July 2016 Award winning supplier of SOLIDWORKS in Australia and New Zealand
www.nzman-
14 REGIONAL MANUFACTURING
21 SMART MANUFACTURING
Ashford Handicrafts of Ashburton.
A new generation of robots.
Best value for everyone…?? - Metals New Zealand CEO Gary Hook Sixteen hundred tonnes of steel from China were found to be non-compliant to design standards for use in four bridges on the $450 million Huntly bypass that forms part of the new $2 billion Waikato Expressway. Contractors Fulton Hogan and HEB Construction admitted to RNZ News the steel tubes were not good enough and they did not comply with standards for structural steel, which for bridges are demanding as they must resist impacts, heavy loads and low temperatures in public safety critical applications. It has been revealed chose a very low bid for the steel piling tubes. They must have been concerned about product quality though. It has been reported the first quality assurance tests were done in China by the local steel mill and tube manufacturer; and it’s reported the second tests were done in New Zealand on samples sent here from China. Both lots of tests said the steel met the specification required under New Zealand Standards. However, the steel failed a third set of testing on the ‘as delivered’ product. The contractors said the weak steel was detected prior to use, but it has also been reported that workers have said the piling tubes performed badly in use. It’s been
31
REAR VIEW Brexit highlights export access challenges into the EU.
Four ways steel producers can boost their bottom line by Mark Hoppe, Managing Director, Atradius
reported that the contractors went for a bid option that was 30 - 40 percent lower than an average market price for these tubes. The New Zealand Transport Agency (NZTA) is the client for this project and in infrastructure procurement capability terms has been regarded as ‘leading the way’ in New Zealand for many years. In October 2013, the Government launched their new Policy (Principles & Rules) for Procurement by government agencies. These stress the desire and need for more strategic procurement (read “not lowest price”) in pursuit of the ‘best value for everyone’. Metals NZ believes the relatively new Principles and Rules are what is needed both to deliver on the ‘best value for everyone’ objective but also to comply with our trade obligations for WTO, GPA and TPPA. This Huntly bypass non-compliant imported product is timely as MBIE is reviewing the Policy framework for product assurance in light of the recent steel mesh
continued on page 8
Steel producers are facing an oversupply of cheap steel that is only likely to get worse. China is responding to the glut by producing even more cheap steel: reportedly increasing production by as much as 4.5 million tonnes, which is almost as much as all the steel produced in Australia last year (1).
One of the smartest, fastest, easiest, and most cost-effective steps steel producers can take to protect their businesses is to get trade credit insurance. While this decision may not fit into accepted economically-rational parameters, it will certainly affect New Zealand steel suppliers, which are tiny compared to the steel powerhouse
that is China. Prices will likely collapse as NZ manufacturing companies source cheaper steel from China, Japan, and the United States. This global oversupply is likely to remain a problem for some time and may drive steel manufacturing plants out of business all over the world. This comes at a time when steelmakers are already operating on ever-tighter margins. While the lower prices may be a boon for manufacturers, steel producers need to protect their cash flow, find ways to economise, and look to boost their bottom line. They can do this by finding ways to innovate; by creating value-added services, for example. By creating a reason to charge a price premium, this can help them weather the storm. Manufacturers can also leverage the demand for sustainability by arguing that the environmental impact of cheap, imported steel outweighs the cost savings. However, one of the smartest, fastest, easiest, and most cost-effective steps steel producers can take to protect their businesses is to get trade credit insurance.
continued on page 16
Affordable 3D design Still the best value-for-money investment for designers. Not just for solid parts and assemblies. Powerful tools for sheet metal design and development.
Purchase annual maintenance to receive new versions and upgrades, access to user forum and support. Geomagic Design provides all the features and tools for mechanical and sheet metal design. Geomagic Design can be installed on as many computers, at any locaon that has internet access, as you want and you can acvate/de-acvate the installaons yourself as you move between locaons.
enquiries@baycad.biz
06 8337093
www.baycad.biz
FOOD GRADE COMPLIANCE IS EASY WITH CHEMZ
OUR NEW FOOD GRADE RANGE GIVES YOU PEACE OF MIND The Ministry for Primary Industries & AsureQuality are more stringently enforcing their guidelines with regard to Food Grade Lubricants and their use. As CHEMZ FOOD GRADE range is C15 & C26 approved it can be applied to machinery without removing product from the production line so there's no costly downtime and CHEMZ DNA (Directional Nozzle Applicator) System allows for safe, precise application with no waste. CHEMZ FOOD GRADE range is also NSF approved giving exporters and the Dairy Sector peace of mind too. Your company is reliant on effective food processing and production for both export and local markets and your machinery is vital to your success. CHEMZ understands this, hence the new range of Food Grade Aerosols. For more information visit CHEMZ.CO.NZ or call 0800 CHEMZ.
H1 APPROVED
(400ml) Part No. 7204 A dry, non-sticking lubricant that is an excellent release and parting agent for use on food handling and sorting lines. It lubricates and protects therefore eliminating sticking, binding and squealing on rubber, plastic and metal parts. Leaves a dry fogging film which resists dirt and dust build-up providing good water and chemical resistance.
FG44 LUBE 4 PENETRENE - MPI C15 H1 APPROVED
(400ml) Part No. 7244 - (5L) 7248 & (20L) 7249 A multi-tasking product that lubricates, penetrates and stops corrosion on food processing equipment and machinery. The low viscosity of Lube 4 stops noisy squeaking and squealing. Penetrates effectively breaking free corroded components. It leaves a thin non-drying colourless film which is safe on most surfaces including plastics and rubber.
FG24 BELT GRIP - MPI C26 H1 APPROVED
(400ml) Part No. 7224 Suitable for incidental food contact. A tacky formulation which adheres strongly to belts assisting transmission efficiency and drive. Suitable for both indoor and outdoor belt applications irrespective of humidity or temperature conditions. The formulation keeps belts flexible, pliable and resistant to cracking, ensuring and extending the life of old belts.
FG84 PTFE DRY LUBE - MPI C15 H1 APPROVED
(400ml) Part No. 7284 Suitable for incidental food contact. Contains PTFE (Polytetrafluorethylene) based dry film lubricant and can be used where ever oil or silicone free lubrication is required. A white, non-toxic odourless film that provides a lubricated medium with low frictional proper ties and is unaffected by water, steam and most chemicals.
FG74 FG SILICONE LUBE - MPI C26 H1 APPROVED
(400ml) Part No. 7274 Suitable for incidental food contact. Contains a high quality food grade approved silicone. Non-toxic, nonstaining, tasteless, odourless and contains no solvents. Prevents sticking and binding on all food equipment and machinery, slideways and stainless steel chutes.
THE FOOD GRADE RANGE AND ITS ATTRIBUTES
FG04 DRY FILM SILICONE - MPI C26
FG94 MEAT RAIL LUBRICANT - MPI C26 H1 APPROVED
(500ml) Part No. 7294 - (5L) 7298 & (20L) 7299 High performance Meat rail spray formulated as a friction modifier for conveyor rails and transport chains subject to high temperatures and loads in the food industry allowing easy transfer of carcass gambrel skids and trolleys. Suitable from low temperatures 0˚C up to 240˚C assisting in corrosion and rust prevention.
FG15 CRS (CONTAMINANT RELEASE SPRAY) H1 APPROVED
MPI C26 - (500ml) Part No. 7215 (5L) 7218 & (20L) 7219 High performance inert blend of chemicals formulated for the release of organic contaminants, dirt, grease,grime and oil from machinery and electrical equipment in the food industry.
FG54 HI TEMP CHAIN LUBE - MPI C15 H1 APPROVED
(500ml) Part No. 7254 High performance chain spray developed for the lubrication of Roller, Drive & Bi-planer conveyor chains subject to high temperatures & loads in the food industry; slaughterhouses, bakers, beverage & food manufacturing etc. Exceptional resistance to high temperatures +240˚C.
FG64 HI-LO DUAL TEMP GREASE H1 APPROVED
MPI C15 - (500ml) Part No. 7264 High performance extreme pressure food grade lubricant which is suitable for the lubrication of numerous applications in the food industry operating at both low or high temperatures -40˚C to +180˚C Freezers, chillers, ovens and sterilisers.
PROUDLY NEW ZEALAND OWNED & OPERATED
CONTENTS
Forget about all the reasons why something may not work. You only need to find one good reason why it will. - Dr. Robert Anthony
ADVISORS Craig Carlyle
DEPARTMENTS
8
1 5 EDITORIAL
Four ways steel producers can boost their bottom line.
Minister for Manufacturing – Who’s catching up?
Is Director of Maintenance Transformations Ltd, an executive member of the Maintenance Engineering Societyand the Event Director of the NationalMaintenance Engineering Conference.
6 BUSINESS NEWS
Business outlook stable over next six months. Brexit means trade negotiators.
Catherine Beard
Is Executive Director of Export NZ and Manufacturing, divisions of Business NZ, NewZealand’s largest business advocacy group, representing businesses of all sizes.
7 MANUFACTURING TECHNOLOGY The switch that could double USB memory.
Simplifying manufacturing processes using CAD. Information delivers the key to unlock energy savings.
10 PROFILE
10
11 COMMENT
14
Engineering the future.
Dieter Adam
Chief Executive, New Zealand Manufacturers and Exporters Association has a Ph.D. in plant biotechnology, consulting and senior management roles in R&D, innovation and international business development.
Your next big idea.
12 ANALYSIS
Colluding not colliding: disruptive information in the public sector.
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.
13 FOODTECH PACKTECH Biggest show in over decade.
14 REGIONAL MANUFACTURING Ashford Handicrafts of Ashburton.
16
16 BUSINESS NEWS
Risk is everywhere, but so is mitigation.
18 BUSINESS NEWS
Dr Wolfgang Scholz
Got a trade? Got it made!
Is HERA Director and a Fellow of the Institute of Professional Engineers NZ.
NZMEA: Skills needs and education.
20
20 SMART MANUFACTURING A new generation of robots. New areas for robots.
Garth Wyllie
Is EMA’s Executive Officer, Manufacturing & Industry Groups. He is a strong advocate for the manufacturing sector. In his 20-plus years with the organisation Garth has managed a range of sector groups, with manufacturing being a key focus.
IoT in the warehouse.
26 FOOD MANUFACTURING
23
New Marlborough salmon farms come on stream.
28 WORKSHOP TOOLS
Air respirator series launched. Fire prevention in a breaker.
30 ENERGY Unlocking bioenergy potential.
31 REAR VIEW
Dr Stephen Hicks, HERA: Brexit highlights export access challenges.
4
NZ Manufacturer July 2016
/
www.nzmanufacturer.co.nz
26
Minister for Manufacturing -Who’s catching up? A few years ago I made a bit of a noise and issued some challenges through articles and editorials over time. I said that if we can have a Minister for Horse Racing why on earth couldn’t we have a Minister for Manufacturing? Seemed fairly simple to me. There was quite a bit of feedback, all positive, manufacturers who believed that it was a logical step and one that was well overdue. I even had one large institution ask if they could pick up the baton and gain further support. To take the emphasis off me and allow me to do other things. Well, that Institution knows who it is and I ask them on reading this editorial to pick up the baton and get on with it. Today the Green Party has come out suggesting a Minister for Manufacturing and – naturally enough – institutions have come out to say it is a great idea. Let’s just do it! A focussed, committed person who can deal with Hawkins Construction, issues with the Christchurch rebuild, China and the steel fiasco, keeping an eye on Fonterra and the real value of New Zealand’s hi-tech industries.
enough without producing any product and ask why. Who will marry up similarities with Callaghan Innovation and see how they can work together to be more effective. Someone who can look into new manufacturing initiatives in the centre of the North Island and really – hand on heart – provide a viable reason for skilled workers to leave Auckland, lower their costs and provide a better way of life for their families. Not what is going on now where money in built up centres is being chewed up for the ‘privilege’ of living there. Not the Paula Bennett way of lassoing the people and herding them out of town. But if Government doesn’t have the will, considers the position to be just another cost when money could be spent on a new flag design – well, there’s your next election topic!
