November2014
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G20 SUMMIT “if the pledges were kept, it would mean “an extra Australia and New Zealand” added to the world economy.” -British Prime Minister David Cameron on world economic growth.
The Third Industrial Revolution… The price of energy and food is climbing, unemployment remains high, the housing market has tanked, consumer and government debt is soaring, and the recovery is slowing. Facing the prospect of a second collapse of the global economy, humanity is desperate for a sustainable economic game plan to take us into the future. Here, Jeremy Rifkin explores how Internet technology and renewable energy are merging to create a powerful “Third Industrial Revolution.” He asks us to imagine hundreds of millions of people producing their own green energy in their homes, offices, and factories, and sharing it with each other in an “energy internet,” just like we now create and share information online. The Five Pillars of the Third Industrial Revolution Rifkin describes how the five pillars of the Third Industrial Revolution will create thousands of businesses and millions of jobs, and usher in a fundamental reordering of human relationships, from hierarchical to lateral power, that will impact the way we conduct business, govern society, educate our children, and engage in civic life.
The five pillars of the Third Industrial Revolution are: (1) shifting to renewable energy; (2) transforming the building stock of every continent into green micro–power plants to collect renewable energies on-site; (3) deploying hydrogen and other storage technologies in every building and throughout the infrastructure to store intermittent energies; (4) using Internet technology to transform the power grid of every continent into an energy internet that acts just like the Internet (when millions of buildings are generating a small amount of renewable energy locally, on-site, they can sell surplus green electricity back to the grid and share it with their continental neighbours); and (5) transitioning the transport fleet to electric plug-in and fuel cell vehicles that can buy and sell green electricity on a smart, continental, interactive power grid. The creation of a renewable energy regime, loaded by buildings, partially stored in the form of hydrogen, distributed via a green electricity Internet, and connected to plug-in, zero-emission transport, opens the door to a Third Industrial Revolution. The entire system is interactive, integrated, and seamless. When these five pillars come together, they make up an indivisible technological platform—an emergent system whose properties and functions are qualitatively different from the sum of its parts. In other words, the synergies between the pillars create a new economic paradigm that can transform the world. Big Data and the Third Industrial Revolution The intelligent TIR infrastructure—the Internet of Things—will connect everyone and everything in a
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The hassle free apprenticeship service Contact Apprentice Training New Zealand to find out how we can recruit, employ and manage apprentices to train in your business.
0800 526 1800 www.atnz.org.nz
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MANUFACTURING TECHNOLOGY
Largest Samsung lathe heading to NZ customer.
Qualification comes from dedication Recently, Hornby based B&D Doors (NZ) Ltd. celebrated 12 of their manufacturing team earning a National Certificate in Core Skills (Manufacturing) and another 11 of the team (as well as this qualification) earning a National Certificate in Competitive Manufacturing (Level 2) by hosting a lunch and graduation ceremony at their Christchurch Head Office & manufacturing site. This has been a 27 month journey which started on the 5th of June 2012 when B&D Doors started “Project Commitment” which was not only the physical shifting of their Christchurch operation to a new site but also the commencement of members from the manufacturing team working towards gaining a nationally recognised qualification in manufacturing. For the majority of the learners this will be their first and only qualification as many left school at a young age. More importantly, it is a meaningful and recognised qualification for the manufacturing industry. With an average employee age of 46 and most of the learners having not been in the education system for over 30 years, the first 12 months of the course was targeted at improving numeracy and literacy skills to help with ensuring the success of Joseph Mau gaotega this initiative.
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NZ Food Manufacturer News – Developments – Opportunities the m o r F
to the
NZ Food Manufacturer brings you all the latest news and developments in food manufacturing
For further information and to advertise visit
www.nzfoodmanufacturer.co.nz Doug Green T: 0064 6 870 9029 E: publisher@xtra.co.nz
NZ Manufacturer November 2014
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CONTENTS DEPARTMENTS
ADVISORS
NEWS 5 BUSINESS Trading partner confidence good news for
Larry Wiechern
Is the Manager of the Maintenance and Reliability Centre, Manukau Institute of Technology.
NZ.
TECHNOLOGY 6 MANUFACTURING Byrun, the walking, hopping, jumping robot. PowerSHAPE- the comprehensive CAD programme.
6 Craig Carlyle
8 IC3D Steel 2.0 has improved management.
Is Director of Maintenance Transformations Ltd, an executive member of the Maintenance Engineering Societyand the Event Director of the NationalMaintenance Engineering Conference.
MANUFACTURING TECHNOLOGY
NEWS 10 BUSINESS A new place to call home.
Catherine Beard
11 Largest Samsung lathe heading to NZ
MANUFACTURING TECHNOLOGY
Is Executive Director of Export NZ and Manufacturing, divisions of Business NZ, NewZealand’s largest business advocacy group, representing businesses of all sizes.
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customer.
INTERVIEW 12 THE Tim Williams, Packaging House.
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14 Are you a victim or a victor of the counterfeit ANALYSIS
Brian Willoughby
Is Senior Vice President of the NZ Manufacturers and Exporters Association and Managing Director of Contex Engineers and Plinius Audio.
culture?
INTERNET OF THINGS 15 THE The Zero Marginal Cost Society
Lewis Woodward
Is Managing Director of Connection Technologies Ltd, Wellington and is passionate about industry supporting NZ based companies, which in turn builds local expertise and knowledge, and provides education and employment for future generations.
18 DEVELOPMENTS Millennium Plastics successful at Plastics Industry Design Awards.
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THE FUTURE OF MANUFACTURING 19 High-speed and five-axis machining from Delcam.
Dr Wolfgang Scholz
20-21 THE FUTURE OF MANUFACTURING
Is HERA Director and a Fellow of the Institute of Professional Engineers NZ.
Additive manufacturing trends in aerospace.
FUTURE OF MANUFACTURING 22-23 THE Infrared thermography prevents the spread
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Bruce Goldsworthy
of viruses. Why it pays to join the circular economy.
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.
MANUFACTURING 24 FOOD Avoid going backwards, dairy farmers.
REPORT 26 ENERGY Industrial energy efficiency a full-time job. 27-28 DEVELOPMENTS Staff Wanted. NZ steel standards could lower. $2.8 trillion opportunity for our exporters.
VIEW 29 REAR More industry needed in industrial training. MANUFACTURER 30-31 NZ Editorial Calendar 2015.
the
FactoryFloor Manufacturers’ Trading Post
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Building NZ’s reputation as a leader in food safety in China.
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NZ Manufacturer November 2014
EDITORIAL
The Future of Manufacturing (for us)
PUBLISHER
Media Hawke’s Bay Ltd,1/121 Russell Street North, Hastings, New Zealand 4122.
MANAGING EDITOR Doug Green T: +64 6 870 9029 E: publisher@xtra.co.nz
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Holly Green, Nick Inskip, Tim Williams, Eugene Moreau, Joe Hiemenz
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Vol.5 No. 10 November 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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Security and climate change overshadowed G20 talks on boosting global economic growth at the summit, although the leaders did sign off on a package of measures to add an extra 2.1 percentage points to global growth over five years. In this ever-changing world, New Zealand will benefit from the decisions reached, although to be fair, maybe not in the way the decisions have been arrived at. The benefits we need to focus on directly include manufacturing, thanks to global economic integration which has made possible the continuous re-orchestration and relocation of production into new forms of value reaction and innovation. Make no mistake; innovation in manufacturing will come from many corners of the world by emerging economies that are coming to grips with new manufacturing processes and technologies. And we better be ready! The emerging economies – think Brazil, think Myanmar – will be right up there and offering really competitive products at really competitive prices. So do more New Zealand companies set up shop in Asia, for example, to be as competitive as the locals? And think about this; it isn’t that many years ago that ‘The Circular Economy’, ’The Internet of Things (IoT)’, ‘The Future of Manufacturing’, ‘Manufacturing Technology’, ’Additive Manufacturing’ and ‘Bioengineering’ were part of some futuristic thinking, problematical to deal with and a little too far away to even consider. Cute little buzz words when all we wanted to talk about was 3 axis machining! It’s like the issue of climate change…it’ll never, ever happen; we’ll never see the ice melt or have the hottest year on earth as was recorded last year. As a country we manufacture some terrific things. As long as our technologies, price structuring, equipment and skills are top notch we will continue to do fine. Our markets will continue to buy from us in smaller number but they will be buying quality products. -Doug Green, Publisher,
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Manufacturers’ Trading Post
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ASIA
MANUFACTURING NEWS
Doug Green
NZ Manufacturer November 2014
Accomplishing the impossible means only the boss will add it to your regular duties.
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BUSINESS NEWS
-Doug Larson
Trading partners’ confidence good news for NZ Growing optimism in our main trading partners is good news for New Zealand, according to Paul Kane, Partner, Privately Held Business, at Grant Thornton New Zealand. Commenting on the recently released Grant Thornton International Business Report (IBR) survey, which showed big jumps in business optimism in China, Australia, the United Kingdom and the United States, Kane believes this will be reflected in higher demand for New Zealand products and services. “China, our biggest trade partner, has seen business optimism rise from 31% at the end of the third quarter last year to 55% to the same period this year. Australia has gone from 23% to 53%, the United Kingdom 76% to 82% and the United States 52% to 69%. “China and Australia are our two biggest trading partners, so optimism in their markets is good for New Zealand. The significance of the rise in Australia should not be overlooked as their economy impacts ours in so many ways, not only trade, but also immigration. Perhaps this rise in their
Commercial & industrial growth
confidence will see a strengthening in numbers of people moving across the Tasman to live. “Even if this does occur, migration to New Zealand is so strong that it will have little impact on these numbers overall, with no respite for areas such as the Auckland housing market. “New Zealand’s business confidence has also increased in that time from 64% to 80%, although it did peak at 88% in the first quarter this year,” he said. Kane feels that this uplift in confidence will keep New Zealand’s levels high for some time. “The survey ranks New Zealand as the third most optimistic country of the 34 surveyed, behind India (95%) and the United Kingdom (82%) and level with Ireland. It really does indicate exactly where our economy sits and although we may have dropped slightly from the 88% peak at the end of the first quarter, several others have also come off their highs.
“China, our biggest trade partner, has seen business optimism rise from 31% at the end of the third quarter last year to 55% to the same period this year.”
“As a country, we’re actually travelling pretty well.”
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
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Greater East Tamaki Business Association Inc.
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NZ Manufacturer November 2014
MANUFACTURING TECHNOLOGY
A budget tells us what we can’t afford, but it doesn’t keep us from buying it. .
