy is frequently the second largest operating cost. But many companies lack cost effective measurement systems and modelling tools and/or performance and management tools to optimise energy use in individual production operations, much less in real-time across multiple operations, facilities, or an entire supply chain.

There are numerous ways that IoT and automation of environmental controls such as HVAC and electricity can create cost savings for manufacturers.

Connected energy solutions can provide peak demand charge avoidance and enable economy model operations. Certain IoT-enabled HVAC systems also offer integrated weather data and prediction analysis to help manufacturers understand expenses and plan energy usage.

GE says efficiency improvements of 5% in a small industrial power plant generating 15MW can save over $200,000 on average per year.

Proactive maintenance Manufacturers have widely accepted the concept of preventative and

condition-based monitoring but many are still in the process of implementing these programs. Lower cost sensors, wireless connectivity and big data processing tools make it cheaper and easier to collect actual performance data and monitor equipment health. If the manufacturer has equipment that’s supposed to operate within a certain temperature range, the company can use sensors to actively monitor when it goes out of range and prevent malfunctions.

IoT can help a manufacturer improve overall equipment effectiveness (OEE).

Measuring vibrations to detect out of spec operations is another example.

Businesses, particularly industrial businesses, lose money when equipment fails. With new sensor information, IoT can help a manufacturer improve overall equipment effectiveness (OEE), save money by minimizing equipment failure and allow the company to perform planned maintenance.

Connected Supply Chain Just in time manufacturing isn’t a new concept, but IoT, analytics and IP networks will help manufacturers gain a better understanding of the supply chain information that can be delivered in real- time.

By connecting the production line and balance of plant equipment to suppliers, all parties can understand interdependencies, the flow of materials, and manufacturing cycle times. IoT enabled systems can be configured for location tracking, remote health monitoring of inventory, and reporting of parts and products as they move through the supply chain, among many other things.

IoT systems can also collect and feed delivery information into an ERP system; providing up-to-date information to accounting functions for billing. Real-time information access will help manufacturers identify issues before they happen, lower their inventory costs and potentially reduce capital requirements. www.nzmanufacturer.co.nz

28

NZ Manufacturer August 2014

THE FUTURE OF MANUFACTURING

You are the only person on earth who can use your ability.

- Zig Ziglar

Army helicopter can fit in your pocket It weighs 16 g, can fly for up to 20 minutes, and fits in the palm of your hand. It’s the Prox Dynamics PD-100 Black Hornet, a mini helicopter which uses embedded cameras and a digital data link to provide real-time video for ground troops.

Information is king on the battlefield, and this pocket-sized UAV offers advanced situational awareness for soldiers with negligible impact on troop load.

Ever been on a hike with 70-100 pounds strapped to your back? It sucks..Military service members tote heavy loads regularly (especially in a warzone), so any “additions” can’t weigh them down further. And at .035 lbs, the PD-100 Black Hornet provides a valuable service without burdening anyone.

Under the Cargo Pocket Intelligence, Surveillance and Reconnaissance (CP-ISR) program, the Natick Soldier Research, Development and Engineering Centre has been tasked with developing a small aerial system to give dismounted troops increased situational awareness.

And situational awareness — and knowing more than the enemy — wins wars.

“While larger systems have been used to provide over-the-hill ISR capabilities

on the battlefield for almost a decade, none of those delivers it directly to the squad level, where soldiers need the ability to see around the corner or into the next room during combat missions,” the Army said.

One of these squad-based ISR systems is the Black Hornet. Operated remotely via GPS, this diminutive drone is small,

quiet, and virtually undetectable. And at 4 inches x 1 inch, it won’t present a fat, enticing target for the enemy.

The PD-100 was already issued to the UK Armed Forces last year, and early returns are promising. The company will need to initiate a data-link redesign to make the pocket-sized ‘copters compatible with the US Army’s

tactical network.

Otherwise, there should be few hurdles to the Black Hornet’s immediate deployment with US forces, and the system will pay for itself the first time it uncovers an ambush, weapons cache, or other imminent threat.

Universal track for robots Because the latest generation of articulated robots can be mounted in any position, they provide a flexible configuration for manufacturing operations.