PUBLISHER
Media Hawke’s Bay Ltd,1/121 Russell Street North, Hastings, New Zealand 4122.
MANAGING EDITOR Doug Green T: +64 6 870 9029 E: publisher@xtra.co.nz
CONTRIBUTORS
Dieter Adam, Holly Green, Elizabeth Ashford, Janice Davies, Evelyn Johnston, Dr. Stephen Hicks www.mscnewswire.co.nz
ADVERTISING
Doug Green T: + 64 6 870 9029 E: publisher@xtra.co.nz
DESIGN & PRODUCTION Kim Alves, KA Design T: + 64 6 879 5815 E: kim.alves@xtra.co.nz
WEB MASTER
Jason Bowerman E: jason.bowerman@gmail.com
PUBLISHING SERVICES On-Line Publisher Media Hawke’s Bay Ltd
DIGITAL SUBSCRIPTIONS E: info@nzmanufacturer.co.nz Free of Charge.
MEDIA HAWKES BAY LTD T: +64 6 870 4506 F: +64 6 878 8150 E: mediahb@xtra.co.nz 1/121 Russell Street North, Hastings PO Box 1109, Hastings, NZ NZ Manufacturer ISSN 1179-4992
Success Through Innovation
EDITORIAL
Vol.7 No.6 July 2016 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.
Affiliates
Someone who will see that research money has gone far
Doug Green ASIA
MANUFACTURING NEWS
www.nzmanufacturer.co.nz
/
NZ Manufacturer July 2016
5
BUSINESS NEWS
Mere change is not growth. Growth is the synthesis of change and continuity, and where there is no continuity there is no growth. - C.S. Lewis
Business outlook stable over next six months Most businesses expect overall business conditions to remain stable over the next six months, according to employers surveyed by the EMA. In its mid-year Employers Survey, 56% of respondees said they expected business conditions to remain the same, while 38% said they expected it to improve. When asked about their own businesses, 53% said they expected to see it grow over the same time period. “Our economy is tracking well and I’m not surprised by these responses,” says Kim Campbell, CEO, EMA.
While 52% of respondees said they had increased their staff numbers over past six months, 66% said it was still difficult to attract suitably skilled candidates. The top three positions most difficult to recruit in are professionals, technicians and managers - which is the same as a year ago. “Most employers see a skills shortage in their industry sector. What’s new is that there are increased shortages in sales workers, machinery operators and labourers. In particular, the latter two sectors relate to the ongoing
infrastructure development underway such as road construction and demand for scaffolders.” While most employers will meet their skill needs over the next 12 months by recruiting staff with the required experience (58%), they will look also look at training and upskilling current staff as a way to fill their skills shortage. Some (22%) also seek skilled migrants. The full report is available on the EMA website www.ema.co.nz
Brexit means trade negotiators The new post-Brexit landscape will require more work by New Zealand trade negotiators, says ExportNZ. Executive Director Catherine Beard says the vote for Britain to leave the EU will have an impact on New Zealand’s trade arrangements, if new trade deals will need to be struck between the EU and Britain. “For example, New Zealand meat
exports to the EU and UK are linked, and those deals may need to be unpicked and renegotiated. Unfortunately, this will create uncertainty. “Our goods exports to Europe are already highly tariffed and New Zealand exporters are hopeful of changing this with a NZ-EU free trade agreement as soon as possible. Britain’s exit from the EU could slow this process down.
Commercial & industrial growth
“Services exports to the UK will also be affected. British tourists make up a large proportion of all tourists to New Zealand. If Brexit results in to the pound dropping lower, higher interest rates and lower growth in the UK, we may expect to see fewer UK tourists coming here. “However the Brexit vote must be seen in the context of the larger moves in exports over recent years - New
Employment growth
Zealand is increasingly trading with Asia and Australia rather than the EU and Britain. “Thirteen percent of our food exports go to Europe while 50 percent go to Asia. “New Zealand’s larger export trend is from feeding the West to feeding the East, and this is likely to continue.”
Economic output
Crime rate East Tamaki is the largest industrial precinct in Auckland with 2000 businesses and a growth rate higher than the regional average. getba.org.nz
getba Greater East Tamaki Business Association Inc.
6
NZ Manufacturer July 2016
/
www.nzmanufacturer.co.nz
Opportunities don’t happen, you create them. - Chris Grosser
MANUFACTURING TECHNOLOGY
The switch that could double USB memory Scientists at Hokkaido University have developed a device that employs both magnetic and electronic signals, which could provide twice the storage capacity of conventional memory devices, such as USB flash drives. from a magnet to a non-magnet state. The
team
investigated
two
forms of strontium cobalt
oxide
(SrCoOx): is
an
one insulating
non-magnet while the other is a metal magnet. By changing the oxygen content in this compound, the The use of magnetic signal along with electronic signal - Using two forms of strontium cobalt oxide with different oxygen content, the device can be switched from an insulating/non-magnet state to a metallic/magnet state simultaneously by electrochemical oxidation/reduction reaction at room temperature in air.
Conventional USB flash drives are electronic data storage devices. They store information by using millions of small gates that process information into “words” consisting of various combinations of the numbers 0 and 1.
A team of scientists at Hokkaido University’s Research Institute for Electronic Science investigated the possibility of using a magnetic signal along with the electronic signal to allow double the storage capacity in these “multiplex writing/reading” devices. In addition to the binary 0/1 method of storing information, this would add an A/B store for the information as well. To do this would require finding a material that can switch back and forth
team could cause it to switch between the two forms. However, the two methods currently available
to
do
this
have
big
drawbacks. One method requires using a high temperature heat treatment. This would make it impossible to use in devices that work at room temperature, such as your mobile phone. The other method involves using a dangerous alkaline solution. This would require a device that
www.nzmanufacturer.co.nz
is sealed so that the solution does not leak. This method is difficult to miniaturize and is thus not suitable for information storage devices. The team developed a new method to use strontium cobalt oxide safely at room temperature in air. They applied a sodium tantalate thin film, which can be used at room temperature without leaking alkaline solution, over layers of strontium cobalt oxide. When a three-volt current was applied (or about one-seventh of the voltage required in currently available USB flash drives), the insulating form of SrCoO2.5 reversibly switched to its metal magnet form, SrCoO3, in three seconds. By comparison, current devices can store information in 0.01 seconds. Making the device smaller would shorten the time needed for the compound to switch between an insulator and a magnet, the researchers say. This would allow the storage of an even larger number of photos and videos in mobile phones, for example.
/
NZ Manufacturer July 2016
7
MANUFACTURING TECHNOLOGY
The best way to finish an unpleasant task is to get started. - Anonymous
Simplifying manufacturing processes using CAD As we all know, manufacturing is the production of merchandise for sale; using labor, machines and tools. Manufacturing process management refers to the technologies and methods that determine how labor, machines, and tools are put to use during production. For manufacturers, planning manufacturing processes can pose some difficulties. Hence the need for large enterprises to hire project managers. But for small manufacturing businesses, hiring a project manager may not be practical. And this is where the need to consider other planning and execution techniques come in.
Using CAD for Product Design Designing a functioning prototype is the first stage of the product manufacturing process and with the aid of 3D CAD applications like Autodesk’s Maya or Microstation, a realistic representation of your product can be designed, analysed and have its functionalities tested to gauge its performance once built. These techniques are being used every day by both major corporations and SMEs to save cost as the following case study will show. GINTIC Institute of CIM—a national Research & Development (R&D) Center and a BIM company in Singapore— have continuously made use of CAD techniques to simplify their production processes in multiple ways. In 2014, GINTIC commenced the design of knee-joint prosthesis uniquely suited to Asians in order to reduce muscle strain cue to continuous kneeling. To accomplish this, the Singaporean institute made use of CAD applications
to design the prototype and test its efficacy in order to cut cost before production. This new project adds to GINTIC’s use of CAD as a product design tool and its previous success in using CAD to design jewelries and a lightweight, diskless laptop computer means this new goal is certainly achievable with the aid of computer aided design techniques.
Using CAD for Product Testing Computer aided design also helps simplify the processes involved with testing new products while saving huge amount of resources because these tests can be carried out using CAD software before starting the physical production process. This process has been successfully put to use by organizations involved in the manufacturing of large scale projects such as airplanes, vehicles and even elevators as can be seen from the example of Shanghai Edunburgh Elevator—a Chinese elevator manufacturing and installation firm. For years, Edunburgh Elevator had been saddled with the difficulties that comes with the design analysis, engineering change management, product analysis and collaboration issues when developing elevator plans for its clients. To solve these research and development problems, the company integrated the use of CAD software applications offering BIM services to create a streamlined design ecosystem for its engineers, architects and project managers working on similar projects. One year into the use of Solid Edge as its elevator design tool and NX Nastran for design process simulations, Edunburgh Elevators’ realised exceptional productivity
gains which includes a shortened R&D cycle, easy collaboration, real-time troubleshooting, access to exceptional design functionality and most importantly reduced costs. And according to Mao Zhongwe— Chief Engineer Edunburgh Elevator—the integration of CAD has drastically reduced the time employees spend working on a project as well as improved turnaround durations thereby increasing the company’s competitive edge.
Using CAD in Additive Manufacturing Another interesting manufacturing process in which the use of CAD techniques cannot be overlooked is in the field of additive manufacturing otherwise known as 3D printing. In fact, the use of CAD is an integral process to manufacturing intricate 3D objects as every printing enthusiast knows. This is because a 3D printer is fed a digital 3D model prototype which serves as the map for the printer to copy when manufacturing an item.
Although 3D scanners can be used to produce a digital 3D model, it does not have the capabilities of a CAD software to produce intricate designs, test the breaking point and stress analysis of components as well as create entirely unique designs before going into production. Finally, it is worth noting that learning the use of a CAD application comes with its own challenges due to the steep learning curve associated with most CAD software tools and for an entrepreneur or business owner, you are left with little or no time to study the design processes involved. In such situations considering an outsourced BIM operating technique were you engage the services of a CAD design firm that collaborates with you in bringing your ideas to life must be considered. This leaves you enough time to focus on your core business operations while allowing you to simplify your manufacturing processes at an affordable cost.
continued from Page 1
Best value for everyone…??- Metals New Zealand CEO Gary Hook non-conformance event. This particular event will add further complexity to the review as it would appear that reliance on third party certification alone is just not enough if the reports are accurate.
When you think about it, how then does this drive the ‘Best value for everyone’ objective particularly when non-compliant material gets through undetected? The Huntly bypass example also points to the need to review the application
8
NZ Manufacturer July 2016
/
of Government Procurement Rule #22 Subcontracting. This Rule effectively allows main contactors to make lowest price-quality traded procurement decisions. When you think about it, how then does this drive the ‘Best value for everyone’ objective particularly when non-compliant material gets through undetected? RULE 22 - Subcontracting 1. Once a supplier has been awarded the Contract, any subsequent subcontracting that the supplier does is not subject to the Rules.
www.nzmanufacturer.co.nz
2. However, an agency should ask that a prime contractor meet certain procurement standards in its subcontracting. The standards should be consistent with good procurement practice, as outlined in the Principles, the Rules and other procurement guidance. Metals NZ is less concerned for NZTA contracts given their rating in procurement capability. What does this say though for contracts managed by other government agencies where rigor for product quality assurance is
highly likely to be less so. The glut in Chinese steel as capacity outstrips demand in a soft market there is widely known, and so this example sends a message to the bargain hunters to be mindful of the risks and policymakers the need to plan for the fact that this is unlikely to be just a one-off event. It’s not easy though when supply chain circumvention beats quality assurance systems.