-William Feather
Byrun, the walking, jumping, hopping robot In movies, robots can walk, talk, and even pretend to be human. Their real-life counterparts are considerably more limited. But this gap is closing, and Engineered Arts, a UK robotics company, is seeking to bring reality closer to fiction. Engineered Art´s current flagship product is RoboThespian, the robotic actor. A full-sized humanoid with a biologically inspired design, RoboThespian is used by research and education centres the world over, to inform, to entertain, and to investigate new developments in robotics. Institutions in over 20 countries, including NASA Kennedy Space Centre (USA), Gazientep Planetarium (Turkey), Questacon Science Centre (Australia), and numerous universities world-wide are using RoboThespian every day. Maplesoft technology was used in the design and modelling of balancing and talking RoboThespian robots. MapleSim, the system-level modelling and simulation platform from Maplesoft was used to design the biologically analogous humanoid robot leg integrating a novel actuator, studying its static and dynamic stability, and building the designed leg to determine strategies for its control. However, RoboThespian, for all his conversational appeal, is largely static. His legs are powered, but he can merely squat and stand in place, never moving from a fixed location. Enter Byrun, the latest Engineered Arts endeavour. Using MapleSim, Byrun’s designers and engineers have developed a biologically analogous leg design which will give Byrun the ability to walk, run, jump and hop. Byrun will be a new kind of full-scale dynamic humanoid that will take social robotics to the next level. With a faster, stronger, more dexterous upper body, a virtually infinite array of facial features (courtesy of his projective head display), and the same speaking and singing abilities as his predecessor, RoboThespian, Byrun has the potential to revolutionize human-robot interaction. In Byrun, they to integrate more human-like dynamics into the mechanical design. Using a human-inspired approach at a hardware level makes walking, running and jumping possible without rigid, robotic-looking motion. MapleSim assisted in Byrun’s design by allowing engineers to simulate complex, nonlinear, compliant components such
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as his pneumatic muscles and parallel springs. These are used for safety compliance, shock absorption, energy efficiency, and human like smooth motion curves. Engineered Arts specialises in unconventional actuation solutions, chosen to best suit the application. Motors are fast and precise, but inefficient and rigid. Pneumatic actuators, on the other hand, are powerful and energy efficient, but difficult to control. The conventional approach in robotics is to use a single actuator for a single joint - Byrun will use a parallel electro-pneumatic design, where multiple actuators control single joint actions. This approach utilises the best facets of both types of actuation, while compensating for their drawbacks. Conversely, some actuators will generate coupled motion across several axes, to imitate (for example) the organic design of the human shoulder. This makes for more natural-looking motion, but can be potentially difficult to control. Here, once more, Maplesoft comes to the rescue, providing advanced solvers that can tackle the difficult multi-variant control equations used to develop Byrun’s
motion algorithms.
the complexity of calculation.
By creating virtual prototypes of each design phase in MapleSim, Byrun’s engineers can investigate the feasibility of mechanical solutions without needing to create a laborious series of prototypes.
In the case of Byrun, they were able to dramatically simplify the leg dynamics, making the computations much faster. This is extremely powerful and has real impact on our project timelines and deliverables.
The software helps to create the design parameters in a very fast virtual environment explained Guillaume. There is no longer the need to rebuild the robot for every design iteration, which saves significant time and cost, and allows for more radical options.
In addition to designing Byrun’s electro-pneumatic hybrid legs and upper body for fully mobile walking and running, engineers are also developing a robotic hand with the same principles, creating a compact, highly efficient compliant manipulator.
As well, complex kinematics can be easily simplified with the use of Maple - this is a powerful tool as the resources required for the project are considerably reduced. Byrun’s hardware requires modelling mechanical, electrical, thermal and pneumatic elements - with the help of the simulation tool MapleSim, the component requirements can be largely anticipated in advance.
They have designed an elbow joint with unconventional kinematic characteristic in humanoid robotics with electro-pneumatic parallel actuation, and are currently making a full torso-shoulder-arm model in MapleSim.
The team at Engineered Arts Ltd. has also found MapleSim useful for its ability to simplify complex calculations. MapleSim’s ability to automatically generate complex mathematical models, such as the leg dynamics, is outstanding. Different parameters can be altered at different stages to reduce
This model will be used for solving forward kinematics, inverse kinematics, end-effecter dynamics and compliance. Robots like Byrun are setting a new standard for both humanoid and more general robotic design. To be worth its cost, this robot must perform something never seen before. If it can do just 10% of John Travolta’s walk, Margot Fonteyn’s dance and Julia Roberts’ smile, we have a winner.
NZ Manufacturer November 2014
There’s an enormous number of managers who have retired on the job. -Peter Drucker
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MANUFACTURING TECHNOLOGY
PowerSHAPE Pro CAD for CAM Delcam has launched the 2015 version of its PowerSHAPE Pro CAD for CAM system for modelling for manufacture and reverse engineering. The new release includes improvements in direct modelling, surface modelling and reverse engineering, plus support for data from Creaform HandySCAN handheld scanners. By offering a combination of solid, surface and direct modelling, together with reverse engineering functionality, PowerSHAPE Pro provides the most comprehensive range of design techniques available in a single CAD program. Having all the different technologies in the same package reduces the need to transfer data between multiple programs and so streamlines the whole product development process. At the same time, the combination of quick and easy direct modelling options, together with powerful and flexible surface modelling, makes PowerSHAPE Pro the perfect choice for design for manufacture. The improvements in direct modelling build on the introduction of the Smart Feature Manager and the Smart Feature Selector in recent releases. The Smart Feature Manager allows users to identify all the features, such
as fillets, slots, bosses etc, within a solid in a single operation and so makes the analysis of the imported data easier and faster. The Smart Feature Selector then allows multiple similar features to be found and selected using either a specific value or a range of values. Once the particular group has been selected, all the features within it can be edited simultaneously. For example, all holes having a diameter of 5mm can have their diameter increased to 10mm in one operation. This new functionality will speed the preparation of models for manufacturing significantly. For example, one common problem in product designs that are to be moulded or cast is that fillet sizes are set so small that they restrict the flow of material. The Smart Feature Selector can be used to identify any fillets below the required radius and then all the fillets found can be increased to the desired minimum size simultaneously. Another potential application is in tidying up models created by reverse engineering, where features that are intended to be identical, such as a series of holes, will often show small variations. In such cases, all the items within a specified tolerance band can be selected and then all adjusted
together to the same precise size.
from the actual part.
One of PowerSHAPE Pro’s great strengths has always been its surface modelling capabilities, giving the user the ability to create any shape they can imagine. These capabilities have been further improved with new dynamic point editing.
The main enhancement to PowerSHAPE Pro’s reverse engineering functionality is a more automated method for capturing cross-sections through a mesh. The software now fits lines and fillets to the cross-section where it can, with the user able to control the tolerance used. This method uses the mesh as a guide instead of treating it as exact geometry, with the priority of capturing the design intent rather than ensuring a precise fit to the scan data.
Another strong area for PowerSHAPE Pro that has also been made faster and easier is the ability to morph complete models into a new shape. One key application for this option is in compensating for springback in press tools or warpage in moulded products. The user can alter CAD directly based on scan data from a sample part collected as a point cloud or as a triangle mesh, with a choice between either updating the CAD model of the part to match the as-produced item or adjusting the tooling design so that it can produce parts matching the original CAD data. Another important application of morphing is in updating parts that need to be repaired but that have changed their shape during use. A typical example is turbine blades that have been distorted by heat so that their shape no longer matches the CAD data used for their manufacture. Again, the original CAD data can be adjusted to match scan data captured
With PowerSHAPE Pro 2015, a number of fillets of different radii can be altered simultaneously to a new size
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NZ Manufacturer November 2014
MANUFACTURING TECHNOLOGY
If work is so terrific, why do they have to pay you to do it? -Peter Drucker
IC3D Steel 2.0 has improved management features IC3D, a leading provider of hardware and software solutions for the Manufacturing, Architectural and Engineering industries, has introduced the latest version of its steel structural design and management software, IC3D Steel™ for SolidWorks®. IC3D Steel 2.0 introduces a raft of features centred on improving project flow and management, and simplifying organisational tasks like notating bolt lists and depicting virtual bolts in a design.
are stored logically for easy retrieval, backup or archiving. Important project meta-data such a customer’s details, project number and document-numbering scheme can be configured at project setup. IC3D Steel uses this data whenever it creates or updates a document in the project; meaning drawings can be consistently labelled for additional security.
Other new features address the complexity inherent in steel fabrication projects. For example, with steel designs generating up to ten times as many bolts, nuts and washers as steel members, the usual performance of SolidWorks can become compromised as assemblies become very large. IC3D Steel 2.0 features ‘virtual bolts’
IC3D Steel was first conceived as a dedicated steel design tool for SolidWorks. It built upon SolidWorks’ parametric modeller and its core Weldments Design function, to build a ‘structural workflow’ application that is perfect for building and detailing with steel. The aim is to make the design process quicker, simpler and error-free. Refined with additional functionality, the software that makes it easier for designers and design teams to manage their projects within a specified workflow, and gives them additional tools to simplify organisation within projects. In IC3D Steel 2.0, projects are organised individually, all relevant files are associated automatically, and files
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in each of its joint details to manage the problem, so work is unaffected no matter how many bolts are used in the design. A new ‘Bolt List’ report generates a complete list of these fasteners for ordering, and this can be broken down into individual joints or summarised for the whole project. The new features don’t come at the cost of steepening the learning curve.
Work spares us from three evils: boredom, vice, and need. – Voltaire
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NZ Manufacturer November 2014
BUSINESS NEWS
There’s no secret about success. Did you ever know a successful man who didn’t tell you about it? -Kin Hubbard
A new place to call home If you’ve been pondering a business expansion, relocation or simply a change of pace, then Taupo could be worth considering. Taupo has a strong and growing economy with low unemployment and a thriving business sector. The region has an abundance of affordable commercial property available for lease or purchase, as well as significant tracts of undeveloped land ideal for those that require a purpose built facility. One of the main perks of basing your
business in Taupo are the affordable operating costs which are lower compared to the big cities – both rent and wages are lower and many other business expenses are the same or lower compared to the main centres around New Zealand. Taupo also offers you and your family the lifestyle you have dreamed of. It has the big city amenities and features without the hassle and stress of big city living – and importantly, an ideal environment to raise a family, “It
is a safe place, with a strong local community and sense of civic pride,” says Kylie Hawker-Green, from Enterprise Great Lake Taupo. “People who live here, love living here.” “We are committed to rolling out the red carpet for new businesses in Taupo,” says Kylie. “We want to prove to business owners who are considering a move here that Taupo is filled with great opportunities for business. So to prove it, we’re encouraging those considering a move to register for a
Taupo Tiki Tour. We’ll host you in Taupo for a day, introduce you to property developers and land owners, discuss your requirements, answer any queries you have and connect you with the right people.” For those who decide to make the move, the ‘Welcome Home to Taupo’ pack provides a $20,000+ package of benefits for those who are bringing their business to Taupo. The pack includes everything you need to get your business established such as stationery, signage, printing, power, engineering and planning advice, telephone and internet, marketing, advertising, memberships to local groups and even the Mayor’s cellphone number! A recent arrival, formerly from Auckland, says living in Taupo is like always being on holiday. “In summer, by 5:30 I’ve finished work, grabbed the family, and we’re out on our boat enjoying a swim and a BBQ. Back in Auckland, we wouldn’t have even got home by then, let alone got the boat on the car.” “We want our local businesses to not just exist, but to be booming,” says Kylie. “We have so many strong businesses here that are succeeding at a local, national and international level and we think there are others out there who’d like to do the same.”
Sam Coxhead and Keri Harper who moved to Taupo from Auckland to raise their family and are loving the lifestyle and community. They have established the award winning Design Builders Taupo in partnership with ex-Kapiti Coast builder Matt
To register for a Taupo Tiki-Tour, or find out more about bringing your business to Taupo, visit www.greatopportunities.co.nz .
New form of protection from IRD penalties, interest Taxpayers with volatile income can now protect themselves in advance from the risk of incurring hefty IRD late payment penalties and use of money interest (UOMI) if they have a better-than-expected financial year.
the extra income, and therefore has a higher tax bill, any late payment penalties and UOMI incurred up to the amount of tax covered will be eliminated when they pay the principal and an exercise fee.
Tax SHIELD™, a new product from Tax Management NZ (TMNZ), lets taxpayers put an arrangement in place whereby they pay an upfront fee to cover the portion of their income that is volatile, says the tax pooling intermediary’s chief executive Chris Cunniffe.
“Our clients tell us their biggest worry is the hefty late payment penalties and use of money interest they are charged if they get their provisional tax wrong because it can undo all the hard work that has driven their increased profitability,” says Mr Cunniffe.
Volatile income can mean tax is underpaid and results in late payment penalties of up to 20 percent per annum and UOMI of 8.4 percent.