The new generation Track Motion Overhead (TMO) universal linear axis can move practically any industrial robot that is currently available on the market – whether ceiling-mounted, wall-mounted or elevated.

Thanks to its excellent load-carrying capacity and high degree of rigidity, the TMO can move robots or any other machinery weighing up to 5,000 kg with great accuracy and stability.

Process tasks that were previously only possible with complex specialist machinery – or by using more robots – can now be performed using just one articulated robot mounted in the optimum position.

Users have maximum flexibility in the configuration of their production processes with it. www.nzmanufacturer.co.nz

NZ Manufacturer August 2014

Never make someone a priority when all you are to them is an option.

29

DEVELOPMENTS

- Maya Angelou

Building skills in the Manufacturing industry As your industry training organisation (ITO), Competenz is working with your industry to review your qualifications. The aim is to develop a simpler, more relevant suite of qualifications that makes it easier for you to grow skills, careers and businesses in the manufacturing industry. This review is known as a ‘Targeted Review of Qualifications’ or TRoQ. Which qualifications are under review?

What stage is the review at?

The industry governance group has confirmed and developed the high-level qualifications needed and are now ready to apply to the New Zealand Qualifications Authority (NZQA) for approval to list these qualifications.

First though, a technical advisory group will meet to work through the unit standards that

• National Certificate in Manufacturing (Core Skills) (Level 2)

lead to the qualifications and confirm that all

• National Certificate in Manufacturing (Metal and Related Products) (Level 2)

The draft qualifications will then be sent

• National Certificate in Manufacturing (Metal and Related Products) (Level 3)

consultation

• National Certificate in Steel Manufacturing with strands in Electric Arc Furnace (EAF) and Oxygen Bodenblasten Maxhutte Process (OBM) (Level 3)

content is correct. out to the manufacturing industry for wider before

being

submitted

in

November. It is expected the new qualifications will be ready to launch in quarter one of 2015.

To have your say on the future of New Zealand’s manufacturing qualifications, visit

• National Certificate in Manufacturing (Metaland Related Products) (Level 4)

troq.competenz.org.nz or contact Mathew

• Diploma in Manufacturing (Level 5)

your industry. Mathew will tell you how you

Following the review, these qualifications will be reduced into a new suite of ‘New Zealand Certificates’.

Vandy who’s leading this review on behalf of can attend a meeting of our working group or comment on draft documents (e.g. draft training programme and unit standards).

Mathew Vandy, Industry Manager.

Few businesses ready for health and safety law changes Too many businesses are ill-prepared for increased health and safety obligations under the Health and Safety Reform legislation that will become law early next year and this is putting them at risk, according to a health and safety expert.

employees, contractors and visitors safe.

The new law, which is expected to come into effect in April 2015, will increase employers’ responsibilities to have safe work practices and to be sure that employees know how to work safely.

“Businesses should immediately begin work on determining how they will meet the new requirements, if they have not already done so.”

This means that directors, owners and managers, who are duty holders with influence and control over the business, will need to know about all of their business’s operational risks and hazards and how they are being managed. They will also be expected to verify that the organisation’s safety management is effective and meets the Health and Safety Reform law’s requirements.

The onus will also be on duty holders to lead the organisation’s safety performance by making sure the changes are implemented and organisational practices are keeping

Brent Sutton, Health and Safety Solutions Manager at health and safety development organisation Workbase, says anecdotal evidence suggests many businesses have done little to prepare for their new obligations, which is a concern because the new law will be more prescriptive.

He notes that the law will extend health and safety duties and responsibilities across all parties in a supply chain, and some contracting and principal organisations are already beginning to impose the new health and safety compliance requirements on their supplier businesses.

“The risks for smaller organisations go beyond higher legal penalties and include the risk of losing their contract business from larger organisations.

“Larger organisations concerned with the increased reputational risks are likely to stop using contractors and suppliers that are not demonstrating an ability to manage their own health and safety risks.”

Mr Sutton says addressing the situation starts with boards and business owners knowing what steps to take.