The best advice has to be know your supplier.
Failure is only the opportunity to begin again more intelligently. - Henry Ford
MANUFACTURING TECHNOLOGY
Information delivers the key to unlock energy savings The information-enabled Connected Enterprise helps manufacturers to get the most from production while minimising energy consumption Demand for energy is increasing. Manufacturing consumes more than a third of the global energy resources used globally. Volatile energy prices, inconsistent supply and increasingly stringent environmental regulations directly impact the profitability of manufacturers. With electric motors as the driving force behind most production output, improved motor control performance and motor efficiency means greater overall production efficiency. Reducing a fan or pump operating load by only 20 percent can result in up to 50 percent energy savings. In today’s competitive environment, this is a saving that manufacturers simply cannot afford to ignore. According to Rosanne Sabiston, business manager power control business at Rockwell Automation, “Energy is expensive and it’s becoming more expensive as we move towards renewable energy. The cost of energy is going up and while any manufacturing plant can produce a product, the ones that survive are the ones that can do it smarter and at a lower cost.” Manufacturing gets ‘smarter’ Smart manufacturing is driving new opportunities for end users as they look to optimise their production and supply chains by bringing together islands of information. Advances in technologies such as the Internet of Things, are enabling devices to get smarter and meet endusers networking, integration, diagnostics and intelligence demands. These intelligent devices can be easily integrated into a facility and provide access to information about energy usage in real time. Motors and drives
are gaining improved integration and connectivity. “Motor control devices such as variable speed drives and overload relays are becoming more intelligent. By connecting them over Ethernet, manufacturers can proactively monitor where their energy is being used, providing information that enables decisions to be made about where energy savings can be made,” explained Sabiston. Measuring power and energy Energy monitoring and efficiency technologies are advancing their real time data capabilities and mobility. To remain competitive, organisations need to keep informed of the latest technology advances in power and energy management. To address this, Rockwell Automation has developed solutions to help monitor, manage and optimise energy usage to reduce overall energy costs. FactoryTalk EnergyMetrix is a web-enabled management software package that gives plant operators access to critical energy information from virtually any location. This software provides a complete energy-management decision support tool, providing the capabilities to capture, analyse, store and share energy data with key stakeholders. This knowledge can then be distributed to optimise energy consumption, manage power quality, correlate energy usage, determine cost to production, negotiate energy rates and improve efficiency.
data analytics to understand and take action on power quality issues and energy management activities. The power of real-time data Accurate, real-time data is essential in leveraging energy as an area of cost savings within the plant. This is particularly important when it comes to intelligent motor control, as motors consume up to 50 percent of the world’s energy consumption. Intelligent motor control enables the integration of motor control devices into the plant-wide control system. This level of connectivity delivers improved energy management and reduced energy consumption, which improves both profitability and environmental impact for manufacturers and other heavy industries. The intelligent MCC allows users to monitor and analyse operations from anywhere at anytime. With access to more detailed information over longer periods of time, users can better predict potential problems and prevent catastrophic failures. Allen-Bradley IntelliCENTER software provides the ultimate window into a plant’s MCC. This level of integration is complimented by IntelliCENTER Energy, which provides automatic, pre-configured set up of EnergyMetrix for devices in the MCC and shows
real-time energy consumption and historical trending for all intelligent devices directly from the IntelliCENTER Software. While the concept of layering an energy management system on top of intelligent motor control is not new, many plant operators often struggle with the implementation because it involves converging operational technology with information technology, this convergence is highlighting a skills gap between the site electrical and the corporate IT sectors of today’s companies. To provide the unique opportunity to see the complete Connected Enterprise for motor control and energy management, Rockwell Automation recently held PowerTechED in Perth. PowerTechED appealed to people from a wide variety of industries such as food & beverage and manufacturing through to mining and heavy industries, all under the one roof. PowerTechED provided a unique opportunity to get ‘hands on’ with the latest hardware and software solutions for a wide range of industries. “The event had a strong focus on higher level intelligence and how companies can use information to improve business performance and drive profitability,” said Sabiston.
The Allen-Bradley PowerMonitor 5000 leverages new technology and capabilities to capture comprehensive power quality data about a plant’s energy network. This meter provides detailed power quality data that, when used with EnergyMetrix software, can provide a powerful set of
NEC develops ARmKeypad Air The new ARmKeypad Air uses “smart glasses” to turn the arm of a wearer into a virtual keyboard, allowing for contact-free operation. In recent years, smart glasses have been introduced that enable users to perform operations at sites without using their hands. In November 2015, NEC introduced a trial model of the ARmKeypad, which uses smart glasses together with a modified watch to turn the arm of a wearer into a virtual keyboard by recognising contact (vibration) operations.
The new ARmKeypad Air, however, enables contact-free operation through the movement of a wearer’s finger using Augmented Reality (AR) to create the image of a virtual keyboard on the forearm of a wearer.
In addition, because there is no need for users to wear a watch, the ARmKeypad Air is ideal for professions where wearing devices on the arm is not advisable, such as those carrying out medical procedures.
Unlike the existing ARmKeypad, which recognises contact (vibration) operations, this new technology enables contact-free operation, which is ideal for sites where operations must be performed under sterilised conditions, free of direct contact with objects and clothes etc.
Yukio Maruyama, Assistant General Manager, System Integration & Services Market Development Division, NEC Corporation said, “Moving forward, NEC will use the ARmKeypad and ARmKeypad Air to help improve workplace
www.nzmanufacturer.co.nz
efficiency in sectors where hands-free operation is required, such as manufacturing, medicine, security, and distribution.”
/
NZ Manufacturer July 2016
9
PROFILE
Brexit’ doesn’t sound scary. It just sounds like a shitty granola bar that you buy at an airport. -John Oliver
Engineering the Future It was a 1974 Ford Escort that led Suzanne Naylor to engineering. When she started the somewhat overwhelming task of picking a study path, she had just purchased her sweet wheels and needed somewhere that had good parking – a problem familiar to most city dwellers. Her closest campus was not only an easy drive, but it had free parking. Job done – all she had to do now was pick a degree. Because she loved the environment and animals, Suzanne went through and circled all of the courses that featured those two buzzwords. It also had to be a degree – to please her parents – and what was left at the end of that selection process was one unexpected choice: A Bachelor of Environmental Engineering (now Bachelor of Engineering Technology). Up until then, Suzanne only had a vague picture of what an engineer was: hard hats, building sites, and male. To her, engineering was either structural or civil, bridges or buildings. But the course description ticked all her boxes, and meant she could ride her Ford Escort to classes in freedom. She was sold. And because she’d kept studying Maths and Science throughout high school, she went straight into the degree. Fifteen years, and three children later, Suzanne, 34, is now Northern Networks Manager for Watercare. Her job, and her team, covers getting water and wastewater to and from most of Auckland and she manages one of the biggest maintenance contracts in New Zealand.It’s not just bridges and buildings, it’s everything. It’s
making communities and cities work like clockwork. And when it comes to problem solving, it’s high stakes. “You come to work every day and it’s like, ‘What’s going to happen today? What’s going to break today?’ You know the saying for the police, ‘get better work stories?’ I always say, ‘Engineering could smash that.’ We get the best stories.” Fixing things forms the reactive part of being an engineer, but the other, bigger part of being an engineer is the creativity behind it. It’s not an exaggeration to say that everything that makes up our modern world was created by an engineer. And whether it’s a smartphone, an Airbus, an electric car, it’s not just about coming up with a solution. It’s about having the vision to create something the world didn’t know it needed, and now can’t live without. It’s having a blank slate, every day, and getting to work on filling it in. For Suzanne, both her big-picture work and day-to-day role has revolved around the environment, just as her teenage self wanted. Her very first role at Watercare was in odour monitoring at the Mangere Wastewater Treatment Plant, which is exactly what it sounds like. It was for a summer student job at the time, and she applied with two friends for the role. One friend’s nose was too sensitive for the smells, the other’s wasn’t sensitive enough. In a Goldilocks-style twist, Suzanne’s nose was just right. It may not have been the most glamorous start, but it kicked
off one heck of a career. Three months of nosing her way around the wastewater plant saw Suzanne moved to an environmental planning team, before moving into environmental compliance – both over in the UK for her OE, and then back in New Zealand. Her skills were both universal and in demand – Suzanne jokes that apart from the nose test, she’s never had an official job interview in her life as doors have continued to open for her as she’s moved throughout the industry. “If you’re good at what you do, people will always want you. And at the end of the day, you can’t survive without engineers. There are a lot of opportunities for females to do well in engineering.” It wasn’t always this way – there’s a reason why the stereotype of an engineer is, as Suzanne puts it, ‘Beard. Glasses. Pocket protector.’ But she’s already seen the shift in the industry in just her years of working there, and believes it’s only the beginning. While Maths and Science do play a part in the black and white background of a good engineer, it’s creativity and vision that elevate someone to being a great engineer. “Engineers have to be leaders. You always have to make a decision, even when you’re new to the job. And you have to have passion – waking up and wanting to come to work each day is huge. You always want to learn more and push more and make things better. There’s also a combination of being both a really good team player but also
having the ownership to work on your own thing. It’s quite an independent career, very much ‘you just do your thing and let me know if there’s a problem.’”
“The coolest thing I’ve realised about being an engineer is that you really do make a difference,” In 2009, Suzanne was made Headworks Engineer, which meant that all of the raw water assets like catchments, dams, water pipelines, aqueducts and tunnels fell under her jurisdiction. For the next six years, Suzanne and her team of 20 managed every aspect of the dams: the infrastructure, the communities they service, heck, even the fish who dwell within them, creating little pathways so they could move freely throughout the dams. This year, she became Northern Networks Manager for Auckland and her responsibilities got a little bigger. “In the first 20 minutes of the meeting, there were 200 people out of water that we had to fix. Every day really is that different.” The influence of technology and the internet has meant that a lot of industries are now scrambling to keep up with the pace of change. But not engineering. For one thing, they’re the people driving the change. And secondly, the creative streak that runs through engineers means they’re always looking for a different way to do things. The concept of learning the rules so you can then break them is at the heart of every engineer, who refuses to rest on the laurels of their last good idea. “The coolest thing I’ve realised about being an engineer is that you really do make a difference,” Suzanne says. “Every day you come to work and at some level, you make a positive difference to something. And that’s a really good feeling.” Make the world by considering a career in engineering. Visit maketheworld.nz
10
NZ Manufacturer July 2016
/
www.nzmanufacturer.co.nz
COMMENT
If you’re ever having a bad day at work remember you’re not David Cameron and you didn’t unintentionally lead the UK out of the EU. -Anon.
Your next big idea - Access solutions from your brain-waves -Janice Davies Inspiration is lodged within your mind…if you allow it time to surface. Bill Gates, Donald Trump, Oprah Winfrey, Jack Canfield have done it for business. Paul McCartney, for music. Henry Ford and Eli Howe, for inventions. Alexander the Great, Napoleon Bonaparte, Duke of Wellington, Frederick the Great for Military decisions. Otto Nobel and Thomas Edison for science. Donny Deutsch for advertising and his TV show, and I’m sure many others have used this process to uncover new solutions.