“Having listened to their concerns, we have developed Tax SHIELD™ to remove the anxiety of late payment penalties and UOMI.”
However, using Tax SHIELD™ means that in the event a taxpayer earns
With Tax SHIELD™, the amount of tax set aside for taxpayers is
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‘date-stamped’ and held in an IRD account administered by the Guardian Trust, says Cunniffe.
Taxpayers can secure cover using Tax SHIELD™ at their next provisional tax date up until 7 February, 2016.
Late payment penalties and UOMI are eliminated because the IRD treats the tax as being paid on time when it is transferred to an individual taxpayer’s IRD account.
TMNZ is New Zealand’s largest and oldest tax pooling company, and developed all the tax pooling products in the market.
Mr Cunniffe says the very low upfront fee makes Tax SHIELD™ ideal for those taxpayers whose income is difficult to predict and are concerned about exposure to IRD late payment penalties and UOMI of up to 28 percent. “Taxpayers can now be secure in the knowledge that TMNZ will eliminate any potential IRD penalties and interest they will incur if their tax bill is greater than expected.”
It has helped more than 27,000 clients save more than $160 million in IRD compliance costs since 2003. TMNZ’s founder director Ian Kuperus not only came up with the concept of tax pooling, but also helped the IRD implement the tax pooling framework in New Zealand.
NZ Manufacturer November 2014
Success is going from failure to failure without loss of enthusiasm. -Winston Churchill
MANUFACTURING TECHNOLOGY
Largest Samsung lathe heading to NZ customer The largest Samsung lathe imported into New Zealand by Revolution Precision Machinery will be arriving soon. The PL40L is a slantbed lathe with a massive 117mm through the spindle draw tube, 9200KG machine weight, and 1500mm between chuck and tailstock. The PL40L has a reduction gearbox for massive spindle torque and 2500 rpm maximum speed on the 15� power chuck. The PL40L is equipped with the Fanuc CNC system which provides high spindle torque at lower spindle motor rpm and is a good fit for large diameter work piece turning. This PL40L was manufactured at the impressive new Samsung Machinetool factory in Gimhae City - South Korea, where the complete machine is built under strict quality control management. Samsung operate a complete in-house manufacturing system so quality can be managed at every step of production. The Samsung PL40L lathe was chosen because the other Samsung PL series lathes operating in New Zealand have excellent customer satisfaction and are continually achieving high turning accuracy and size repeatability. The extremely strong bed design and high
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build quality were also a factor in this Samsung lathe purchase. Revolution Precision Machinery engineers will be installing and providing service for the PL40L lathe based on their experience gained from the many CNC machine tool installations carried out over the past 12 years. The high reliability and durability of the Samsung CNC machines will allow the operators trouble free use for many years. A growing and satisfied New Zealand customer base has helped expand Samsung Machinetools local reputation for building highly accurate and durable machinetools.
Samsung factory.
Worldwide, Samsung lathes and machining centres have gained a very good reputation with sales continually increasing over the past 10 years, especially in the competitive USA and European machinetool markets. For more information on the Samsung Machine Tools range of CNC machinetools contact Phil Robinson, sales engineer for Revolution Precision Machinery (RPMcnc) Email: sales@ rpmcnc.co.nz Phone: CHCH 960 0892 AKL2650380 Web: www.rpmcnc.co.nz
Samsung production line.
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NZ Manufacturer November 2014
THE INTERVIEW
Success in almost any field depends more on energy and drive than it does on intelligence. This explains why we have so many stupid leaders. -Sloan Wilson
Delivering more expertise Tim Williams, Merchandise Manager, Packaging House NZM: How is business? TW: The last 18 months have been an interesting time, with a number of changes within our business and the market we operate in. Packaging House supply across a number of different industries which has meant we have been protected by the down turn in some sectors by the resurgence of others. In particular the food processors, logistics and timber markets have been very good for us.
NZM: Is the current market one in which Packaging House has confidence? TW: We do have confidence in the current market, the continued high dollar has obviously had some challenges for the export sector, but we still see innovative New Zealand companies working around this, particularly in the timber sector. The other side of the high dollar is that it has allowed us to deliver even more value to our customers by importing a far greater portion of core packaging consumables, expanding our range and ensuring global competitiveness.
NZM: Has this been a good year for Packaging House? And 2015? TW: This year has been a mixed bag, with some big wins and successes in our key target markets offset by increased challenges in other areas. We are very well positioned to continue on a strong growth curve into 2015 with a number of new ranges as well as industry aligned sales teams in place to deliver more expertise to our customers and build on the ground work that has been laid in the back half of 2014.
NZM: What are the main factors for Packaging House’s success? TW: We have a very customer centric focus. Our vision is to make life easier for our customers, providing a full one stop range of everyday business essentials. It our role to ensure these are supplied on time in the most cost effective manner so our customers can concentrate on their own core business. By doing this we are adding real value to our customers and we achieve this through a national network of branches, expert sales teams and customer service staff who are second to none in terms of service, support and advice. www.nzmanufacturer.co.nz
NZM: Where are your growth markets? TW: We have a compelling product, service and delivery offer covering everyday business essentials across a wide range of industries. Our key product categories cover industrial packaging, chemicals, hygiene, toilet tissue, medical consumables, food packaging and food service consumables. This broad range is supported by a highly trained team of sales and customer service packaging experts. NZM: Does the company invest in R & D? TW: Innovation is key to our ongoing success and development. We have and will continue to make significant investment in innovative products, services and ordering systems to make life easier for our customers. These systems include a fully interactive website and edi capabilities supported by a dedicated e business resource. We also attend the large global packaging shows in Dusseldorf, Shanghai and, USA as well as having office based in Shanghai to ensure global competitiveness as well as being at the forefront of emerging technologies. Our global sourcing programme encompasses over 500 products, with manufacturing sites across, China, Korea, Vietnam, Malaysia, Thailand, Europe and the USA. This programme includes full auditing of our manufacturers to Wesfarmers approved standards, incorporating, quality control, ethical sourcing, ethical labour policies and sustainable manufacturing practices.
NZM: Describe to our readers what makes your work force essential to your future? TW: Packaging and the associated equipment that we provide is a highly specialised area, it requires highly trained experts to really provide value to our customers. Our business is structured through out to deliver this expertise to our customers, with marketing, category, sourcing and sales teams all aligned into industry teams, across industrial packaging, hygiene, medical and food service to ensure we fully understand and meet our customers’ needs. It is this team of experts that differentiates Packaging House and makes us the leading national packaging distributor.
These innovations were around making life easier for our customers through specific machinery, that will streamline their production facilities, sandwich and salad sealing machinery at the Fine Food show and a full range of tape, strap and stretch film machinery at Foodtech. We will continue to bring new innovations to the market and show case at various trade shows.
NZM: Company philosophy? TW: Put the customer at the centre of everything we do and when making decisions, ask the question, will that make life easier for our customers.
NZM: Company Mission Statement? NZM: Are there incentives for staff? TW: Yes, all staff are incentivised based on either achieving individual or company sales targets, in addition all staff are shareholders in the wider parent company Wesfarmers via an annual share option. NZM: Do you export? TW: On a very small scale up into the Islands, predominantly Fiji. NZM: Is Packaging House a trade fair exhibitor and if so why? TW: We have only started back at trade fairs this year after a 5 year break. We exhibited at the Fine Food show as well as Foodtech Packtech and both shows were very beneficial due to having an innovative new offer for both.
TW: To be New Zealand’s distributor of choice by making life easier for our customers and reduce their total cost of procurement.
NZM: NZ for business – how good is it? TW: NZ is great for business, sure we have some limitations around size, scale and location but that is more than offset by the need to just get on and do things, the majority of NZ businesses are very entrepreneurial. We deal with over 7,000 customers nationally and some of the innovative, world class products, services and technologies we see and help to protect and send on a regular basis are incredible.
NZ Manufacturer November 2014
13
Work spares us from three evils: boredom, vice, and need.
PACKAGING MACHINERY
– Voltaire
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NZ Manufacturer November 2014
A successful man is one who can lay a firm foundation with the bricks others have thrown at him.
ANALYSIS
-David Brinkley
Are you a victim or a victor of the counterfeit culture? You and you alone have the power to choose. A counterfeit is a product, service, or package for a product that uses, without authorisation, the trademark, service mark, or copyright of another intended to deceive prospective customers into believing that the product or service is genuine. The truth is, detecting the difference between a counterfeit and the real McCoy is challenging and often it takes an experienced industry expert to determine the difference. If you think New Zealand has somehow been overlooked by the counterfeit culture then you are mistaken. Larry Wiechern, a senior lecturer of engineering at the Manukau Institute of Technology, says that everywhere he looks there is a story to be told about counterfeit products. “I have a car boot full of counterfeit products collected from businesses I have visited,” he says. “The problem I see is that incidences of counterfeit parts are unconnected, and in isolation don’t amount to much. But once you start looking at the whole picture it is a dreadful mess.”
It’s not just bags and watches
• military (tanks)
The one hour documentary Counterfeit Culture explores the dangerous and sometimes deadly world of counterfeiting, and reports a staggering $700 billion in counterfeit trade that represents nearly 10% of the global trade. A lot of people mistakenly belief the counterfeit culture is restricted to retail consumer products, such as branded watches and purses in retail distribution. This creates the perception that counterfeiting is a harmless financial crime that affects trademark piracy and copyright infringement of branded products.
• bearings
On the contrary, counterfeit products can be found as replacement parts or even as OEM components in different product assemblies and applications in many industries and types of product applications. Common examples of counterfeit products include: • high strength mechanical fasteners (bolts) • construction (bridges, cranes, high rise building) • aircraft (wing attachment, landing gear)
• electrical and electronic components (extension cords, circuit breakers, relays, electronic chips, switches, transformers) • power tools. The list can go on.
Eugene Moreau
What can be done about counterfeits creating havoc in your business? Silent complicity will sustain the growth of the counterfeit culture. It’s time to step up and protect our businesses from becoming a victim of the fake. Trace the path of your product to the origin of manufacture.
Counterfeiting crosses industry borders with ease Counterfeiting is a problem facing every successful company in virtually every industry imaginable, in every part of the globe: food, drinks, clothes, shoes, pharmaceuticals, electronics, auto parts, toys, currency, tickets for transport systems and concerts, alcohol, cigarettes, toiletries, building materials and much, much more. While counterfeiters reap significant profits, millions of consumers are at risk from unsafe and ineffective products.
Conclusion The problem and challenges of counterfeit products are multiplying. Whether you are a consumer, manufacturer, a construction company or a maintenance operation, you are exposed to the corrosive return of unsafe fake and counterfeit products in our New Zealand market.
The honey trap is set with the simple, brutal allure of ‘cheap price’ and while some consumers recognise the difference between a cheap price and a bargain they still forge ahead taking on the risk of the counterfeit lottery wheel spin.
*Eugene Moreau is Business Facilitator at EnterpriseMIT
One person making one decision starts the revolution to defeat the counterfeit culture in an organisation. Someone has to start it. Why not you?
www.enterprisemit.co.nz
Protect your business and break the counterfeit culture. What we offer Whether you’re a consumer or a
Five questions answered in this seminar:
manufacturer, a construction company or a
• What are counterfeits in our industry, and
maintenance operation, you are exposed to
where do they come from?
the counterfeit culture.
• What damage do they cause to business and
If you own an SME, or you’re responsible for
the economy?
purchasing new and replacement products for your business, you cannot afford to miss this
• How do we stop counterfeits crossing our
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• Hear the experts talk about the serious
• What are the hidden and often irrecoverable
• See counterfeit examples, and hear stories
costs of counterfeiting?
of damage and business disruption. • Walk away with a checklist to protect your business.
www.nzmanufacturer.co.nz EMIT030
Location: MIT Manukau Date:
Wednesday 11 March, 2015
Time:
3–6pm (3 hours)
• Who wins from the counterfeiting game?
impact of counterfeits.