“This can be easier said than done, especially for the vast majority of New Zealand businesses that do not have a dedicated health and safety role.”

“Managing health and safety risks requires employers to understand and comply with a wide range of documents covering legal compliance, duties, requirements, guidance and standards. Many of these documents are long, and written in complex legal and technical language.”

Mr Sutton notes that getting to grips with health and safety requirements is particularly challenging for small and medium-sized enterprises. This is significant because they are often in the highest-hazard industries, such as forestry, agriculture, fishing, manufacturing and construction.

Doing more of the same is not an option, says Mr Sutton, but more needs to be done to support businesses to comply.

“Industry bodies need to take a more hands-on role in supporting businesses to develop practical, industry-specific workplace health and safety systems that are simple, easily understood,

used by everyone, and integrated into all parts of the organisation.”

In the meantime, Mr Sutton suggested that businesses could make a start on preparing themselves by: 1.

Identifying all of the business’s hazards and risks.

2. Understanding the business’s health and safety obligations, and its strengths and gaps. Businesses could develop this knowledge by speaking with relevant industry associations or similar businesses, or through external verification of how well their health and safety system is working.

3. Developing a plan for implementing the health and safety changes, and making it manageable by creating a prioritised list.

4. Addressing the business’s greatest health and safety risks first.

The regulator, WorkSafe New Zealand, provides guidance and standards for many industries on their website: http://www.business.govt.nz/worksafe/ information-guidance/guidance-by-industry www.nzmanufacturer.co.nz

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NZ Manufacturer August 2014

This one step - choosing a goal and sticking to it - changes everything.

- Scott Reed

Reduce development risk Offering both tools and services, Maplesoft Engineering Solutions help engineers validate and optimise product designs, produce extremely fast simulation code for hardware-inthe-loop and other types of simulations where execution speed is critical, and develop specialised analysis and design calculation tools.

Maplesoft Engineering Solutions also support model development for model predictive control, an advanced technique used to represent the behaviour of complex systems.

The Maplesoft Engineering Solutions team has expertise in a variety of engineering fields and extensive experience in model-based design.

By leveraging the unique benefits of MapleSim and Maple, advanced engineering design tools from Maplesoft, they help engineers reduce development risk, create better products, and get to market faster. MapleSim and Maple are also

available for engineers to use directly in their own development projects.

MapleSim is an advanced system-level modelling and simulation tool from Maplesoft that applies modern techniques to dramatically reduce model development time, provide greater insight into system behaviour, and produce fast, high-fidelity simulations. MapleSim is based on Maple, the technical computing software for engineers, mathematicians, and scientists.

Maplesoft Engineering Solutions are used by customers in a variety of domains, such as electric and hybrid-electric vehicles, ground transportation, space systems, batteries, mining, and manufacturing.

Past projects include a robotic arm for drilling in mines, a motion platform for driving simulators, a torsional vibration analysis tool for marine drivelines, batteries for hybrid-electric vehicles, and dialysis machines.

While projects vary greatly, they frequently involve the following: High performance plant models for hardware-inthe-loop (HIL) applications.

Generating high-fidelity plant models from many system design tools typically results in code that is not fast enough for real-time, HIL execution, and engineers often perform a trade-off between model fidelity and performance.

Designing and troubleshooting 802.11ac networks correctly the first time There is now a range of new 802.11ac features in AirMagnet Survey PRO/ Planner and AirMagnet WiFi Analyser PRO to help organisations optimise their migration or co-existence path to the new 802.11ac technology standard.

With new modeling applications, toolkits, and the industry’s only 3x3 portable capture and analysis capability, businesses can now leverage the industry’s first complete wireless lifecycle solution to design, deploy and troubleshoot 802.11ac networks accurately, quickly and more cost effectively.

As enterprise networks rely more heavily on Wi-Fi networks and increasingly face bandwidth and capacity challenges, IT is transitioning from the 802.11a/b/g/n wireless standard to Gigabit 802.11ac for more reliable connections, better performance, and higher capacity.

Independent research firm Infonetics Research estimates 802.11ac access points (APs) could well account for three-quarters of access point shipments by 2017.