That is…unless the ‘younger generation’ are called in with their brains re-wired in a different way from the 35+ aged group. Let’s look at the experts above. Every one of them contributed in a significant way to mankind’s development. From Eli Howe having a dream whereby he was chased by warriors with a spear that had a hole in the end…and thus invented the much used – sewing machine needle. Then there’s Bill Gates with his technology and Otto Nobel, who in 1936 discovered that a nerve impulse is a chemical and electrical event. Every one of these ideas propelled mankind ahead at the time of introduction of their idea to the world, They’ve explained it in an array of definitions from:
And let’s not forget, Sir Peter Jackson and his creativity for the global phenomenon and contribution to the world of movies and entertainment. So if it’s been used in scientific breakthroughs, military decisions, new inventions and business why aren’t we using it more? Part of this may be our technological world, where everything is chalked up to left brain thinking and the only creativity is us learning ‘how to mess’ it up when we’re learning something new.
Opinion Manufacturing Profiles Letters to the Editor Politics of Manufacturing Trade Fair World Diary of Events World Market Report Q/A Export News Machine Tools Business Opportunities Commentary As I See It Business News Appointments Around New Zealand Australian Report New to the Market Lean Manufacturing Equipment for Sale Recruitment Environmental Technology Manufacturing Processes
• An ‘aha’ or Eureka moment, • Sudden mental problem.
revelation
to
• Knowing, of sensing the truth without explanations. • Direct link to soul, highest self, God or Universal Mind • Decision making process that was fast and over in split seconds Bill Gates, Oprah and Donald Trump have called it intuition or gut
reaction, which every person on earth experiences. The reason intuition evolved was to increase our chances at survival and it’s often referred to as our sixth sense. There’s no logical reasoning accompanying it but that makes sense because it’s from our creative/emotional/genius side of the brain – it’s called a feeling or emotion. Intuition in Latin means ‘to see within’. So let’s call this Intelligent Mastery because often the first alert to experiencing it, is failure to understand its importance. I’ve experienced this myself and others have confirmed the process. It’s also synchronicity and co-incidences popping up in your life, answers to your problems while taking a shower, or doing the dishes. When out of the blue a solution ‘pops’ into your mind, always when you were least expecting it. Intuition (for ladies) or gut reactions (for men) appear to be on a need to know basis and even used in life-and-death decisions. It makes sense then, that our brains, have solutions trapped within them that will help solve some of today’s global issues. History tells us so, and so it must be. Accessing this genius mind John Assaraf says is tapping into the front cortex part of your brain. Everyone has got access to it in our brains, it’s just having the ‘smarts’ to be
able to access it. Einstein, said: Imagination is more important t h a n Knowledge, which embraces the concept that creativity makes the world go around. It creates the future, employment, revenue and solves world problems – so now it’s time to learn to use it. One can either wait for the ‘eureka’ moment or consciously zero into the right headspace to discover new solutions and ideas thus benefiting from creativity as a key to business expansion.
Your Next Big Idea – Creative Intuitive Business Expansion Workshops is where Janice Davies is The Attitude Specialist, teaches people solution thinking. A Professional Speaker, Success Coach, Author and Infopreneur Janice educates at conferences, workshops and online, on a variety of topics for success, empowerment and positive thinking. Janice has written her memoirs and movie script for a transformational movie out in 2019. Contact her janice@attitudespecialist.com
NZ MANUFACTURER • AUGUST 2016 Issue • Features
FoodTech PackTech 2016 Preview
www.nzmanufacturer.co.nz
Project Management Disruptive Technologies
Smart Manufacturing Regional Manufacturing Advertising Booking Deadline – Friday 19th August 2016
Editorial material to be sent to :
Advertising Copy Deadline – Friday 19th August 2016
Doug Green,
Editorial Copy Deadline – Friday 19th August 2016 Advertising – For bookings and further information contact: Doug Green, P O Box 1109, Hastings 4156, Hawke’s Bay Email: publisher@xtra.co.nz
P O Box 1109, Hastings 4156, Hawke’s Bay
At NZ MANUFACTURER our aim is to keep our readers up to date with the latest industry news and manufacturing advances in a tasty paper morsel, ensuring they do not get left behind in the highly competitive and rapidly evolving manufacturing world.
Email: publisher@xtra.co.nz Tel: 06 870 9029 Fax: 06 878 8150
www.nzmanufacturer.co.nz
/
NZ Manufacturer July 2016
11
ANALYSIS
The mediocre teacher tells. The good teacher explains. The superior teacher demonstrates. The great teacher inspires. ~ William Arthur Ward
Colluding not colliding: disruptive innovation in the public sector -Evelyn Johnston Innovative disruption is not something new. We have been innovating since our distant ancestors first learned to tame fire and some even attribute the first human disruption to the opposable thumb...
During the first industrial revolution,
several new technologies, including electricity, the steam engine, and the internal combustion engine, allowed for the mass production of manufactured goods. We know that discount retailers disrupted full-service department stores, personal computers disrupted the mainframe and minicomputer, and cell phones disrupted landlines. More recently, and an unavoidable topic at the moment, tech start-ups such as Uber, Spotify, Netflix and Airbnb, have caused major sector disruption, becoming known as ‘unicorns’, each being valued at over a billion dollars. But with disruption having occurred roughly as early as humans have walked the earth, why is there such a sudden buzz about the topic? “With disruption having occurred roughly as early as humans have walked the earth, why is there such a sudden buzz about the topic?” The difference is pace. We are now able to move faster than ever before. And because we have become accustomed to this rapidity, we now expect not only the private sector to respond to our needs at speed, we also expect the same from our public services. Making government interact with
easy
to
So how do government departments, which have traditionally been known as slow-moving, ripe with siloes and full of red tape, provide the public with the types the services they expect? Shouldn’t it be easy to apply for a passport? Why is it necessary to provide the same information about the birth of a child to 16 different touchpoints within government? As an immigrant to New Zealand, when applying for a work visa, I was required to fill out a stack of paper-based forms which I had to carefully take from one doctor to another and then to the
12
NZ Manufacturer July 2016
/
immigration office hoping that the strong Wellington winds didn’t blow them out of my hands on my way. Fortunately, New Zealand is one of the few governments worldwide focusing on enabling better public services for all New Zealanders and is currently answering those questions. As a part of the Digital Five (D5), which also includes Estonia, the United Kingdom, Israel, and South Korea, there have been some significant initiatives across the New Zealand government which will support disruptive innovation in the public sector. “New Zealand is one of the few governments worldwide focusing on enabling better public services.” A meeting of government minds I recently attended the GOVIS conference (Government Information Systems Managers’ Forum) which was themed around innovative disruption and modernising government. The aim was to answer how government can adapt to and anticipate the demands of its citizens. So what were my key takeaways? Kicking off the conference, we heard Rt. Honourable Peter Dunne MP explain that New Zealanders want to spend less time dealing with government and its processes and more time enjoying their lives; and that they want their interactions to be both easy and occurring at a time of their convenience, not that of the government. One of the ways this is happening, and a key topic of discussion at the conference, is by ensuring future government services revolve around the customer, not government agencies. Collaboration is key An example of how we are helping the government to collaborate more effectively is through Intergen’s Cohesion ECMaaS (Enterprise Content Management as a Service) which has been recently implemented by Ministry for Primary Industries (MPI) and others. The service allows MPI to not only manage and share information internally, but in time will also allow cross-agency collaboration as well. Policy, technology and
www.nzmanufacturer.co.nz
modernisation As much as I’d like to, I can’t take credit for the title of this blog. Secretary of Treasury Gabriel Makhlouf, used this phrase a few times during his keynote address. He referred to the challenge government faces in putting policies in place to protect New Zealand whilst still meeting and anticipating their needs. He talked about the macro-economic factors that have led to disruption and how decision-making processes which are inflexible are unlikely to be able to cope with disruption. By moving away from a more traditional, top-down policy process to one which uses information and evidence, not assumptions and assertions, government will be able to adapt and anticipate the demands of its customers. In policy creation, information can come from the use of data analytics and it’s important, he says, to understand not just the data itself, but the people behind the data. Agility and driving for the conditions Another topic at the conference, which also seems to be unavoidable at present, was the need to be agile and to ‘fail fast’. If you read any articles on Silicon Valley or if you are interested in start-ups this is not a new concept. However, how does this apply to government? Pauline Lamb, Chief Operation Officer of Airways New Zealand, spoke about adapting to the needs of customers
who cannot wait for government policies to catch up. She used an example of when a private sector company approached Airways and said that they wanted to launch 120 balloons into New Zealand airspace every week. Airways proceeded to explain that they would need to follow a strict set of rules making it very difficult, therefore they couldn’t do it. The company brought in a different mentality into the organisation and said, “Pauline, tell me how I can rather than how I can’t”. Overnight they turned around solutions to how they can and they brought a very agile way of being into the organisation. Gabriel Makhlouf also touched on the importance of agility, saying in his closing remarks, “Be nimble, adaptable and flexible. Don’t try to create the perfect product. It’s unlikely to exist and even less likely to last.” He added that the avoidance of failure shouldn’t be the main objective, asking the public sector to be bold and innovative. As part of the government’s ICT Strategy and Action Plan, not only will the government sector need to work across agencies to achieve Better Public services, it will also need to leverage off of the innovations within the private sector. *Evelyn Johnston is the IT Client Director specialising in enterprise solutions at Intergen Limited a subsidiary of Empired Limited.