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NZ Manufacturer November 2014
The light at the end of the tunnel has been turned off due to budget cuts. -David Brinkley
15
THE INTERNET OF THINGS
The Zero Marginal Cost Society: The Internet of Things, the Collaborative Commons, and the Eclipse of Capitalism - Jeremy Rifkin seamless network. People, machines, natural resources, production lines, logistics networks, consumption habits, recycling flows, and virtually every other aspect of economic and social life will be connected via sensors and software to the TIR platform, continually feeding Big Data to every node—businesses, homes, vehicles, etc.—moment to moment in real time. The Big Data, in turn, will be analyzed with advanced analytics, transformed into predictive algorithms, and programmed into automated systems, to improve thermodynamic efficiencies, dramatically increase productivity, and reduce the marginal cost of producing and delivering a full range of goods and services to near zero across the entire economy. Some of the leading IT companies in the world are already busy at work on the build-out of the Internet of Things infrastructure for a Third Industrial Revolution. GE’s “Industrial Internet,” Cisco’s “Internet of Things,” IBM’s “Smarter Planet,” and Siemen’s “Sustainable Cities” are among the many initiatives currently underway to bring online an intelligent infrastructure that can connect neighbourhoods, cities, regions, continents and the global economy, in what industry observers call a global “neural network.”
continued from page 1 information and energy, a new digital manufacturing revolution now opens up the possibility of following suit in the production of durable goods. In the new era, everyone can potentially be their own manufacturer as well as their own internet site and power company. The process is called 3D printing. 3-D Printers run off a three dimensional product using computer aided design. Software directs the 3-D printer to build successive layers of the product using powder, molten plastic, or metals to create the material scaffolding. The 3-D printer can produce multiple copies just like a photocopy machine. All sorts of goods, from jewellery to mobile phones, auto and aircraft parts, medical implants, and batteries are being “printed out” in what is being termed “additive manufacturing,” distinguishing it from the “subtractive manufacturing,” which involves cutting down and pairing off materials and then attaching them together. 3-D entrepreneurs are particularly bullish about additive manufacturing, because the process requires as little as 10 percent of the raw material expended in traditional manufacturing and uses less energy than conventional factory production, thus greatly reducing the cost.
The energy saved at every step of the digital manufacturing process, from reduction in materials used, to less energy expended in making the product, when applied across the global economy, adds up to a qualitative increase in energy efficiency beyond anything imaginable in the First and Second Industrial Revolutions. The democratization of manufacturing is being accompanied by the tumbling costs of marketing. Because of the centralised nature of the communication technologies of the first and second industrial revolutions—newspapers, magazines, radio, and television—marketing costs were high and favoured giant firms who could afford to devote substantial funds to market their products and services. The internet has transformed marketing from a significant expense to a negligible cost, allowing start ups and small and medium size enterprises to market their goods and services on internet sites that stretch over virtual space, enabling them to compete and even out compete many of the giant business enterprises of the 21st century. As the new 3-D technology becomes more widespread, on site, just in time
customised manufacturing of products will also reduce logistics costs with the possibility of huge energy savings. The cost of transporting products will plummet in the coming decades because an increasing array of goods will be produced locally in thousands of micro-manufacturing plants and transported regionally by trucks powered by green electricity and hydrogen generated on site. The lateral scaling of the Third Industrial Revolution allows small and medium size enterprises to flourish. Still, global companies will not disappear. Rather, they will increasingly metamorphose from primary producers and distributors to aggregators. In the new economic era, their role will be to coordinate and manage the multiple networks that move commerce and trade across the value chain. Rifkin’s vision is already gaining traction in the international community. The European Union Parliament has issued a formal declaration calling for its implementation, and other nations in Asia, Africa, and the Americas, are quickly preparing their own initiatives for transitioning into the new economic paradigm.
The network is designed to be open, distributive and collaborative, allowing anyone, anywhere, and at any time, the opportunity to access it and use the Big Data to create new apps for managing their daily lives. The increased energy efficiency and accompanying productivity gains that come with the shift into a Third Industrial Revolution infrastructure, prepares the way for a sustainable circular economy. Using less of the earth’s resources more efficiently and productively and making the transition from carbon based fuels to renewable energies, is a defining feature of the Collaborative Age. 3D Printing and the Third Industrial Revolution While the Third Industrial Revolution (TIR) economy allows millions of people to produce their own virtual www.nzmanufacturer.co.nz
NZ Manufacturer November 2014
Work spares us from three evils: boredom, vice, and need. – Voltaire
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NZ Manufacturer November 2014
Work spares us from three evils: boredom, vice, and need. – Voltaire
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NZ Manufacturer November 2014
DEVELOPMENTS
The successful man is the one who finds out what is the matter with his business before his competitors do. -Roy L. Smith
Millennium Plastics successful at Plastics Industry Design Awards Recently, Hamilton-based Millennium Plastics Ltd was awarded the overall Supreme Award at the 2014 Plastics Industry Biennial Design Awards for their contribution to the design and development of Waikato Milking Systems’ all-new Electronic Milk Meter. The company also took out Gold Awards in both the Primary Product
and Conventional Injection Moulding Process Categories. Millennium Plastics General Manager Tony Rutz said, “We are extremely honoured to receive these three awards. It is great validation for our staff, who are truly the very best in New Zealand. “At Millennium Plastics, we do things
a bit differently. We’re not simply another plastics design and moulding company. “Our expertise lies in working side-by-side with our customers to ensure their original product ideas and designs capture the greatest value for their business and achieve the product benefits they promise their customers.” Waikato Milking Systems new Electronic Milk Meter provides accurate real-time milking data, enabling dairy farmers to improve herd management decisions and long term profitability of their herds. Product Design Manager Jim Pharaoh, said “Our first concepts for our electronic milk meter were developed several years ago. Several prototypes were trialled on farms resulting in a computer model which was submitted to Millennium Plastics for their critique and manufacture of the meter which was released to farmers in August this year.
“The modern milking shed is a very challenging environment to design for as you need to develop products to withstand contact with milk, heat, cleaning chemicals and moisture. Over the years we’ve found that with careful material selection we can satisfy all those criteria while also injecting a high level of innovation and creativity into our product designs. “Simplicity is the cornerstone of Waikato Milking Systems’ design philosophy and the modern plastics technology Millennium Plastics allows us to make very complex forms to create simple, effective products. The end result is that we supply products to our customers that are both reliable and fit-for-purpose.” Millennium Plastics specialises in the design, development, and manufacture of high-end plastic products. It works with clients in a range of industries, including dairy, animal health, electronics, medical and safety.
Left to Right, Jim Pharaoh Product Design Manager at Waikato Milking and Tony Rutz, General Manager Millennium Plastics.
Qualification comes from dedication continued from page 1 As well as the benefit of the qualification management team has witnessed all of these employees grow in many different ways, including the following; • Significant improvement in communication skills • Developing processes and equipment at home to improve their work areas • Talking in front of groups • Purchasing their own homes • Moving out of home for the first time • Improvement in English as a second language • Applying for promotions and being successful • Continued education As a business, B&D Doors (NZ) Ltd have managed to retain these people and seen a high level of engagement whereas many other Canterbury manufacturing companies have lost staff during this turbulent time. Both qualifications are based on the Lean Manufacturing Principals and cover the following common modules. • 497 – Demonstrate Knowledge of Workplace Health and Safety Practices • 17593 – Apply Safe Work Practices in the Workplace • 19506 – Demonstrate Knowledge of Company Quality Policy on a Manufacturing Site • 1501 – Apply Competitive Manufacturing Practices in a Competitive Manufacturing Organisation • 21504 – Apply Quick Changeover Procedures • 21505 – Apply JIT Procedures in a Competitive Manufacturing Organisation • 21506 – Apply Cost Factors to Work Practices in a Competitive Manufacturing Organisation • 21507 – Interpret Production Costs • 21508 – Apply 5S Procedures in a Competitive Manufacturing Organisation • 21332 – Demonstrate Knowledge of Establishing Improvements in a Manufacturing Organisation • 21330 – Perform Calculations for Manufacturing Production Processes • 21329 – Maintain Housekeeping in a Manufacturing Environment
For the National Certificate in Competitive Manufacturing (Level 2) the additional subjects were also passed. • *21502 – Sustain Process Improvements in a Competitive Manufacturing Organisation
www.nzmanufacturer.co.nz
Top row, Left to Right Tulipe Gale, Geoffery Bowkett, Tom Tanswell, Joseph Maugaotega, Colin Miles, Scott Russell, Patrick Lewis, Rochelle Chapman, Shane Peters, Brent Wigney. Middle Row, Left to RighT Zane Branthwaite, Sue Vallance (Tutor), Ray Baxter, Ian Roberts, Paul Labrooy, Marguerite Bodger, Mikel Kavanagh, Pita Faau. Bottom Row, Left to Right Ray Brown, Michael Sullivan, Paul Dryden (Operations Manager), Neil Taylor, Chris Lamond, Malcolm McNeice, Robbie Thoms. • *21503 - Manage impact of change on own work in a Competitive Manufacturing Organisation • *21515 - Undertake Root Cause Analysis in a Competitive Manufacturing Organisation
All of these subjects were taught and practically applied to their own work areas and teams. B&D Doors is New Zealand’s leading manufacturer of sectional and roller doors and supplier of automatic openers and other related products servicing the commercial, industrial and residential markets. The company has a workforce of 90 people and manufacturing sites in Auckland and Christchurch. Products are marketed through nationwide dealer networks under the Garador and Dominator brands. B&D Doors is part of the DuluxGroup group of companies.
NZ Manufacturer November 2014
Every employee rises to the level of his own incompetence. -The Peter Principle
19
THE FUTURE OF MANUFACTURING
Enhancements to PowerMILL CAM system deliver high-speed and five-axis machining One of the most eagerly awaited presentations leading to SE-Asian delegates at the Delcam Autodesk ‘Asian Technical Summit’, held this year in the cultural and tourism centre of South Korea, Gyeongju City, was the 2015 enhancements to the company’s PowerMILL CAM system for high-speed and five-axis machining. This included improvements to the Vortex high-efficiency, ‘area-clearance’ strategy; more flexible collision-checking to also cover near misses; and better raster finishing.
Speed - Minimises calculation times
Demonstrating their global technical leadership Mark Forth, advanced manufacturing systems manager and Charlie Jones, senior applications engineer, positioned the update product against future challenges to manufacturers around the world, including Australia and New Zealand – with some startling statistics.