But just moving to 802.11ac will not solve all IT challenges. According to Gartner, “More bandwidth is good, and 802.11ac can better support high transaction dense environments; however, this does not solve the underlying problem of poorly or inadequately implemented WLANs.”**

possible.

To help address these challenges, AirMagnet Survey PRO, the industry’s most accurate wireless design and site survey solution, and AirMagnet WiFi Analyser PRO, the premier solution for mobile auditing and troubleshooting Wi-Fi networks, now include 802.11ac functionality to help IT teams effectively phase new wireless infrastructure into existing WLANs without blindly performing a 1-to-1 rip-and-replacement of existing equipment.

The AirMagnet tools also let IT teams solve 802.11ac network issues correctly the first time, which prevents costly repeat visits and, more importantly, minimise user downtime.

802.11ac technology also places greater capacity demands on an organisation’s wired infrastructure, which means they must validate the capacity and quality of their Ethernet backbone before any rollouts. Fluke Networks not only offers market-leading Wi-Fi solutions with its AirMagnet tools, but also wired analysis solutions such as the OptiView® XG Network Analysis Tablet, OneTouch AT Network Assistant and LinkRunner Pro, which verify the readiness of the wired backbone to support Gigabit Ethernet.

Wireless engineers and system integrators are already facing challenges integrating new equipment and ensuring deployments meet and maintain the Gigabit Wi-Fi standards.

However, with the AirMagnet tools, the users are assured of designing and deploying networks that “simply work” and with the maximised performance

Materialise launches latest 3-matic STL Software Materialise has launched the latest version of the 3-matic software, a tool which allows 3D designers to modify their designs with even greater accuracy all at STL file level.

design functionalities, Materialise has produced an update that enables the creation of watertight designs to ensure the quality of 3D printed end products.

The 3-matic 9.0 has been improved to offer better design modification and simplification abilities including 3D texturing, remeshing and forward engineering to create lightweight structures without compromising on strength or functionality.

New features include a ruler to allow for better visualisation in the design process and conformal structures that follow the exact geometry of the 3D model. Point-based patterning has also been added meaning users can create an overall pattern on their objects with just one click and an automatic rib pattern function has been included to create clean rib structures that conform

Taking note from customers who suggested a focus was needed on rendering, robustness and new www.nzmanufacturer.co.nz

to the 3D model.

Users will also benefit from a 2D UV page allowing easy positioning of 2D textures and also sliced based texturing in the Magics Build Processor, which can handle sliced based 2D texturing in even large 2D files.

Materialise have already announced

that the 3-matic is expected to be made available through the Altair Partner Alliance program for Altair HyperWorks users this year. APA is an on demand software licensing system which gives customers access to third party applications without additional costs.

NZ Manufacturer August 2014

Remember, there are no mistakes, only lessons.

Love yourself, trust your choices, and everything is possible.

- anon

31

REAR VIEW

Outside the Silos - Nick Inskip them ‘networks’. Likewise New Zealand Trade and Enterprise (NZTE) have similar silos though they call them ‘sectors’.

There is little question that silos make things easy to manage. Staff responsibilities and competencies are typically aligned with the silo they operate in and there is usually someone who manages the silo and is accountable for how it operates.

They are a great way of making sure that people with the most appropriate skills are available when needed to support activities that fit in the confines of the silo.

Silos are quite common around the countryside. They are usually used to store grain or feed for animals.

They keep like materials together and make it easy for the farmer to handle them.

But it isn’t only on farms that we see silos, they are almost everywhere and do pretty much the same function of keeping things together and making it easy for those charged with handling them.

Some obvious silos in New Zealand are the Government’s Science Challenges, which were no doubt set up with the best of intentions but recent commentary from researchers suggest that many are finding it hard to see where what they are doing fits within them.

Organisations like Callaghan Innovation also have silos, they call

And that is where the problem lies; what about the things that don’t fit the silo but might be every bit, or even more worth doing than what is in the silo?

By their nature silos focus attention, and in a resource constrained environment such as research they ensure that budgets are assigned and delivered to those areas. Some would say that only makes sense, but what if the silos are aligned with legacy activities?