To handle yourself, use your head; to handle others, use your heart. - Eleanor Roosevelt
FOODTECH PACKTECH
Foodtech Packtech biggest show in over a decade New Zealand’s biennial Food & Beverage Manufacturing, Packaging & Processing Technology trade event, Foodtech Packtech (FTPT), is on track to be the biggest in over a decade with leading industry suppliers from all over New Zealand and many from overseas participating this year. Nearly 200 exhibiting companies will be showcasing the latest technologies, products and services to inspire New Zealand’s Food & Beverage manufacturing, packaging and processing industry. Held at the ASB Showgrounds, Auckland on the 11th – 13th October the event covers all facets of food and packaging industry capability. “There’s a huge pipeline of innovative new products being launched onsite at the show, in some cases southern hemisphere firsts,” says the organiser XPO Event Manager Deb Haimes EPNZ, for example, are bringing the latest industrial inkjet printers from LEIBINGER, representing the highest level of quality and reliability in product marking – perfect for food manufacturers. The automated Sealtronic nozzle seal always prevents the ink in the printhead from drying out. Together with Clean Instant Start and Stop Technology, it also ensures small-character inkjet printer start up on the production line every time without needing maintenance. “EPNZ always looks forward to the Foodtech Packtech show,” says EPNZ Manager Gary Clare. “It’s a great chance to see existing clients again and also brings the opportunity of meeting new clients and exciting challenges”. The Foodtech Packtech 2016 theme of Adding Value to NZ’s Food Chain will be dominant over the three days through live product demonstrations, special features and a very full schedule of free industry lead education and learning seminars. This year’s event is co-located with the Materials Handling & Logistics Expo (MHL), which the organisers XPO Exhibitions are most excited about. “Bringing MHL to the show helps complete that value chain ‘pasture (or sea) to plate capability’ for food manufacturers.” says Deb. The overall event seminars are organised in partnership with NZIFST, bringing together leading experts and professionals to share their knowledge, skills and ideas that are critical to the sustainability and growth of the vibrant F&B industry. “There is very strong industry support for Foodtech Packtech 2016,” says Deb “which, I believe, reflects the current industry and economic sentiment. FTPT 2016 is set to showcase many amazing examples of successful hi-tech Kiwi Food & Beverage Manufacturing capability.” “Every Foodtech Packtech, the buzz grows. With world-class seminars, the cream of suppliers, a myriad of opportunities to network and do beneficial business this is the not to be missed event for 2016.” Foodtech Packtech 2016 runs from 11-13 October at the ASB Showgrounds in Auckland. Free registration is now open for Industry Professionals wishing to attend. Simply visit www.foodtechpacktech.co.nz
www.nzmanufacturer.co.nz
/
NZ Manufacturer July 2016
13
REGIONAL MANUFACTURING
Nothing shows a man’s character more than what he laughs at. - Johann Wolfgang von Goethev
Ashford Handicrafts continues to grow Elizabeth Ashford, Director of Ashford Handicrafts Ltd of Ashburton shares the company story. The company has produced over 800,000 spinning wheels and weaving looms for local and international markets. They also operate a woollen mill…and work long hours Describe your company’s main areas of activity. Ashford Handicrafts Ltd, founded in 1934, is the world leaders in the manufacture of spinning wheels, weaving looms and textile equipment. Today we, together with our loyal team of 31 staff, have produced over 800,000 spinning wheels and weaving looms in our 3000 square metre factory in Ashburton. Destined mainly for the hobby market, but also for rehabilitation and self-sufficiency, our products are sold throughout the world. Our products are made from a native NZ hardwood, Silver Beech, sourced from a sustainably-managed forests with Forest Stewardship Council approval. The timber is stacked and air-dried for up to 12 months before kiln drying using our dehumidifier. Most of our products are sold in kitset. We also operate a woollen mill in Milton and dye, card and comb up to 30 ton of wool annually for spinners and felters. We do some contract machine work. What area(s) of the business are currently being developed? In 2012 the NZ$ had been above 80 cents US for most of the year and predicted to get stronger. As 90% of our production is exported the increasing strength of the currency was a real threat. We had to become more efficient or risk losing market share
14
NZ Manufacturer July 2016
/
through having to increase our prices. In 2013 we commenced introducing continuous improvement (LEAN) throughout the plant. In the three years since we have improved staff communication, introduced 5S, improved the layout and condition of the factory, and invested heavily in new machinery. Our plant has changed from a traditional wood working plant to one based on computer control. The new machinery with their very high safety features also help us meet our H&S obligations, We are tertiary accredited under ACC’s Workplace Safety Management Practices and have been since 2001. Currently in our CNC department we operate the following: - FX30 - SCM 142L - SCM 142S - SCM CU - SCM Universal 2412 - Weinig Opticut saw And in our factory we have new: - CKX-600 lathe - DMC Eurosander - Superset NT Plus moulder We operate a water-based, electro-static semi-robotic spray line. Does the company place much emphasis/outlay on R & D? We are continually working towards improving productivity and reducing waste. We are also continually introducing new products to sell through our existing supply chain. Where do you export to and where are future opportunities? We export to over 40 countries with our main markets being USA, Japan, Canada, Germany, UK, Australia, Scandinavia. We support our products with books, videos and training.
www.nzmanufacturer.co.nz
Richard Ashford.
How do you find current business conditions? We are enjoying high demand for our products and although we have invested heavily in more efficient machinery we have been required to work overtime and still are unable to meet all orders ex-stock.
We have been required to work overtime and still are unable to meet all orders ex-stock. What assistance would be beneficial to your company’s growth? A low, stable NZ$! Staff. Is it challenging getting the right staff? We are fortunate to have a very loyal staff with low staff turnover however we have struggled to recruit CNC
operators and we were forced in 2014 to recruit from Manilla. This staff member has proved very successful and is still with us and has recently been granted residency. We support the apprenticeship model and have, over the years, trained many apprentices. We intend to appoint at least one new apprentice next year. However we are concerned the unit standards are not keeping pace with the industry changes. The future. What is the 5 year plan for the company? Where to from here? Our son and son in law have recently joined the business and we look forward to continued growth in the next 5 years.
SEE US AT STANDS #3078 AND #3155
AURORA
PROCESS SOLUTIONS Providing market leading solutions to the process industry for over 18 years. Specialists in specifying, supplying and servicing critical components of your process. We cover bulk materials handling, fluid process, quality assurance and more. Call us today - Unlock your process potential.
MAGNETS ELIMINATE FOREIGN MATTER
Remove ferrous and work hardened stainless steel contamination from your product stream. Ultra-high strength magnets for dry, liquid, viscous, bulk applications and much more. HACCP endorsed verification service of existing magnets.
HEAT TRANSFER
Plate & Tubular heat exchangers. Skid systems. General warming & cooling duties, Energy recovery, Pasteurising, CIP heating and much more.
BAG FILLING & CLOSING • • • • • • •
TAYLOR Open mouth and valve bag fillers Form fill seal and belt packers Bulk bag filling and dispensing Net or gross weighing FISHBEIN Bag closers Portable & automatic systems Consumables and servicing
ROBOTIC PALLETISING
Fuji-Ace No.1 Palletising Robot with over 10,000 installations worldwide. Bag, sack and box palletising, Pallet dispenser, wrapper and transfer accumulation options available.
PIGGING SYSTEMS
Recover valuable product from your transfer lines and equipment with a LIAG pigging system. Recover product, clean process lines, reduce cleaning fluids. Wide range of hygienic valves and consumables.
PRODUCT CONVEYING
Conveying systems for a huge range of powder and granular product. Vertical, horizontal, high-speed or drag. FLOVEYOR aeromechanical conveying. Screw feeding and custom hopper units. Bag conveying equipment and accessories.
CALL US AND EXPERIENCE OUR QUALITY SERVICE TODAY. 0800 55 77 33 | sales@aurora-nz.com | www.aurora-nz.com www.nzmanufacturer.co.nz
/
NZ Manufacturer July 2016
15
BUSINESS NEWS
The only thing you need to know about #Brexit is that Donald Trump thinks it’s a great idea. -Anon.
Risk is everywhere, but so too is mitigation Natural disasters such as hurricanes and extreme winter weather can wipe out engineering and manufacturing (E&M) operations, decimating production schedules and customer delivery dates. The financial impact can be substantial. Taking into account the predicted increase in natural disasters due to climate change, it is estimated that by 2030 the annual global economic cost of natural disasters could be as much as €328 billion (DHL Engineering and Manufacturing 2025+). Socio-political threats such as conflict, terrorism, migration, and political instability can also severely disrupt E&M operations. Research by Maplecroft indicates that these types of threat are a growing phenomenon; it currently categorises 36% of countries as geopolitically “high risk”, which is a 4% increase on figures released in 2012. Research from the World Economic Forum reveals that large disruption to the supply chain is likely to impact a company’s share price by 7% on average. However, with today’s E&M tendency for longer and more complex supply chains, and with profitable opportunities to be found in developing markets and in increasingly remote locations, it is strategically impossible to entirely avoid risks in
the supply chain. They are everywhere; therefore the best solution to this is preparation. Fortunately, E&M organisations have many ways in which to mitigate increasing global risk. Companies can now identify, monitor, and plan for events capable of damaging productivity, disrupting the supply chain, and destroying profit. In addition to well-informed high-speed risk assessment, E&M companies can monitor incidents to identify the scale and likely duration of impact, and enable informed decision-making and proactive response. What’s needed of course is transparency in the global supply chain. This allows E&M companies to continuously track, collate, and analyse the world’s most disruptive events, drawing on the leading risk intelligence data and issuing alerts throughout the organisation in near-real time along with detailed, regularly updated reports. With an efficient supply chain risk management process in place, E&M companies can turn disruption into competitive advantage. For
instance, an organisation can seize the opportunity to be a first-mover in profitable yet risky new markets. An example of this is early market entry into Iran, a country that promises substantial infrastructure and exploration projects within the next few years. Earlier this year, Iran was subject to an easing of international sanctions and, while some restrictions remain, particularly for US organisations, continued compliance with internationally agreed nuclear obligations will result in the ending of sanctions in 2025.
The embargo on buying crude oil from Iran has now been lifted, and trade and shipping restrictions have relaxed. Iran is beginning to look not merely viable but in fact strategically attractive for many E&M companies. The decision to enter and operate in high-risk markets and locations will always be complex. However, risk is everywhere in today’s business landscape. Risk mitigation enables E&M companies to prepare for diverse challenges and to steadily navigate the way towards business expansion and profit.
continued from page 1
Four ways steel producers can boost their bottom line Trade credit insurance can protect businesses in the case of non-payment or late payments by customers. While most businesses grasp the need for other types of insurance, trade credit insurance tends to be last on the list, usually because it is not well-understood. The cost of trade credit insurance is usually lower than most businesses expect, and it can also help boost the bottom line for steel manufacturers in four key ways: 1. Broaden the sales scope Businesses often decide not to sell to certain potential partners because of a low appetite for risk; some partners are deemed too much of a risk in terms of being able to pay their invoices on time. Alternatively, some steel manufacturers may miss out on making sales to some organisations because they’re unable to offer extended payment terms.
16
NZ Manufacturer July 2016
/
by Mark Hoppe, Managing Director, Atradius
Trade credit insurance allows businesses to operate with higher credit exposures on customers. This allows the business to broaden their sales scope and gain access to profits that were previously unattainable.
Trade financiers understand that credit insurance enhances the value of debtor portfolios. Being covered by trade credit insurance can lower borrowing costs and increase the chances of business loans being approved.
The right trade credit insurance provider should also be able to provide extensive credit risk information regarding trading partners. This level and type of information lets steel companies make more informed decisions regarding whom they will sell to and under what terms.
3. Reduce bad debt provision
2. Increase credit lines with lenders For organisations looking to protect their cash flow, the cost of debt can cause concern. So steel manufacturers looking to innovate to protect their business may need to invest wisely. Gaining access to credit lines can be challenging in a tight market.
www.nzmanufacturer.co.nz
When customers don’t pay, cash flow dries up, which is exactly what steel manufacturers can’t afford right now. Decreasing the value of uncollectible debt can help get cash flowing again. By reducing bad debt provisions with credit insurance cover, companies can add intrinsic value back into their balance sheets and further free up cash flow. 4. Decrease credit management costs At any time, due diligence is crucial when choosing trading partners; but in a challenging market, it’s especially crucial. Because trade credit
insurers can give businesses accurate, up-to-date information regarding potential and current trading partners, businesses acquire a better sense of their risk profile. This allows them to make better-informed, more strategic trading decisions. It also translates to lower credit management costs and safer trading. In the current market environment, steel manufacturing companies need to take steps to protect themselves and protect their cash flow. Trade credit insurance is an affordable way to do that, allowing the organisation to investigate and take advantage of market opportunities with confidence. References 1)https://www.worldsteel.org/dms/internetDocumentList/bookshop/2015/ World-Steel-in-Figures-2015/document/ World%20Steel%20in%20Figures%202015. pdf
HEADING
If you want to live a happy life, tie it to a goal, not to people or things. - Albert Einstein
title text
ASB Showgrounds Auckland New Zealand
KEEPING BUSINESSES MOVING
BE PART OF ONE OF NZ’S LARGEST INDUSTRY EVENTS New Zealand's only dedicated materials handling, warehousing and logistics trade show. Get face-to-face with thousands of industry professionals and decision makers.
REGISTER TO ATTEND FOR FREE USING PROMO CODE: NZMANUFACT
www.mhlexpo.co.nz INTERESTED IN EXHIBITING? sales@mhlexpo.co.nz +64 9 976 8367 | +64 (0) 21 487 552 Co-locating with Foodtech Packtech REGISTER AND ATTEND THE MHL EXPO, FOR YOUR CHANCE TO WIN A FORD UP TO THE VALUE OF
+ ORC*
www.foodtechpacktech.co.nz
*Visit website for T&C’s
www.nzmanufacturer.co.nz
/
NZ Manufacturer July 2016
17
BUSINESS NEWS
A leader has the vision and conviction that a dream can be achieved. He inspires the power and energy to get it done. -Ralph Nader
Got a Trade? Got it Made! This month 750 students and teachers joined the Got a Trade? Got it Made! Big Bus Tours 2016 across Auckland, Hamilton, Wellington and Christchurch, visiting 50 workplaces to see what trades and services careers and on-the-job learning is all about.
civil engineering; specialist trades; automotive technology, repair and engineering; social and community care; sales and service; sign-writing; mining and industrial machinery and construction and infrastructure – to name a few.