Customisation – Standardise your processes
A recent World Economic Forum noted that 10-million manufacturing jobs could not be filled due to a growing skills gap. “With the growing global skills shortage – a recent World Economic Forum noted that 10-million manufacturing jobs could not be filled due to a growing skills gap – and the imminent retirement in the next five years of some 40-percent of skilled employees in the US (and New Zealand) engineering sector. Manufacturers want: • 100-percent protection and utilisation of their multi-million dollar investments. • Shopfloor managers to have a fail-safe system for new apprentices. • CAM systems to be easy to use, but also safe and reliable. • Machinists with the confidence to operate CNCs unattended. “Engineers, technicians, skilled trades workers and researchers are all in the top 10 jobs Asia Pacific employers surveyed in the recent 38,000 study by the Manpower Group are battling to fill. Globally 18-24-year olds want ‘professional’ employment,” says Forth. All of the above contextualises engineering boffin Jones’s presentation of the relevance of what he described as ‘world-leading 2, 3 and 5 axis CAM software’ under the Delcam PowerMILL label. “We deliver:
• 64-bit support, multi-threading, background processing Flexibility – Maximises your workshop facilities • Complete control over 3- to 5-axis mills and 8-axis robots Optimisation – Modify toolpaths easily • Powerful toolpath editing for precision machining • Automate specialist tasks Reliability – Complete peace-of-mind • Detect and avoid collisions Ease-of-use – Fast ROI”. • Quickly program complex multi-axis machines.” By way of background, 3+2 machining enables the tool to rotate to an angled position to reach more areas of the part, which can be more aggressively machined, thereby reducing cycle times and improving the all-important surface finish. While simultaneous 5-axis machining gives the operator complete control of the tool orientation around the work piece and allows complex parts to be machined in a single setup, cutting costs and saving time. Delcam, a global leader in computer-aided manufacturing, with an annual R&D budget of 25-percent of sales, believes two enhancements in PowerMILL 2015, in particular, will give even greater reductions in machining time with Vortex compared to conventional roughing. Vortex produces safe toolpaths, with a much deeper cut by using a controlled engagement angle which maintains the optimum cutting conditions for the whole toolpath. Consequently, the higher feed rates and material-removal rates are possible, making the cutting time shorter by as much as 70-percent. In addition, cutting is undertaken at a more consistent volume-removal rate and at near constant feed rate – so extending tool life and protecting the machine. “The first change allows toolpaths to approach the part from outside the stocks at the cutting height for open pockets or in areas where earlier cuts have made this possible. 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.
“Changes to the roughing algorithm have now reduced the number of lifts per toolpath slice to the Mark Forth. minimum needed, and so made area clearance much more efficient.” Delcam has also evolved additional improvements in their breakthrough ‘collision-checking’ within the software. “Firstly and significantly, collision-checking has been changed so that warnings can also now 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 will 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, and that makes 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.” Companies using four- or five-axis machines with trunnions or similar tables, will be helped by another improvement. Says Forth: “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.” Turning to the improvement in raster finishing, which has also been added to the 2015 upgrade, Forth noted the software was now able to automatically set the most appropriate angle for each region of 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 which already existed for steep-and-shallow finishing and face milling, is most beneficial when finishing and series of pockets aligned in different directions.” A number of improvements have been made to the PowerMILL interface.
“The extra time which can be saved depends on the shape of the part, but an additional saving of around 20-perecent should be expected above the earlier releases of Vortex,” Jones says.
Jones again: “Most important is a clearer form for the strategy selector which 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.
Another problem in the 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.
“In addition, 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.” www.nzmanufacturer.co.nz
20
NZ Manufacturer November 2014
THE FUTURE OF MANUFACTURING Aerospace is the industry that other industries look to for a glimpse at what’s on the horizon. Aerospace has a long history of being an early adopter, innovator and investigator. What this industry was doing decades ago has now become commonplace, almost pedestrian. For example, the aerospace industry was the earliest adopter of carbon fibre, and it was the first to integrate CAD/ CAM into its design process. There are many other examples that show that trends in aerospace are predictors of future trends in manufacturing across all industries.
Additive manufacturing trends in aerospace Executive Summary Until the 21st century, all disruptive innovations followed the same adoption curve. But with exponential technologies and digital connectedness, disruptive innovations now have steeper adoption bell-curves as implementation rates accelerate.3D printing is one such accelerating disruptive innovation – and it’s ready for aerospace manufacturing now. Ideal for small volumes and customized production, 3D printing makes lighter-weight, fully assembled components at a fraction of the cost and time compared to just a few years ago. Extending the frontier of the possible Innovation in aerospace is accelerating, advancing frontiers at the component and product levels in manufacturing operations, in rethinking supply chains and, in some cases, at the business model level. Parts can now be created with complex geometries and shapes that in many cases are impossible to create without 3D printing. Low aerospace volumes make 3D printing an attractive, lower-cost alternative to replace conventional CNC machining and other tooling processes for smaller-scale parts and finished assemblies. Aerospace innovators are embracing 3D printing beyond prototyping and are aggressively pursuing new
applications for the technology. Some leading aerospace manufacturers are already using it to fabricate jigs and fixtures, production tooling and final end-use parts for lightweight wing assemblies in small aircraft and unmanned aerial vehicles (UAVs). Production parts for instrumentation (Kelly Manufacturing), air ducts (Taylor Deal) and wingspans (Aurora) are airborne today in commercial, military aircraft and UAVs. New 3D printing design freedoms encourage simpler, lower-cost design and assembly. 3D printing poses a competitive threat to slow adapters wedded to status-quo methods for prototyping, tooling and custom part production using CNC machining, aluminium casting and injection moulding. Complexity is free with 3D printing. Barriers to adoption and the status quo Despite widespread interest, the biggest barriers in implementing this new manufacturing revolution are internal: breaking down status-quo beliefs on what’s possible and rethinking existing tooling and manufacturing methods prove difficult. True, existing processes and behaviours are hard to change and manufacturing without a traditional factory is unrealistic. However, we see accelerated adoption of 3D printing in specific industries such as aerospace and a general spread
of the use of technology as designers and engineers expand what’s possible with this technology. Additionally, unlocking investment capital and resources to learn and adopt new design and manufacturing techniques is difficult for some aerospace original equipment manufacturers (OEMs) and suppliers, who are locked into a quarterly driven revenue cycle and budgets. However, the improvements that 3D printing offers should drive adoption deeper into related processes and increase competence, confidence and competitive flexibility. Driving down cost and weight, safely Innovative aerospace manufacturers want to drive down cost and weight of aircraft, improve economy and design aesthetics and adhere to stringent FAA regulatory and compliance standards. The type and scale of 3D printable parts is increasing alongside the size of print bays and the range of 3D printable material types. For aerospace, the availability of lightweight, flame- and chemical-resistant 3D printing material is key to broader application. Fracture-resistant material able to withstand temperature extremes and G-force stress also increases the range of applications.
www.nzmanufacturer.co.nz
By Joe Hiemenz, Stratasys, Inc
Manufacturing Processes 3D printing has helped shape aerospace for 20 years and is well established for prototyping and testing concepts. Before the term “3D printing” gained notoriety, manufacturing experts employed the process known as “additive manufacturing” to cut costs and time to market. Beyond design and prototyping lie many additional opportunities to leverage 3D printing for custom manufacturing tools. Tooling Rotary wing and fixed wing repair specialist Advanced Composite Structures (ACS) performs low-volume component manufacturing using composite parts. This work requires layup tools, mandrels, cores and drill guides. When these are produced through CNC machining, ACS invests several months and many thousands of dollars. And when changes occur, costs rise and delays mount. ACS adopted 3D printing and uses it for nearly all of its composite tooling needs. On average, 3D printed layup tools cost only $400 and are ready for use in 24 hours – saving thousands of dollars and weeks of production time from traditional methods – and leaving room for last-minute corrections or changes.
NZ Manufacturer November 2014
21
Never try to teach a pig to sing. It wastes your time and it annoys the pig.
-George Bernard Shaw
3D printing really shines for hollow composite parts, such as a capsule for a remotely piloted vehicle. Wrapping composites around a soluble core made with 3D printing eliminates tooling bucks and two-piece clamshell tooling. Piper Aircraft uses hydroforming for hundreds of aluminium structural parts on new aircraft. In the past, it used machined tools for sheet metal forming. Piper determined that polycarbonate tools could withstand hydroforming pressures ranging from 3,000 to 6,000 psi, making it suitable for forming all of its structural parts. And 3D printing’s speed can’t be beat. “I can program an FDM part in 10 minutes while a typical CNC program takes four hours to write,” said Jacob Allenbaugh, manufacturing engineer, Piper Aircraft. “The FDM machine can be much faster than a CNC machine and does not require an operator in attendance.” Another 3D printing advantage: “Material waste with FDM-based 3D printing is much less than CNC machining because the FDM support material is typically less than 20 percent of the total,” said Allenbaugh. Piper’s next phase of plastic 3D printing hydroforming tools will focus on building a more efficient aircraft by moving to more complex and organically shaped parts made possible by 3D printing. Jigs, Fixtures and Surrogates While 3D printing is making a significant impact in manufacturing, some of its applications such as injection moulding and jigs and fixtures are being overlooked due to lack of headline appeal. But attention should be paid: Many manufacturing tools can be created with 3D printing faster and less expensively than with traditional methods. Moulds, templates, surrogates, jigs and fixtures can all be ready for use in hours, not weeks. Surrogates — which are placeholders
for the production assemblies — are full-featured low-cost replacements for high-value parts. 3D printed surrogates are used on the production floor and in the training room. For example, Bell Helicopter used surrogates to assess an Osprey hybrid aircraft’s tail-wiring configurations. Bell used an FDM-driven 3D printer to build polycarbonate wiring conduits. Technicians installed the branching conduit’s six mating sections inside the Osprey’s twin vertical stabilisers for on-the-ground confirmation of the wiring path. Using FDM-driven surrogates, conduits were ready for installation in two and a half days, nearly a six-week reduction from Bell’s alternative using cast aluminium parts. Bell also spent substantially less for the 3D printed parts. Production In addition to prototypes and tooling, modern 3D printing technology can produce durable, stable end-use parts — bypassing the production line altogether. The Production Series of 3D production systems — the Stratasys® line of larger, top-of-the-line 3D printers — uses a range of materials, including high-performance thermoplastics, to create parts with predictable mechanical, chemical and thermal properties. Boeing, for example, uses 3D printing while manufacturing aircraft for multiple airlines. Although the plane itself is essentially the same from one order to the next, the interiors vary; as a result, a particular air duct may bend to the right instead of upward. Thus ordering a custom $40,000 tool made overseas to create just 25 of these parts is extravagant and time-consuming. Boeing overcomes these problems by 3D printing the custom end-use parts and installing them directly on the aircraft. GE Aviation is another company using 3D printing in its production process. 3D printing has realised a weight reduction of over 500 pounds per engine in external fittings and castings, which can result in significant fuel consumption improvement for its customers. “The current machines will rapidly find applications in tooling and jigs, replacing long cycle machined parts in the near term,” said Dr. Todd Rockstroh, consulting engineer for GE Aviation. “As your technical staff engages the technologies, the applications will follow.”
Commercial/ Military Ta y l o r - D e a l Automation uses 3D printing to prototype for its engineering and modification of specialty fluid and air handling parts. “With 3D printing we have design flexibility, cost reductions, weight savings and improved lead times,” said Brian Taylor, president, “all with low-quantity production.” Taylor’s 3D printing material of choice is ULTEM®9085 resin, which meets FAA flame regulations. Having a flight-grade material “gives designers much more flexibility when designing parts. It allows us to reduce engineering time and manufacture a less expensive part.” The design and manufacturing flexibility results in more efficient aircraft. The 3D printed parts contain less material, so their weight is approximately one-third or less that of the metal parts they replace. (UAS)Unmanned Aerial Systems UAS production is another rapidly growing segment for 3D printing because of the industry hurdles 3D printing easily clears: complex systems, manufacturing iterations, low volumes, structural complexity, the need to save weight and the absence of passenger safety regulations to hinder deployment. Aurora Flight Sciences, which develops and manufactures advanced unmanned systems and aerospace vehicles, fabricated and flew a 62-inch wingspan aircraft — where the wing was composed entirely of 3D printed components. This manufacturing approach reduces the design constraints that engineers face when using traditional fabrication techniques. The design of the wing’s structure was optimized to reduce weight while maintaining strength. “The success of this wing has shown that 3D printing can be used to rapidly fabricate the structure of a small airplane,” said Dan Campbell, structures research engineer at Aurora.