And even worse, that they soak up the available funds to the exclusion of activities outside the silos such as emerging sectors. Perhaps even worse is that silos propagate strategies and further concentrate attention, leaving little for non-silo areas.

In a world of increasingly globalised trade, silos can easily become inward looking towards ‘what it is we already do’, rather than outward focused on ‘where are the niches we can excel in’?

This is a challenge when the resources we assemble to support the silos are narrowly-focused, which means they aren’t typically looking for, or even aware of other opportunities.

Another issue with silos is that once they are established they maintain themselves over time regardless of their relative performance in relation to emerging activities, which often go unrecognised amongst the ‘noise’ created by activities in the silos.

But there is a whole world of activity outside the silos, sometimes these are individual companies doing something as unique as using titanium powder metallurgy for forging high-tech dive helmet parts for the US market, or whole platforms such as the Above Ground Geothermal and Allied Technology (AGGAT) platform that encompasses areas as diverse as geothermal and waste heat energy conversion through to mineral extraction from brine, and includes a national research roadmap but doesn’t fit readily in any silo.

But everyone outside the silos isn’t alone, industry associations like the HERA, Metals New Zealand and others often take on the support role for industry, which is especially important where industry activities fall outside the silos. However the challenge is making sure that support actually gets delivered where it is most potential value to New Zealand.

One way to do that is to look at removing the silo gatekeepers and putting control in industry’s hands.

This can easily be achieved through

mechanisms like R&D tax credits that would certainly help, especially if targeted towards export oriented activities, which might also usefully include the costs of export marketing, which can be a considerable burden due to our geographic isolation.

An alternative is to channel support through industry interfaces that are close to what is happening and not constrained by a silo mentality rather than through isolated silos.

But everyone outside the silos isn’t alone, industry associations like HERA, Metals New Zealand and others often take on the support role for industry.

A lot of activity happens outside the silos and some of these are of arguably far more prospective value than those within that are well supported; and we just can’t afford to have them fall through the cracks just because they don’t fit a pre-conceived view of where opportunities are.

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continued from page 6

Medical Plastics Turning creative ideas into sustainable business

Collaborating to compete: A smarter way

Innovation and speed to market are therefore key at Medical Plastics.

These factors provide a competitive advantage which John believes is vital to maintaining business sustainability in a market as small and saturated as New Zealand – “If you’re making simple components that can be stuck in a container and shipped here cheaply, then your business is constantly under threat. Whereas if you can add value through design and development to niche products then you can quite happily have a sustainable business.”

Medical Plastics aims to be a “one-stop shop for people’s creative ideas” from inception right through to earning money for the New Zealand market place. To achieve this, the company

has built a strong relationship with ExportX, an organisation which takes people from New Zealand to the international market, and sells products on Amazon.com.

“So it’s really a win-win for New Zealand, we can strip the cost out of product development and help people get their products ready for international markets where they can earn some dollars for New Zealand.”

As for the future of this dynamic new company? John says “watch this space” – he is expecting his little business to soon become many small businesses.

“We hope to have many different products across multiple industries, but it will just keep coming back to cool, innovative plastic design.”

It is worth contemplating the opposite, the non-collaborative model. There are many examples of organisations with market power that draw more value from the supply chain than they add to it. Australia is prone to this, with its oligopolistic industry structures.

In these instances, non-collaborative behaviour may well stifle growth. We would submit there is short term gain for these particular companies, but at the risk of slower growth of the industry or the supply chain overall and therefore in the long term suboptimal profit for the particular companies concerned. It would be smarter to act in ways that promote growth.

potentially redefining what occurs within a company’s walls. To extend the analogy, it suggests that a company’s walls are becoming quite porous. In this environment a nuanced approach to competition and collaboration is highly desirable and may be a more sure way to create sustainable competitive advantage.

About Peter Carney He has over 25 years of experience in working with and advising Australia’s largest corporates in mining and manufacturing on matters of marketing, strategy, business development and supply chain improvement.

Technology is driving changes in company and market structures. It is www.nzmanufacturer.co.nz

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NZ Manufacturer August 2014

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