Sectors on show included manufacturing design and engineering;
“We wanted to promote the many opportunities that exist for on-the-job
learning and apprenticeships, across as many sectors as we could, in one day,” says Got a Trade chair, Andrew Robertson.
2020 the civil engineering sector will also need 19,600 new people, and in the manufacturing sector, that figure blows out to 40,000.
The Big Bus Tours were part of Got a Trade’s campaign response to the growing need for more young people to enter trades and services roles across New Zealand. Industries like aged care require more than 2,600 new people entering the sector year on year and in construction and infrastructure that figure is closer to 5,000.
“There’s no doubt that there are great opportunities out there for young New Zealander’s” adds Robertson.
Looking forward to 2020, in industries like mechanical and automotive engineering, there’s demand for more than 5,600 and 11,200 new people respectively. By
“But students can’t choose a career they cannot see. The Big Bus Tours really opened their eyes to the full range of opportunities available across Got a Trade’s 140+ industries.” The ‘Big Bus Tours’ was an initiative driven by Got a Trade? Got it Made! - the national campaign to promote trades and services careers and on-the-job learning. Got a Trade is a collaboration of eight industry training organisations; BCITO, Careerforce, Competenz, Connexis, HITO, MITO, ServiceIQ and The Skills Organisation. Together they represent more than 140 industries. The second annual Got a Trade Week, celebrating those making headway in their trades and services careers, runs 22-26 August 2016. www.gotatrade.co.nz
Students from Hamilton Boys High School visiting Gallagher in Hamilton on Wednesday 8 July.
Skills needs and education We are continuing to see a disconnection between our education system, both secondary and tertiary, and what industry needs to grow our economy and prosper. We have heard from manufacturers for a long time about the challenges in finding new skilled staff coming through the education system with the right skillsets to replace an aging workforce.
exposed to a global hunt for talent.
More recently, these comments have been mirrored in other sectors.
For manufacturers, immigration can be a useful tool where there is an immediate shortage and the skills or level of experience to do the job just is not available in New Zealand at that point in time. Immigration can also bring new talent and ideas - however, this should not be the long term solution, or a replacement for getting Kiwi’s trained in areas of need through the education system.
The shortages we often hear about are among the ‘skilled practitioner’ level and highly skilled trades workers (NZQF levels 5 and 6), be that a technically skilled team leader in a manufacturing operation or a hotel manager in the tourism sector. Manufacturers are also facing shortages in the area of ‘highly skilled experts’, for example, graduate mechatronics engineers.
Recent stats from the OECD show New Zealand has high rates of numeracy, literacy and problem solving skills when compared to most OECD countries – we have the potential, the key step is helping students gain the additional professional skills being in demand, and making them aware of where opportunities and industry needs lie.
An aggravating factor is the fact that it is exactly these skilled people who are in short supply in many advanced economies – including Germany, for example, as I found in discussions with German manufacturers during a recent visit there.
The Government has taken initiatives in selected areas, such as the engineering e2e initiative, but beyond its current pursuit of partial solutions the Government needs to undertake a root cause analysis of the underlying problems if it wants to ensure sustainable growth of the New Zealand economy, bringing together all parties; students, educators, academics and
Young New Zealanders with a good technical education are well-regarded internationally and we are increasingly
18
NZ Manufacturer July 2016
/
www.nzmanufacturer.co.nz
real businesses - and the focus needs to be wider than just the tertiary sector. Government also needs to ensure the education system has the funding needed to provide the world class education we expect for the next generation - this includes not only the tertiary level, but vitally secondary, trades training and apprenticeships. Part of the solution may also be talking to students earlier in their education life, to help them look forward and see what areas they need to focus on through high school, such as STEM subjects, and what kind of career prospects could lie ahead. As a manufacturing country, we also have a responsibility to try to inform students and build excitement – currently many students just don’t see a career in manufacturing as their top option. Manufacturers also need to have a look at what they are doing themselves to solve the problem. There has been significant investment by many individual companies into in-house or on-the-job training, but support for and investment in formal training and skills development programmes like the apprenticeship system has been patchy and has room for improvement.
Everybody talks about the need for our economy to move towards value-added products and services, be that in agriculture, tourism or manufacturing. Without enough suitably qualified young people emerging from our education system, that cannot happen, especially with an aging workforce taking skilled workers out of the talent pool and demographic trends reducing the supply of young people entering the workforce. There are wider changes that will be needed to truly transform our economy to one of high-value sustainable growth that really improves living standards for all – but having the skills and talent needed to grow is a core component. The Productivity Commission’s inquiry into new models of tertiary education currently undertaken is a needed step in the right direction. The NZMEA submitted to this and will continue to support it however we can - we hope it translates into real change to make our education system more responsive to the needs of industry and where opportunities for well-paid skilled employment exist.
title text
9 – 10 November 2016 Claudelands Event Centre
Hamilton Sponsor and Exhibitor Enquiries Welcome Expo Open Day 8 November More information:
www.nmec.co.nz
Lifting the Game of Maintenance Engineering Speaker Sponsor
www.nzmanufacturer.co.nz
/
NZ Manufacturer July 2016
19
ADVISORS Mike Shatford is an expert in the field of technology development and commercialisation. His company Design Energy Limited has completed over 100 significant projects in this vein by consulting for and partnering with some of New Zealand’s leading producers. Among Mike and his team’s strengths are industrial robotics and automated production where the company puts much of its focus.
Katalin Csikasz
Katalin is a highly knowledgeable engineer with strong capabilities in; industrial design, quality assurance, product compliance, technical expert support, troubleshooting and process improvement.
20
NZ Manufacturer July 2016
/
www.nzmanufacturer.co.nz
Chris Whittington
Senior Lecturer at AUT, Chris Whittington is a versatile Engineer, Educator and Researcher. Chris has had many years experience in senior engineering and product management. Chris has a strong background in computational modelling, 3-D scanning and printing, and a strong interest in engineering education.
Sandra Lukey
Sandra Lukey is the founder of Shine Group, a consultancy that helps science and technology companies accelerate growth. She is a keen observer of the tech sector and how new developments create opportunity for future business. She has over 20 years’ experience working with companies to boost profile and build influential connections.
Nurture your mind with great thoughts, for you will never go any higher than you think. - Benjamin Disraeli
A new generation of robots In the future, robots and humans will work together more intensively. For machine operators, robots will become as everyday as an electric drill. One of the reasons for this collaboration is demographic change. Robots should support factory workers more ergonomically and efficiently and they should take on monotonous, dangerous and physically exhausting tasks. Processes will become more flexible and transparent and resources will be saved.
has become attractive for small and
Robots are used in enterprises of varying sizes and sectors. With human-robot collaboration their use
for our “robot� colleagues. Robot
medium size firms too. In the past these firms have either not been able to afford or not needed fully automated production lines. A wide variety of uses are being found manufacturers therefore have to make their products as flexible as possible.
Their multiple uses are just one of the many advantages. Equally as important is how they filter and process the accumulation of data. The machine operator teaches a new generation lightweight robot tasks by guiding it; the movement is then automatically programmed.
exhausting tasks.
The machine can then fulfil monotonous, dangerous or physically
for humans. Important norms are
www.nzmanufacturer.co.nz
Human-robot collaboration has been made possible due to innovative safety technologies including sensor systems, cameras and speed and distance measuring
technologies
which
provide the highest level of protection regulated by law.
/
NZ Manufacturer July 2016
21
Management is nothing more than motivating other people. ~Lee Iacocca
In the burgeoning life science, medical and pharmaceuticals markets, robots are breaking into new task areas. In the process not only are they working for man but also, and increasingly commonly, directly with him. More than 200 companies showcased their pioneering developments in this innovative industry at AUTOMATICA 2016, which was held in June in Munich. It is not just their market potential that impresses but the applications themselves. For example, special surgical robots are behind minimally invasive procedures introducing new quality standards to operating theatres. In automatic mode, and according to meticulous programming, the robot can function of its own accord. In the case of telemanipulation, on the other hand, the operator uses joysticks to control the robotic arms by means of an endoscopic camera image – a prime example of man-robot collaboration, only just now making its way into industrial robotics.
more gently and guarantee superior growth rates. “Thanks to their unique performance in terms of path characteristics, accuracy, positional stability and clean-room suitability, the fully encapsulated Stäubli TX series robot sets the standard for medical applications. The six-axis TX60 robots can be integrated directly with the ARTAS system with no modification worth mentioning. As hair loss is very common we already have almost 100 robots in operation for this application alone”, says Stäubli Robotics general manager Gerald Vogt.
dual-arm robot back at AUTOMATICA 2014. “Our dual-arm robot is from the industrial automation stable and was modified for laboratory use. With its total of 15 servo-controlled axes, including a monumental axis and seven axes per arm, the robotic system is more flexible than any human, but above all streets ahead in terms of precision”, according to Dr. Michael Klos, general manager at Yaskawa. (Pictured) The Yaskawa dual-arm robot in action in the laboratory is revolutionisng the testing of medical diagnostic devices.
In a pilot project that is unique in
Hair transplantation by industrial robot These very cost intensive, special operating systems inspired the development of assistance systems for medical procedures, based on classical industrial robots. One of the best examples is ARTAS. The innovative robotic, minimally invasive hair transplant system features a standard Stäubli TX60 industrial robot. The highly accurate six-axis machine removes individual hair roots, which are then reinserted in the places affected by hair loss. Conventionally, the removal of thousands of hair follicles was a time-consuming and arduous process for the patient. With the robotic assistance system, doctors can work incomparably faster and more accurately, treat patients
components for dental turbine drills.
Dual-arm robot revolutionises diagnostic device testing Yaskawa
unveiled
the
CSDA10F
The compact ABB IRB 120 is of proven worth in this precision engineering assembly thanks to its repeat accuracy of one hundredth of a millimeter, thereby satisfying all quality requirements. But the user is not just taken with the accuracy of the robot solution but also by its productivity, which should therefore lead to further automation solutions. the world the CSDA10F is now taking on the testing of medical diagnostic devices – a highly responsible task, on the correct performance of which human lives depend.
Standard robots in the Champions League as well
Stäubli six-axis robots are proving themselves in many life sciences applications. The spectrum ranges from drug manufacturing – pictured here – to automated hair transplants.
NZ Manufacturer July 2016
/
The fact that the latter are not confined solely to end-of-the-line packaging activities is demonstrated by a standard six-axis ABB robot in the assembly of delicate components for turbine drills in dentistry. Precision of the highest order is required when assembling a delicate shaft complete with collet to accommodate dental tools such as drills, milling cutters or polishing instruments. This is the only way to ensure that the tools run perfectly true. (Pictured) ABB’s IRB 120 assembling delicate
The equipment is superior to manual inspection and scores in terms of unlimited reproducibility of the test scenarios, exemplary process reliability as well as previously unachievable efficiency, thereby eliminating the human component as a source of error.
22
Although the hygiene standards for equipment, components and robots in medicine and pharmaceuticals are particularly high there is also a whole string of applications in the Champions League of automation for which no special clean-room robots are required.
www.nzmanufacturer.co.nz
Complex solutions thanks to machine vision Whether in the operating theatre, hair transplantation or the testing of diagnostic devices – machine vision plays a key role in each case. The dual-arm robot application uses three camera systems in all, one apiece on each of the two robot arms, the third one housed statically within the cell. The cameras are not just used for controlling the robot but in point of fact are responsible for the actual quality control, recording and documenting the readings appearing on the diagnostic device display. Machine Vision is tremendously important for many automation projects. This is borne out by the double-digit growth in this industry.