3D printed structures and 3D printed electronics. Aurora worked with Stratasys and Optomec to combine FDM and Aerosol Jet electronics printing to fabricate wings with integrated electronics. “The ability to fabricate functional electronics into complexly shaped structures using 3D printing can allow UAVs to be built more quickly, with more customisation, potentially closer to the field where they’re needed. All these benefits can lead to efficient, cost-effective field vehicles,” said Campbell.
“If a wing replacement is necessary, we simply click print, and within a couple days we have a new wing ready to fly.” Smart parts enhance performance and functionality in two ways: 3D printers enable lighter-weight mechanical structures, and conformal electronics printed directly onto the structure free up space for additional payload.
“If a wing replacement is necessary, we simply click print, and within a couple days we have a new wing ready to fly.”
Another company, Leptron, produces remotely piloted helicopters. For its RDASS 4 project, Leptron used 3D printing to make 200 design changes — each component had at least four modifications — without incurring a penalty in time or cost.
Aurora also uses 3D printing for an emerging application: “smart parts,” which are hybrid parts that include
When the design was ready to take off, Leptron had flight-ready parts in less than 48 hours. www.nzmanufacturer.co.nz
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NZ Manufacturer November 2014
FUTURE OF MANUFACTURING
Always forgive your enemies. Nothing annoys them more. -Oscar Wilde
Infrared thermography prevents the spread of viruses Since the Swine Flu threat and the most recent outbreak of Ebola in West Africa, health care providers and public officials have been using non-contact infrared cameras to quickly scan large numbers of people in public areas for the elevated body temperatures that could indicate a virus infection. Airports, bus stations, seaports, hospitals, schools and other public gathering areas are a few examples of where non-contact thermal imaging could be used to detect and help prevent the spread of virus infections. Non-contact infrared cameras produce an infrared (IR) or thermal image which can detect very subtle temperature differences, letting officials instantly identify individuals who register higher than normal body temperatures, so they can be isolated for further evaluation. Individuals with fevers often have elevated skin temperature and infrared cameras have the ability to measure extremely subtle temperature differences. The body’s highest temperature measurement is generally around the nose, eye socket and oral cavity areas. A non-contact infrared
camera can quickly scan large crowds for individuals who register higher than normal body temperatures and an alarm can be triggered to indicate further testing is needed using a contact thermometer specifically designed to measure body temperature.
Fluke infrared cameras to help in the screening process of H1N1 influenza A (Swine Flu). Fluke infrared cameras provided a means for screening large numbers of people from a distance, quickly and easily with minimal disruption. And since using IR for health
screening required little training, the technology was easy to integrate into existing security measures. With the help of Fluke infrared cameras, seven confirmed cases of persons affected by the H1N1 influenza A were detected at the Mexico City airport.
Benefits of non-contact infrared temperature measurement include: • non-contact, which reduces the chance of spreading infection or disease • immediate temperature measurements • safe and innocuous screening with no risk to public safety • people can be screened while moving, which means travel is not delayed. In 2009, officials at the Benito Juarez Airport in Mexico City turned to
Olympus gives instrumental support to AINDT Each year, the Australian Institute of Non-destructive Testing (AINDT) Conference provides the opportunity for maintenance and quality assurance professionals to learn more about NDT and related technologies from leading AINDT members including Olympus. The four day conference is being held this year at the Sofitel Brisbane Central from 23-26 November. NDT is any analysis technique used to evaluate the properties of materials or
components without causing damage or permanently alter the article being inspected. On its stand at the AINDT Conference, Olympus will be demonstrating a range of NDT, phased-array, remote visual inspection (RVI) and X-Ray fluorescence (XRF) portfolios to attendees. “We continue our commitment to the Institute and its ongoing initiatives promoting the benefits of NDT,” said Graham Maxwell, National Key
Accounts & Technical Manager at Olympus. “We will be demonstrating our range to new customers and showing our continued support and commitment to existing customers.” Olympus staff will be on hand to discuss the latest NDT tools from the company. Richard Nowak, NDT Product Specialist, will be giving practical demonstrations of the Nortec N600 Eddy Current analyser and the RollerFORM phased array wheel probe. A special guest at this year’s conference will be Nicholas Bublitz, who is visiting Australia again from Olympus Scientific Solutions America. He will be presenting a technical paper entitled “Improving Surface Mine Profitability with Phased Array Ultrasonics.” Visitors to the Olympus stand will have the opportunity to meet with Bublitz to discuss a range of NDT solutions or troubleshoot advanced applications with a renowned international product specialist. Bublitz has been a Global Product Support Specialist with Olympus
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SSA since 2012. He is responsible for the global support and industry advancement of all NDT equipment produced by Olympus. Mr Bublitz’s primary focus during his Australian visit will on Phased Array, and Time of Flight Diffraction (TofD) ultrasound. “With the newest technologies and the range of analysis, testing and imaging instrumentation available, we can supply equipment for a wide range of non-destructive applications to a wide variety of industries,” Maxwell concluded. “We are committed to the development of new technologies, products, and services that offer the best solutions to meet the needs of our customers.” The Olympus RollerFORM phased array wheel probe simplifies composite material inspection
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THE FUTURE OF MANUFACTURING Why it pays to join the circular economy \We all know that the current linear economic model is not sustainable. Materials are extracted, manufactured into products and then discarded into landfill – it’s a system that wastes valuable resources, causes environmental damage and will make it near impossible to satisfy the demands of the 3 billion new consumers in developing nations, who are expected to join the middle class by 2030. The concept of the circular economy is about decoupling growth from resource consumption – and maximising the positive environmental, economic and social effects. It’s about designing products so that they are easier to reuse or recycle, like Timberland’s Earthkeeper shoes. It’s about making sure that every product ingredient is biodegradable or fully recyclable, like the chemicals company that has replaced fossil-fuel feedstocks in their production methods. It’s about maximising useful product life by repairing or remanufacturing, like Caterpillar’s parts-refurbishing
programme. The circular economy is about new business models that have shifted from selling products to selling services, such as the tyre company that offers a per-km tyre-leasing service. It is about eliminating waste from production, and making sure any waste is recovered as a valuable resource, whether it’s heat, slurry, nutrients, organic material, metal, salt – whatever. It’s about engaging your customers throughout the life cycle of the product, instead of the few minutes during which they make a purchase; and, ultimately, it’s about gaining competitive advantage. The scale of the competitive advantage is startling. Against a backdrop of resource prices that have more than doubled over the past 10-12 years, erasing the commodity-price decline of the 20th century, our material-saving potential is expected to reach around $1 trillion per year by 2025. The opportunity presented by the circular economy in Europe and the US pales into insignificance compared with what is at stake in developing
An ordering platform for 3D printed grippers SCHUNK eGrip, the world’s first fully-automated design and ordering tool for additive manufactured gripper fingers, is now in BETA testing before being released to the general public. SCHUNK eGrip is a browser-based, license-free application to create and order tailor-made gripper fingers in just a few mouse clicks. Users just have to upload STEP or STL data of the part to grip, and add specific information such as weight, gripper base, mounting direction and relative position of the part to the gripper. The software automatically configures the gripper fingers around the part, generating the optimal finger design, and immediately gives price and estimated delivery information. eGrip is a strong example of the innovative ideas you can realize when you combine the core competences of two leaders in their fields – SCHUNK for Gripping and Clamping and Materialise for 3D Printing software and services. The result of the collaboration is the world’s first fully automated design tools for additive manufactured gripper fingers. What’s more, the browser-based, license-free platform also reduces the design and ordering time for customised gripper fingers to just 15 minutes.
For this collaboration with SCHUNK, Materialise developed a user-friendly interface that automates the design phase and allows for immediate order placement. SCHUNK eGrip integrates with Materialise’s additive manufacturing automation and control software Streamics and places orders automatically in its certified production for laser sintered polyamide. The fully automated process allows parts to be delivered within a few days. For users, this means a time advantage of several weeks compared to traditional manufacturing techniques. Materialise is a provider of Additive Manufacturing (AM) software solutions and sophisticated 3D printing services in a wide variety of industries, including healthcare, automotive, aerospace, art and design and consumer products. Materialise has been playing an active role in the field of AM since 1990, through its involvement in AM for industrial and medical applications, by providing biomedical and clinical solutions such as medical image processing and surgical simulations and by developing unique solutions for its customers’ prototyping, production, and medical needs.
nations, and only decoupling growth from resource consumption will allow developing countries to enjoy the same products, services and standards of living that we have begun to take for granted in the industrialised world. There are those already catching on to this competitive advantage. Take, for example, anyone involved in the World Economic Forum and Young Global Leader’s first annual Circular, which recognises ideas leading the transformation towards a truly restorative industrial economy. Examples also abound in China. The nation is leading the developing world in implementing a circular economic model, which it formally adopted in 2002. It is seen as a way for China to avoid the sort of environmental damage that typically takes place as economies
industrialise. The China Association of Circular Economy claims that the country’s circular economy grew by 15% annually between 2006 and 2010, and projects it will almost double from 1 trillion Yuan ($164 billion) in 2010 to 1.8 trillion Yuan ($295 billion) in 2015. Research shows that in the coming decade, between 6 and 7 million jobs will be created in China.
Snake robot to the rescue University of Waikato Master of Engineering (ME) student Pinwei Jin has designed and built a remote control robotic snake, which he hopes will be used in the future for rescue operations. “Earthquakes and other natural disasters happen frequently in New Zealand and when it comes to the big ones, many lives could be saved if search and rescue operations were conducted more effectively and efficiently,” says Pinwei. Differing from the existing mobile rescue robot systems currently in the market place, he says his Snake Robot provides the flexibility of movement needed in cluttered and irregular environments created by disasters. “The Snake Robot features a wireless camera on its head and is controlled by a wireless joystick to move forward, backwards, left and right. It has 16 degrees of freedom from the eight joints, nine segments, 16 motors and nine passive wheels. Essentially it can move along the ground like a snake.” Pinwei attended high school in a small town in central China. After completing a Bachelor of Engineering at Wuhan University of Technology in China, he heard about the University of Waikato from friends and based on the University’s reputation, decided to enrol. Pinwei is in the final stages of an ME in Mechanical Engineering supervised by engineering lecturer Dr Chi Kit Au. His prototype was on show recently at the University of Waikato Master of Engineering University of Waikato’s Carter Holt Harvey student Pinwei Jin with his Snake Robot prototype at the Carter Holt Harvey Pulp & Pulp & Paper Engineering Design Show. Paper Engineering Design Show. www.nzmanufacturer.co.nz
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NZ Manufacturer November 2014
Early to bed and early to rise probably indicates unskilled labour
FOOD MANUFACTURING
.-John Ciardi
Avoid going backwards, dairy farmers Dairy farmers need to take action now to avoid going backwards once the current forecast pay-out begins to take effect next year, says Justin Geddes, Agribusiness Principal from Crowe Horwath.
New Zealand Government owned AsureQuality and PwC’s New Zealand and China firms are cooperating with COFCO, China’s largest agricultural and food products supplier, to continually improve China’s food safety and quality. All four parties signed a cooperation agreement to that effect on the side-lines of the 2014 Asia Pacific Economic Cooperation Summit in Beijing, China.
2014 was a record pay-out season and dairy farmers have just banked the last of the retrospective payments, but this season’s advance is more than $2 per kgMS below last year’s. “While accounts might look positive now, the recent record past payments are hiding the effect of this season’s lower advance,” he said. “This drop will see a lot of pressure on farm cash flows from May to October next year.” Mr Geddes said that, like any business facing a significant drop in income, dairy farmers should be carefully examining their budget. He recommended: * Looking at all variable costs to see what can be cut or improved. * Being aware that provisional tax for this year is based on last year, so a re-estimation of the 2015 tax is essential. * Looking at capital expenditure and working around or putting off ‘replacements’ wherever possible.