Never hate your enemies. It affects your judgement. -Mario Puzo, The Godfather
In the Fast Lane – AUTOMATICA 2016 showed the future 4.0 AUTOMATICA 2016 (June 21 to 24) exceeded all expectations: around 45,000 visitors (+ 30 percent) and 839 exhibitors from 47 countries (+ 16 percent). One-third of the visitors came from foreign countries. Managing Director Falk Senger: “AUTOMATICA has reached a new dimension. It showed the future of production with deep insights into the possibilities of digitalization, human-robot collaboration and professional service robotics.” Man and machine will work together in the team in the future. People are the focus with their emotional intelligence, and robots assist them. Interest from China was never so great. The number of visitors and exhibitors has more than tripled. The Chinese automation boom is becoming increasingly noticeable at AUTOMATICA. Automation and robotics make Industry 4.0 possible in the first place. Tremendous energy could be felt at the trade fair thanks to the topic. Service robotics recorded a big increase at AUTOMATICA and provided a fascinating insight into the
everyday life of tomorrow: the care car in a hospital or the inventory robot for department stores, service robots as driverless transport systems or assistants for people. New production methods – new work processes: Work 4.0 is a main topic at AUTOMATICA.
A total of 13 delegations came just from China. Song Xiaogang, General Secretary of the China Robotics Industry Alliance (CRIA): “AUTOMATICA is absolutely one of the leading trade fairs for Automation and Robotics, which gives a very strong impression
to the Chinese visitors and exhibitors. Through communication and exchange, CRIA delegation believe, there is a bright future of Sino-German cooperation in automation and robotics.” Full halls and a great atmosphere: 96 percent of the exhibitors and 98 percent of visitors evaluate the trade fair as excellent, very good or good. Sixty-eight percent of visitors believe that the trade fair will increase in importance in the future. Eighty percent of exhibitors plan to come back.
Multi-Channel circuit breakers save on space With a choice of either a 4 or 8-channel CBM electronic device circuit breaker, users no longer need to stack single 18mm wide circuit breakers together in a control cabinet. The Phoenix Contact multi-channel CBM electronic device circuit breakers combine up to 8 channels within the one unit to greatly reduce the need for space. At just 41mm wide, CBM electronic device circuit breakers are also extra slim for ease of use. Their compact design ensures technicians can place the device into smaller cabinets. Plus, because the unit has a smaller footprint, there is greater space within the cabinet for technicians to add other components.
eliminates the need for a technician to have to physically open a cabinet to reset a circuit. The channel can be cleared from the convenience of a programmable logic controller or at the operator interface. Plus, the CBM electronic device circuit breaker also comes with sophisticated remote status signalling concepts, which enable easy monitoring from any location. The circuit breakers also feature an adjustable current per channel of 0.5 to 10 Amps. This allows technicians to choose from six ranges and to set the required protection level for individual circuits. It also eliminates the need for individual circuit breakers to be placed in the cabinet. For additional safety, an electronic locking mechanism prevents accidental changes to the set nominal currents.
Purpose-built, the slim CBM electronic circuit breakers protect susceptible electronic equipment against voltage dips, overloads and short circuit currents, and help deliver maximum system availability.
Each unit also comes with an inbuilt alarm that delivers an early warning when a channel exceeds 80% of the set nominal current. Plus, the multi-stage status indicator that is available for each channel provides constant information about the status of the connected loads.
The smart devices feature a remote reset to clear a tripped channel. This
Designed with flexibility in mind, the multi-channel CBM electronic device
circuit breakers are available in four and eight channel configurations to protect loads at 24 V DC against overload or short circuit currents.
.
Also, the CBM units feature push-in technology for fast and easy connection. The wiring of the devices is tool-free, saving the technician precious time and minimising the opportunity for human error and the need for rework. Perfect for machine building, the CBM electronic device circuit breakers are high performing units and help ensure system availability 24 x 7. Robust and resilient they can be used in a wide temperature range and in environments where shock and vibration are prevalent. In addition, the CBM units meet with the United States Class 1, Division 2, UL approval and can be used for mounting in hazardous areas in both the US and Canada. The CBM electronic device circuit breakers combine extensive functionality with a high level of safety in a very compact design to deliver even greater system availability.
www.nzmanufacturer.co.nz
The CBM electronic circuit breaker.
/
NZ Manufacturer July 2016
23
Keep your fears to yourself, but share your courage with others. - Robert Louis Stevenson
How manufacturers can choose the right solution By Leslie Tarnacki, vice president, human resources and general manager, WFS: A WorkForce Software Company. Manufacturing businesses, under continued pressure from overseas competitors and a fast-moving marketplace, need to manage costs wherever possible to stay competitive. One of the easiest areas to achieve cost savings is by managing personnel more effectively. Many manufacturers already know this and have implemented HR software, or workforce management software, to try to keep a tight rein on costs. However, it can be hard to know if your business has the right technology in place to match its unique needs. Having the right technology is crucial. Simply having a system in place doesn’t guarantee cost savings or efficiencies. In fact, it can be a drain on resources if it doesn’t meet the business’s requirements, or if employee take-up of the new technology is very low. Ideally, your business should have a long-term strategy for workforce management technology. In developing that strategy, the business will gain a strong understanding
of exactly what its needs are, what systems are already in place to serve those needs, and where the gaps are. Then they can make a plan to fill those gaps. Manufacturers that develop a strategy tend to improve appropriate systems, and at enabling employees to embrace the new technology. This is key because automating HR processes reduces workloads and lets staff focus on higher-priority, value-adding tasks; the ones that contribute to the bottom line. There are five key pieces of functionality that the right workforce management solution should have: 1) Calculating employee hours: For most, if not all organisations, the number of hours an employee logs is important. When implementing a system, it’s important all employees can view their timesheets no matter where the employee is working. The system should also automatically ensure compliance with labour laws.
2) Staff rostering: Rostering is about more than telling your employees when you need them to work. By using staff scheduling software to automate rosters, you can optimise staff costs and effectiveness, comply with mandatory time off, and decrease overtime payments and other controllable expenses. Your rostering system must give employees a direct view of their rosters and timesheets. It must also alert managers if there are errors or tasks requiring their attention. This can be particularly important when it comes to reducing worker fatigue: the right system can tell manufacturers when their staff need time off. Adequate time off is essential to reducing workplace injuries and errors. 3) Leave management: The financial impact of employee absence is significant, yet managing it is increasingly complicated, time consuming, and expensive. Automating absence processes enables organisations to mitigate and reduce
these costs. Your system must track all employee leave (holiday, sick, personal). The system should also be in line with compliance laws. 4) Workforce analytics: Automating workforce management processes, from rostering to award interpretations, can have strong and sustained impacts on business performance. These gains become even more valuable when you can monitor results and precisely measure their impact. 5) Employee self-service: A cloud-based solution lets users log in from any web-enabled device without being limited by browser, or the need to install plug-ins or applications, which is especially important for workers in manufacturing organisations, who may not have access to company-provided computers. Self-service and mobile access help boost workplace flexibility and productivity by letting employees access data remotely and at any time, while using a consistent interface.
IoT in the warehouse Research firm Gartner estimates that by 2020, there will be 25 billion smart devices, transmitting data to us, to the cloud and to each other. These devices range from smart cars to home thermostats, from implanted sensors on containers to label tags on our clothes. Many industry leaders believe this is the start of the fourth Industrial Revolution, where enterprises become intelligent and every link in the supply chain talks to each other and is connected. The Internet of Things (IoT) allows for the remote monitoring of equipment, containers, pallets or packages to
see how equipment is performing or to track products throughout the supply chain. Sensors and automatic ID equipment like RFID and bar code readers are among IoT devices. In the warehouse, these devices are used for inventory tracking, receiving, put-away, cycle counting, picking, restocking and data entry. Adopting these technologies and the IoT improves visibility across the entire supply chain, lowers costs and streamlines operations. As the Internet of Things becomes widely accepted, more and more devices are given sensors that can be monitored and controlled. The
Warehouse Control System (WCS) is the key to IoT success, monitoring and controlling all of the intelligence devices in a warehouse. A WCS allows warehouse managers to gather critical key performance indicators to better manage their distribution and fulfillment operations from their wrist. With real-time visibility into warehouse operations 24/7, managers can better meet the demanding requirements of today’s modern distribution operations. Forklifts were some of the first equipment to become intelligent, donned with diagnostics that tells the forklift to signal when it needs to be serviced. A warehouse control systems can direct a forklift to a pick location and tell it at what height the product is stored, speeding picking operations. RFID tags in the warehouse floor can signal the forklift not to exceed a certain speed in a particular location due to traffic in the area, thus avoiding a collision and improving safety. Radio Frequency Identification (RFID) technology can be used to provide location, identification and tracking information, such as identifying when a pallet will arrive in the warehouse. This data can be combined with environmental data, such as weather and road conditions, which can affect the quality of products in transit.
24
NZ Manufacturer July 2016
/
www.nzmanufacturer.co.nz
Conveyors can contain sensors to only turn on when there is a product coming towards a particular section. The conveyor will not be running unless there is a product on it, thus saving energy. The WCS contains the move logic for the warehouse. It knows when inventory is inducted into the material handling system and can trigger each unit to turn on and off, moving inventory through fulfillment areas. Because different materials handlings systems operate at different speeds and have different carrying capacities, the WCS is responsible for achieving throughput optimization by properly buffering and throttling the various equipment. The WCS balances the need to speed up or slow down equipment to keep materials flowing smoothly through the warehouse. Accenture, recently reported that, “the Internet of Things can trim average repair costs by 12 percent, maintenance by 30 percent and downtime by as much as 70 percent. It can also save big on electricity costs through smart energy management systems.”
Leadership is doing what is right when no one is watching. –George Van Valkenburg,
These 3 things make a company truly innovative What are the world’s most exciting innovations? The answer may come from the World Economic Forum’s new class of Technology Pioneers, announced today. The 30 awardees come from seven countries in three continents, and are active in a wide range of industries: from health to agriculture, and from finance to IT. But beyond their geographical and sectorial diversity, they have three crucial aspects in common. They combine innovations, innovate at an ever increasing pace, and work on solutions to global challenges. Here is how they do it. 1. They combine innovations Whereas previous generations of technology pioneers focused on introducing new technologies as such, pioneers in 2016 are increasingly combining technologies. 3D printing, big data, the internet of things, advanced satellites imaging and drones are innovations of the Fourth Industrial Revolution that are reconstituting various industries and sectors. Pioneers bringing these technologies to the table include: Orbital Insight: a geospatial big data company that discovers social, economic, and agricultural trends through satellite image analysis. The company’s technology serves as a “macroscope” allowing the study of trends that are hidden, or too large to be seen by the human eye. Voxel8: a company that 3D prints electronics. Printing a project in one go negates having to make a circuit in advance. This method reduces the number of materials used, simplifies the development of the object and allows perfect integration of electronics, thus reducing its final size. Cylance: a company that applies artificial intelligence and machine learning to cyber security. By unlocking the “DNA” of malware Cylance gives enterprises the ability to predict and prevent advanced threats.
2. They innovate increasing pace
at
an
ever
Some innovations today are rendered obsolete in a matter of years or even months. Conversely, some companies that were founded only a few years ago are leaders in their fields. That contrasts with the past, when truly ground breaking innovations took years or even decades to spread. The first industrial revolution, with its steam power and the rise of the factory system, took almost 80 years to develop, while the more recent computer revolution also progressed slowly. Companies that help bring about this fast-paced innovation include: Magic Leap: a company that creates a mixed reality. Its virtual retina display and software enables interaction between real things and virtual objects. Virtual images are projected onto the retina, creating the same types of neurological effects as real life objects perceived by humans.