* Re-visiting bank funding to see if a change of loan term or type of debt would help navigate any shortfall.
with their advisory team to review
The budget review should be looking a minimum of two years out, said Mr Geddes, who added that the full effect of the drop in pay-out will not be felt until the 2016 season.
current tough environment, he said.
“The impact of this will see some operations struggle to reduce debt, but reward farmers who make an effort to manage the situation now,” he said. “If the pay-out drops further, break-even will become difficult for some.”
operations might have to consider a
Mr Geddes recommended dairy farmers schedule regular meetings
planning now for the impact of the
actual to budget performance, with every item scrutinised. Having a good team of advisors is important in the It was also important for farmers to keep in close communication with their banker, and highly leveraged period of interest-only repayment on loans. “The key message is that, just because the bank account might look healthy at the moment, they should start forecast low pay-out,” he said.
New pastures may be future weed threat Breeding new fast-growing grass varieties that produce more seeds and are resistant to drought, pests, grazing and disease may inadvertently be creating the next generation of invasive weeds, warns an international team of researchers. As the global demand for dairy and beef escalates, farmers are increasingly seeking ways to reap greater productivity from their pastures. The problem is that in making grass varieties more robust, they are more prone to becoming a problem for the environment. For instance, new varieties can invade adjacent areas and spread across the landscape, or they can interbreed with existing invasive weeds. That’s according to Professor of Plant Biosecurity at Lincoln University and lead researcher at the Bio-Protection www.nzmanufacturer.co.nz
Building NZ’s reputation as a leader in food safety in China
Research Centre, Philip Hulme, who has co-authored a research paper published in the latest edition of Proceedings of the National Academy of Sciences (PNAS). “Pasture species such as ryegrass and fescue may not strike people as major threats to the environment but they are regarded by the Department of Conservation as environmental weeds,” explains Professor Hulme. The research team have highlighted the need for government and agribusiness to ensure pasture plants are of low risk to the environment. “Pasture is big business in New Zealand and a large part of our economic success arises from agribusiness developing ever more productive or persistent varieties,” says Professor Hulme. “As a result there is a clear conflict between
economic and conservation outcomes.” Agribusinesses do not have to assess the environmental risk of the new grass varieties they develop, but some consideration in this area might prevent the future spread of environmental weeds. “It is probably those varieties being developed for greater persistence, especially in the face of drought, that might pose the greatest future risk,” suggests Professor Hulme. The researchers have made four biosecurity recommendations for government, industry and researchers: governments should manage a list of prohibited varieties (not just species); develop a weed risk assessment; ensure rapid detection and control of invasive weeds; and develop an industry-pays system.
Drawing on leading New Zealand and international food and agricultural models, the agreement formalises areas where AsureQuality and PwC will support COFCO in embedding best practice in food safety and quality across the food and agriculture industries. The significance of this agreement shows China and COFCO’s commitment to continue improving trust in the safety and quality of China’s food as COFCO becomes a key player in the global agricultural industry within China’s unique situation, where demand has flowed from the country’s rapid social advancements and urbanisation of its people. PwC Global Agribusiness Leader Craig Armitage says, “This important relationship demonstrates our combined ability to build trust in society by marrying industry expertise and experience, government-to-government support and the resources of one of China’s biggest food companies. It will support COFCO in giving the people of China confidence that the food they eat and feed to their families meets the highest international standards of safety and quality.” According to PwC’s 2014 APEC Survey, uncertainty around regulations guiding cross-border physical and virtual trade is creating more and more of a ‘tax’ on this increasingly vibrant economic arena, with a more complex production chain evolving. The faster barriers can be lowered, the faster economies can grow. Reductions in tariffs help, but businesses are looking for more clarity and consistency in product labelling and data sharing. Pressure is building on businesses to get their products to customers as quickly as possible and in an age where raw materials and semi-finished products are exported and imported many times over before a product is finished.
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NZ Manufacturer November 2014
ENERGY REPORT
When you’re up to your armpits in alligators, it’s hard to remember to drain the swamp.
-Ronald Reagan
Industrial energy efficiency a full-time job A PhD focused on increasing the energy efficiency of milk powder production has led University of Waikato engineering graduate Tim Walmsley to a full-time job with the very research group within which he worked as a PhD candidate. “My PhD research demonstrated that steam use in a typical New Zealand milk powder factory could decrease by 10% if exhaust heat recovery for the milk dryer is installed. Lab scale tests indicated issues relating to milk powder build-up and fouling, which is a key reason why dairy companies choose not to install this energy efficient technology, can be avoided through smart heat recuperator design
and purposefully not being greedy in recovering heat,” says Tim. His position as a Research Fellow came about when the University of Waikato’s Energy Research Group was awarded a three-year grant from the Ministry of Business, Innovation and Employment (MBIE) late last year. “Fonterra, Windsor Engineering and the Energy Education Trust co-funded our research bid and a significant part of this successful proposal continues on from my PhD research.” The next step in his research is to prove his design solution at a pilot-scale level before further up-scaling to a full-size New Zealand milk spray dryer. “A milk
spray dryer exhaust heat recovery project is a million dollar investment and a pilot scale installation will help de-risk and bring greater certainty around the economics of a full-scale project.” While studying towards his PhD, Tim won a University of Waikato Doctoral Scholarship, the Todd Foundation Scholarship in Energy Research, and a Claude McCarthy Conference Travel scholarship. These scholarships supported him through his three years of study towards a PhD in engineering, which he completed in June 2014, and provided the opportunity for him to present his work at two international engineering conferences.
Largest commercial solar energy installation an answer to rising energy costs New Zealand’s biggest ever commercial solar energy installation on the Tarewa Mega Centre in Whangarei has been switched on. The owners of the Tarewa Mega Centre, Udy Group, see the installation as a long-term investment in an area which experiences higher energy costs per kWh than other parts of the country. “For us, this is more than just saving money, it is about us reducing our impact on the planet. We are aware
of the need to create a sustainable business, for the company and also our tenants, with the first step being power generation,” says Dan Udy, a director of Udy Group. Tarewa’s air-conditioning system and common areas currently use 326,542 kWh per year. Power generated by the 240kW grid-connected solar electricity system will offset 80-90 percent of the air-conditioners’ operating costs, massively reducing Tarewa Mega Centre’s carbon footprint and locking
in energy savings for at least the next 25 years. The Tarewa Mega Centre is home to leading retail brands including 100% Electrical, Spotlight, Number One Shoes, Bed Bath & Beyond, Pumpkin Patch, Lighting Direct, Reduced to Clear, Supercheap Auto, The Cheesecake Shop and The Baby Factory. Whangarei Mayor Sheryl Mai says she is delighted Whangarei is now home to the country’s biggest commercial solar energy installation.
“It is exciting to know Whangarei is leading the way when it comes to commercial solar electricity installations,” Mayor Mai says. “This solar PV system will deliver long-term benefit for the Centre’s retailers and set a great example for other retailers in Whangarei and around the country.” Udy Group partnered with solar photovoltaic installation company PowerSmart Solar, who are responsible for the installation of New Zealand’s two current largest systems, the 99kW system at Yealands Estate winery in Blenheim and the 100kW system at Palmerston North City Council. PowerSmart is also currently working on a project installing 10 large off grid systems in the Northern Cook Islands and Tuvalu, which will supply 95% of these islands energy needs. Rogier Simons, GM of PowerSmart, says it’s great to see more companies taking control of their rising electricity bills by investing in a solar electricity system. “The 240kW Tarewa Mega Centre installation demonstrates how feasible it is for a business to generate its own clean electricity. This system makes enough power to run approximately 40+ homes and this scale of installation is a real positive step forward for the solar electricity sector in NZ.“ Udy Group is looking to do similar solar energy installations with PowerSmart in the future.
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NZ Manufacturer November 2014
Tell them what you’re going to tell them, tell them, then tell them what you told them. -Communications axim
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DEVELOPMENTS
New Zealand steel standards could lower New Zealand could drive down its steel standards to a lowest “common denominator” if it follows Australia’s lead, Chris Chapman of Chapman Engineering says.
standards fell “to a lowest common denominator”, Chapman said.
with an economic slow-down in Australia.
‘They’ve really ruined their market. I’ve been over there recently and the market is really dead.”
The Christchurch-based steel fabricator has raised questions about the quality of imported pre-fabricated product.
Steel products were normally created from 50 tonne blocks called billets. When buying 50 tonne of beams, a fabricator may get 50 tonne with all the same heat number but they may also get 50 lengths with 30 different heat numbers, Chapman said.
Govan said New Zealand property developers had a “pretty transparent” view of international prices for raw steel - you could find about 1000 sources on a google search - so the question was how to best prepare it.
Engineers required New Zealandbased fabricators to track the origin of all its steel, from beams right down to cleats. “Everything’s recorded so we know where it is in the building.” Chapman says. Developers importing site-ready steel could probably meet the same standard “but then you come back and say ‘is the product they are using suitable?” In Australia, mining companies had gone overseas for pre-fab steel, Chapman said and “Then you’d get the odd fabricator going ‘oh, well, I’ll go and bring it in and save a buck out of it’. But as more people followed suit, steel
Staff wanted
Employment activity reached its highest level as the manufacturing sector continued to show stronger expansion during October, according to the latest BNZ - BusinessNZ Performance of Manufacturing Index (PMI). The seasonally adjusted PMI for October was 59.3 (a PMI reading above 50.0 indicates that manufacturing is generally expanding; below 50.0 that it is declining). This was 0.8 points higher than September, and the highest result recorded so far for 2014. All five seasonally adjusted main diffusion indices were again in expansion during October. Production (62.5) led the way, with its highest result since July 2013. New orders (61.8) rose 1.7 points to remain above the 60-point mark, while employment (57.5) recorded its highest ever result since the survey began in 2002. Deliveries (56.6) eased from its level of activity in the previous month, while finished stocks (51.5) also experienced a lower level of activity from September. All four regions were again in expansion during October. In the North Island, the Northern region (60.2) climbed back over the 60-point mark to show strong activity for the month. The Central region (56.6) continued to build on its momentum with activity at its highest since March 2014. In the South Island, the Canterbury/Westland region (61.6) increased 5.7 points, while the Otago-Southland region (70.6) continued its momentum from the previous month.
This could be because the product came from different suppliers. So, to run off and say ‘I’ll just get a building whipped up in China’, you’ve got to know all the rules and regulations before you start.” A would-be importer, Bert Govan, said Asian still mills that had been domestically focused were looking for “export opportunities” to bring in extra business. Some of these mills had expanded before the Global Financial Crisis but now had spare capacity, particularly
Chapman said his business was able to tell customers “where every stick of steel and what heat number went where”. His company was working on a building that needed a seismic plate, for example. “Now, if we don’t order it at the mill as seismic, for them to test it then and supply it, we have to test it after the fact. We had to test 20 sheets at $300 odd dollars a sheet. And we had to do two tests, to make sure it met the requirements.” Most engineers now asked for all test certification to ensure it complied, Chapman said. “They look at all the tensile strength and so forth. And if they don’t comply then we need to get
more tests done to prove that it.” Steel’s market share in commercial buildings in Christchurch was so small before the 2011 Canterbury earthquakes that no-one kept statistics, Steel Construction New Zealand general manager Alistair Fussell says. New Zealand had three welded beam manufacturers and about 80 per cent of steelwork fabrication was done by the top 10 companies, including Canterbury firms Chapman Engineering, John Jones Steel and Pegasus Engineering. The country could produce about 110,000 tonnes of prefabricated steel a year but was probably producing about 60,000 tonnes at present and had plenty of spare capacity, Fussell said. Construction company Calder Stewart had completed a large new steel fabrication plant in Milton in Southland, boosting the South Island’s capacity.
Iconic kiwi engineer accepts Society honour Iconic Kiwi engineer, Bill Buckley, has been made a patron of the Maintenance Engineering Society of New Zealand in honour of his contribution to engineering and tradesmen.
for export around the world.
The award was presented at a gathering at Buckley Systems Mt. Wellington facility which produces super magnets for the global silicon chip industry. The award was presented by Larry Wiechern of the Maintenance Society.
The Maintenance Engineering Society is active across New Zealand, providing opportunities for maintenance engineers and manufacturing operations to network and share innovations and experiences; both at a national level at their annual conference or at these regional events.
Buckley, a public figure recognised for his achievements in engineering, yachting and motorsport has long been a strong advocate for engineering and apprentices. He was visibly chuffed to be honoured by his peers and spoke warmly of the rich history of New Zealand engineering companies that had formed his career. A group of 120 attendees were treated to a bonnet-up look at the Buckley Systems plant as part of the networking evening. The experienced group were amazed at the size and scope of the operation which machines, fabricates and assembles high technology magnets
While the machining centres were leading edge and fully utilised, evidence of the Kiwi can-do innovative attitude pervaded the Buckley Systems facility .
Bill Buckley poses with members of the MESNZ. From left Glenn Pepper, Larry Wiechern, Craig Carlyle (Secretary), Bill Buckley, Leanne Powley, Barry Robinson and Karolina Bratek
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DEVELOPMENTS
A meeting is an event at which the minutes are kept and the hours are lost. -Anon
Economics Nobel winner shaped industry regulation Frenchman Jean Tirole won the Nobel prize for economics for finding ways to encourage better products and competitive prices in industries dominated by a few companies. Tirole’s work is credited with helping shape the deregulation of industries in developed economies in the 1980s and 1990s. But he has also called for stronger oversight of banks in the wake of the global financial crisis. Tirole, who works at the Toulouse School of Economics in France and has a doctorate from Massachusetts Institute of Technology, is the third Frenchman to win the $1.1 million Nobel Memorial Prize in Economic Sciences, which has been dominated by U.S. economists. This is the first year since 1999 that an American has not been one of the winners. Tirole cannot be easily categorised as pro- or anti-regulation. He agrees with free-market advocates that “because firms know more than regulators, regulation is necessarily going to be imperfect,” said Harvard University economist Eric Maskin, who taught Tirole at MIT and who won a Nobel prize himself in 2007. “But that doesn’t mean there shouldn’t be regulation. You have to be very careful so you don’t do more harm than good.” Tirole said: “The market needs a strong state to function normally.” Left unregulated, companies that have few competitors can refuse to innovate and can charge unnecessarily high prices. But attempts to regulate them often fail. Companies grow close to the government agencies that are supposed to supervise them and find ways to use regulations to keep out competitors. Studying specific markets, including telecommunications and finance, Tirole devised rules meant to align companies’ interests with those of consumers,
nudging producers into providing better products and lower prices. “His contribution is that he has given us a whole toolbox,” said Torsten Persson of the prize committee. “More than that, he has given us an instruction manual for what tool to use in what market ... Politicians would be stupid not to take his policy advice.” They haven’t always listened. Joshua Gans, management professor at the University of Toronto, said American consumers pay unnecessarily high prices for cable TV and Internet access because U.S. regulators didn’t follow Tirole’s advice: He called for requiring cable and phone companies to sell competitors access to “the last mile” of cable connecting homes to telecommunications networks. Instead, giants such as Comcast and Time Warner now control the last mile. To reach a home, a potential competitor has to go to the expense of installing its own cable. That limits competition and allows existing telecom providers to charge higher prices. Even though the economics award is not an original Nobel Prize — it was added in 1968 by Sweden’s central bank.
NZ business culture to blame for flatline productivity NZ business culture to blame for flatline productivity Despite people working longer hours, New Zealand is facing a serious productivity problem, which Paul Kane, Partner,Privately Held Business at Grant Thornton New Zealand attributes to a laid back business culture in this country. The firm says output has increased in recent years but productivity has barely risen since 2000. “Put another way, we are just working longer hours at the same old pay rate.” Paul Kane says Government policy cannot be blamed, with the Organisation for Economic Co-operation and Development (OECD) research finding that New Zealand’s policy settings should generate GDP per capita 20 per cent above the OECD average. Instead, New Zealand‘s GDP is currently about 30 per cent below the OECD average. “Ninety-five per cent of New Zealand businesses are small to medium sized enterprises (SMEs). We could say the relative scarcity of large multinationals deprives our best people of opportunities to develop the kinds of skills that would allow them to become highly productive. “But that is just a smokescreen and, in reality, New Zealand’s business culture www.nzmanufacturer.co.nz
is – broadly speaking – laid back compared with many other countries. We’re not saying New Zealanders aren’t hard workers. We’re saying New Zealanders lack the business edge that’s evident in some other countries.”
attributes apply less here than they do in other OECD countries, despite individual exceptions.”
Owners and managers of SMEs need to be better educated in the fundamental principles of running and growing successful businesses.
“Shining examples include cloud-based
Paul Kane says owners and managers of SMEs need to be better educated in the fundamental principles of running and growing successful businesses. “Many SME owners are ambitious, financially literate, business literate, hardworking and smart. We don’t deny that for a moment. Our point is that as a culture – as a nation – those
He says more SMEs need to create powerful international connections and crack open overseas markets.
accountancy software firm Xero, and Wellington’s Weta Workshop. Both companies worked hard from their early days to make it internationally. This ambition drove them to find ways to do things better, more efficiently, and differently from everyone else.”
$2.16 trillion opportunity for New Zealand exporters ExportNZ says the announcement that New Zealand has the green light to enter the World Trade Organisation’s (WTO) Agreement on Government Procurement (GPA) is a great opportunity for Kiwi exporters. It congratulates the Government on such a positive result following two years of negotiations, and looks forward to seeing New Zealand’s accession to the Agreement. Catherine Beard, Executive Director of ExportNZ says, “Entering this Agreement will open up opportunities all over the world for Kiwi firms, reducing costs and putting businesses on a more equal footing.
“International businesses can already compete for New Zealand government contracts as we’re such an open trading nation, but with this Agreement in place this type of open access will be reciprocated. Kiwi firms will be able to bid for foreign government contracts, worth US $1.7 trillion a year and growing, from right here in New Zealand. “This is a huge opportunity for Kiwi firms currently participating in these foreign supply chains. Now is the time for those and other businesses to also think about raising their capabilities to be ready and able to compete in those big overseas tenders.”
NZ Manufacturer November 2014
Nothing is illegal if a hundred businessmen decide to do it.
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REAR VIEW
-Andrew Young
More industry needed in industry training While 140,000 people are gaining skills through industry training every year, New Zealand’s ‘skills gap’ is predicted to widen. That gap, between supply of and demand for, skilled workers could slow productivity and stall economic growth. However, industry, or work-based, training has gained momentum over recent years, with industry trainees or apprentices achieving 54,000 national qualifications annually. “There is a massive pool of talent amongst the 70% of school leavers who do not attend university, and we’d like to see even more young people choosing industry training,” says Industry Training Federation (ITF) Chief Executive Mark Oldershaw. “But to make sure that the training results in sustainable jobs, it must be based on the job market.” The ITF, which represents all 12 of New Zealand’s Industry Training Organisations (ITOs) has released an open letter asking the Government for changes to create more cohesion and efficiency in the industry training sector. “To keep up with our own growth, and with global and technological challenges, we need to be smarter, quicker and focused on the needs of industry,” says Mark. “The first step is to enable industry to guide the development of training and qualifications. Historically it has been hard to get businesses involved because of barriers such as time, cost and complexity. We need to make it easier for industry to guide us, to ensure training results in workers with the right skills at the right time.” The
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benefits of industry training for New Zealand businesses are becoming more widely recognised by employers across all sectors. Competenz, a large ITO representing the manufacturing, engineering, forestry and food and beverage industries (to name a few), receive constant feedback from employers who say on-the-job staff training is contributing to their success. Hydroponics company Bluelab says training has boosted team morale and business success considerably. “Training ensures the team has the best possible skills to meet the competitive market head on,” says Bluelab Production Manager Mandy Jarvis. Martin Beever, from Beef Jerky company Jack Links, echoes this sentiment, saying training has contributed to the increase in exports. “As we grow the business we need to learn to grow in confidence, and with confidence we build efficiency, productivity and business success,” says Martin. And wine and spirits company Pernod Ricard report that training has created a noticeable improvement in confidence and productivity. But Mark Oldershaw says although industry training success is widespread, industry experience is needed at a broader, strategic level to ensure training and qualifications remain relevant.
apprentices. If we work closer with industry and move more quickly, we can avoid these shortages.” Auckland’s ‘workforce roadmap’, aims to do just that. An alliance of tertiary education providers in the wider Auckland area (including four ITOs, the Manukau Institute of Technology and Unitec), have been working with major construction and infrastructure industry players to get ahead of the game. “The tertiary education sector has not been as well connected to industry as it should be,” says Development Manager for the Alliance Graham Hodge. “We need to ensure the qualifications are better aligned to future workforce needs and to do this we must listen closely and carefully to industry.” Fletcher; Hawkins; Naylor Love Construction; Dominion Constructors Ltd; the NZ Transport Agency; and
the Auckland Council are jointly sponsoring the roadmap, which will guide skills needed in construction and infrastructure for the next five years. “Once, we find out what the industry needs, it’s up to us to deliver the right qualifications, the right skills,” says Hodge. Auckland’s workforce roadmap sets a direction for others to follow. “This collaboration is a great example of what one sector can achieve,” says Mark. “And it’s necessary across all sectors,” says Mark. “We’re asking for a Government-Industry Task Force to ensure industry can guide and lead the future of industry training. Then we can really bridge the skills gap and make more of a difference to economic growth.” *The ITF is a voluntary membership organisation representing all of New Zealand’s Industry Training Organisations.
“Our current shortage of builders is a reminder of the need to be better prepared,” says Mark. “We’ve known for some time about the growing demand in construction, especially in Christchurch and Auckland, and we’re suddenly desperate for 5,000 building
NZ MANUFACTURER • DECEMBER 2014 Issue • Features
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NZ Manufacturer November 2014
NZ Manufacturer Editorial Calendar 2015 February
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April
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Manufacturing
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Technology -
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Manufacturing
Manufacturing
Manufacturing
Technology - CAD CAM
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Advanced Materials
Control Engineering
3D Manufacturing
IoT
Lean Manufacturing
Composites
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Environmental Technology Energy Report The Future of Manufacturing
Energy Report
Energy Report
Export
July
Manufac
Technolo
Control Eng
Marine In
Aviatio
Environm Workshop Tools
Technolo
The Future of
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Manufacturing
Human Resources
IoT -‐ Connecting Everything
In Focus
2015 2015
austech 2015 26-29 May
Preview
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Melbourne
SouthMach 2015,
SouthMach 2015
Christchurch
22-23 July
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NZ Manufacturer November 2014 Doug  Green
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y
August
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October
cturing
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Technology -
Technology -
Technology -
gineering
Software
Hi-Tech Machines
ndustry
Workshop
ogy -
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Technology
mental
ogy -
Agricultural Supply Chain
Property Report
Machinery Energy Report
Export
The Future
Success
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November Manufacturing
December/January 2016 Manufacturing Technology -
Technology -
IoT-Connecting Everything
Control
Automation & Control
Engineering
Workshop Technology
Food Manufacturing
Supply Chain
Workshop Tools
Human Resources
The Year in Review
Industrial Safety
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Preview
h 20125
National
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Maintenance Engineering Conf. Opinion
Export Success
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NZ Manufacturer November 2014
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