Wrightspeed: a company that produces hybrid-electric powertrains for heavy duty trucks. This technology makes commercial trucks greener and more energy efficient. It uses high-power electric drives with micro-turbine generators for urban truck fleets. 3. They work on solutions to global challenges Companies have long faced criticism for chasing profits at all costs, without taking into account the larger challenges the world is facing. Today, with the world at a tipping point in terms of climate change and other challenges, that narrow corporate perspective is changing. Many of today’s technology pioneers believe these global challenges need addressing. They include Synthace: a synthetic biology company that uses
computational modelling and big data analysis to produce novel bio-based chemicals and other products. They harness the ability of micro-organisms to produce products from renewable feed stocks. Farmers edge: a data acquisition and analysis company. It focuses on precision agriculture and data management solutions. Through the integration of highly accurate data science and services on the farm, Farmers Edge helps growers around the world achieve the highest sustainable yields possible. WaterSmart Software: a big data and cloud computing company. It uses behavioural psychology and mobile and online tools to help water utilities educate and engage customers to save water and money.
Kensho: a company that provides a next-generation analytics and knowledge platform for investment professionals. Its intelligent computer systems are capable of answering complex financial questions posed in plain English, by combining massively-parallel statistical computing with natural language inputs, big data and machine learning. PrecisionHawk: a data acquisition and analysis company that combines unmanned aerial systems (drones), artificial intelligence and remote sensing technologies to improve business operations and day-to-day decision making across a wide range of data-intensive industries.
Are you a Kiwi manufacturer who is NOT appearing in NZ Manufacturer? Why Not? We offer: •Case Studies•Analysis•Interviews•Opinion Articles•New Products to the Market from our Innovators and Developers FOR New Zealand and overseas readers.
Is your company busy making fantastic products and we haven’t heard about you? Doug Green Publisher
Why Not? Contact us now to enhance your market share.
P 0064 6 870 9029
publisher@xtra.co.nz
www.nzmanufacturer.co.nz www.nzmanufacturer.co.nz
/
NZ Manufacturer July 2016
25
FOOD MANUFACTURING
A leader has the vision and conviction that a dream can be achieved. He inspires the power and energy to get it done. -Ralph Nader
New Marlborough salmon farms come on stream The first new space allocated for salmon in Marlborough in 9 years has finally come on stream with the official opening of two new salmon farms operated by New Zealand King Salmon. The Pelorus Sounds farms at Waitata and Kopāua A third farm in the Tory Channel, Ngamahau has begun operating and an official opening is expected later in the year. The sites add to the operating farms the company has in the Queen Charlotte Sound and the Tory Channel – Ruakaka, Otanerau, Te Pangu and Clay Point. The three new farms will enable New Zealand King Salmon to approximately double salmon production from around 6,000 metric tonnes to 12,000 over the coming years. The extra production is destined to fill the strong demand from international markets, in particular North America. The first harvest from the Waitata farm took place this week producing excellent quality salmon averaging more than four kilograms in size.
26
NZ Manufacturer July 2016
/
The farms are located on sites where the water is cool, deep and with high flow, optimal conditions for raising salmon. NZ King Salmon CEO Grant Rosewarne says salmon farming has helped put Marlborough on the menu as a world-class culinary destination. “Not only do we grow the best salmon in the world, we tell the NZ story with our brands.”
with the Best Aquaculture Practices
“Salmon represent one of the most sustainable ways of producing animal protein and these farms are an important addition to the regional economy. They also support the government’s commitment to creating sustainable food sources through aquaculture.
resource consents and environmental
(BAP) certification, and we are in an elite group of less than one per cent of salmon farmers recommended as ‘Best Choice’ by Monterey Bay Aquarium’s Seafood Watch and Ocean Wise,” Mr Rosewarne says. The new sites are in the first stage of farming with small increases allowed every three years in accordance with
conditions, Mr Rosewarne says. It will be up to 16 years before each is fully productive. “The farms provide green jobs for locals, support for local industry and suppliers and add to the region’s rapidly growing reputation for high quality seafood. “Once fully operational, salmon farming in Marlborough will generate around $230 million in direct revenues
“These two new farms – and Ngamahau yet to be officially opened – are recognition of our commitment to meeting the best practice guidelines for salmon farming issued by the Marlborough District Council in 2013 and supported by our company. “Our environmental credentials are in demand and internationally recognised through our accreditation
www.nzmanufacturer.co.nz
NZ King Salmon CEO Grant Rosewarne and Dr. Nick Smith, Minister for the Environment.
If you’re offered a seat on a rocket ship, don’t ask what seat! Just get on. –Sheryl Sandberg plus
flow-on
business
local
The pens at the new farms measure
companies supporting the industry.
between a third (Kopaua) and two
These include transport operators,
thirds (Waitata) of a hectare - a rugby
engineering firms, science providers,
field is approximately one hectare -
tourism operators, local contractors
while they sit in water between 35 and
and retail shops.”
55 metres deep.
Both farms have been built to blend
Modern technology is playing an
in with the local environment with
increasingly important role in salmon
nautical-style
muted
farming. The Kopāua farm’s computers
camouflage colours. The pens are a
are controlled from the Waitata
new Wavemaster design with a lower
farm just across the Waitata Reach, a
profile. They are flexible so as to better
practice developed by NZ King Salmon
cope with the seas in the more exposed
at its Te Pangu and Clay Point farms in
sites of the Pelorus Sound.
the Tory Channel.
barges
for
and
Once fully operational, salmon farming in Marlborough will generate around $230 million in direct revenues plus flow-on business for local companies supporting the industry.
FOOD MANUFACTURING
Introducing
A point of difference in today’s busy FMCG market.
Developed by AsureQuality, inSight™ provides shoppers with independently verified information about the products they are about to buy. After a successful application process, producers can place the inSight™ logo and a QR code on their product packaging.
When shoppers scan the QR code at the point of sale they can access information about the product, including: • • • • •
Environmental sustainability Social and ethical concerns Nutritional information Safety and quality Origin
Why the Need for inSight™? inSight™ takes product assurances into the 21st century inSight™ is a new brand developed by New Zealand Government owned AsureQuality, global experts in food safety and quality. We know how important food safety and quality is to you. We wanted a way that you could get independently verified information about a product, that would give you confidence in it before paying for it. inSight™ makes sense because: • You want to know more about the food you are eating
A new innovation taking product assurances into the 21st Century
Freephone 0508 00 11 22 | www.aqinsight.com
www.nzmanufacturer.co.nz
/
NZ Manufacturer July 2016
27
WORKSHOP TOOLS
Speak when you are angry and you’ll make the best speech you’ll ever regret.
-Ambrose Bierce
3M Speedglas launches heavy duty powered air respirator series The 3M Adflo powered air purifying respirator (PAPR) has become one of the most popular and widely awarded powered air welding respirators in the world. A slim, robust system designed specifically for welders has now been released in a heavy duty (HD) version to deliver added features and improved performance. The new 3M Adflo HD Series features the new super lightweight heavy duty battery (40% lighter than the previous model) which can extend battery
operating time to 12 hours. This can give the welder an extra four (4) hours over the standard systems. The HD series also features the new one hour rapid charge. This allows the welder to charge the heavy duty battery from 0% to 80% capacity in approximately one hour. The new Adflo PAPR HD system is available with 3M Speedglas Welding Helmets which all feature the new 3M Speedglas Welding Lens 9100XXi with Speedglas TrueView for crisp colour
and clarity. • 3M Speedglas Welding Helmet 9100XXi Air • 3M Speedglas Flip-Up Welding Helmet 9100XXi FX Air • 3M Speedglas Flip-Up Welding & Safety Helmet 9100XXi MP Air Existing Adflo customers can upgrade to the lighter HD system with rapid charge by purchasing an upgrade kit that includes the all new HD battery pack and charger.
For more information please go to www.speedglas.com.au
Electric Torque Wrench for swift, reliable bolting with SMART technology Enerpac is introducing to Australasia its brand new Electric Torque Wrench to improve bolting efficiency and performance for industries requiring high repetition and high precision such as mining and energy, infrastructure, oil and gas, power generation, petrochemical and processing plants.
technology based on Enerpac’s 50 years of experience as an industry leader in bolting solutions and is fully backed by Enerpac’s extensive service and distribution network throughout Australasia and New Zealand to facilitate optimum reliability and safety compliance.
The Electric Torque Wrench – in maximum torque capacities from 1625-8135Nm (1200-6000 ft-lbs) – incorporates the latest advanced SMART safety and efficiency
The Electric Torque Wrench complements Enerpac’s Pneumatic Torque Wrench and comprehensive range of hydraulic torque wrenches and bolting tools, which is highly
Enerpac’s new Electric Torque Wrench, left, and the view from the rear of the tool showing the LED display, right.
valuable to companies seeking time-saving choice, consistency of quality and traceability of outcomes. http://www.enerpac.com/en-au/news/ new-electric-torque-wrenches Advances incorporated into the design of the Electric Torque Wrench include a large seven-inch touchscreen on the control box as well as a bright 3-line LED display on the back of the tool, so that it can be read easily, even in bright sunlight. The control box is designed to simplify complex jobs through the creation of automatic presets. In addition, fastening records can be viewed on-screen and transferred through a standard USB connection. The new Electric Torque Wrench is highly versatile with a full range of sockets and extensions to suit different applications, and can even supply non-standard versions on request to suit special applications. The LED display on the back of the tool is excellent for minimising downtime.
It has pass/fail indicators, increase/ decrease selection buttons for torque, direction turn selection and indicators – so the user can monitor and manage the fastening process without returning to the control box. Efficiency and reliability are key considerations with this new tool. Each tool is performance tested and shipped with a factory calibration certificate to optimise torque accuracy and repeatability and to facilitate traceability and safety compliance. Enerpac also provides free training sessions on how to safely and effectively use the new tool. The Electric Torque Wrench has a high speed continuous rotation, which allows it to perform the job faster than manual methods. It is built with a low friction planetary gearbox to minimise wear and extend uptime. The user can input a nominal torque value followed by a specific angle of rotation, allowing for functionality, efficiency and ease-of-use.
Electric Torque Wrenches YOUR SIMPLE SOLUTION
FOR SMART BOLTING
• Durable & robust design • Display & controls on tool • Simple operation • Data recording Visit www.enerpac.com/en-au/etw AUS 1800 225 084 sales@enerpac.com.au www.enerpac.com.au
28
NZ Manufacturer July 2016
NZ 0800 363 772
neville@enerpac.co.nz www.enerpac.co.nz
/
PNG +675 7988 9115
patrick.molloy@enerpacpng.com www.enerpac.com.au
www.nzmanufacturer.co.nz
The greatest leader is not necessarily the one who does the greatest things. He is the one that gets the people to do the greatest things.- Ronald Reagan
Image analysis system detects facilities failures An image analysis system supports quality improvements and increased productivity by detecting signs of operational failures in production line facilities and deviations in worker activities on the front lines of manufacturing. The image analysis system is expected to be able to dramatically improve the in-process guarantee rate(1) for products through a transition from “representative point management” in quality assurance based on lots to “all point management” (continuous monitoring of the status of Man, Machine, and Material) based on individual product serial numbers. Furthermore, by shifting the role of on-site management supervisors from a focus on “after the fact” measures to the monitoring of trends and preventative measures using obtained image data, they will tie these activities into the prevention of failures before they occur. In recent years, mega-recalls in various industries have brought about a renewed awareness of the importance of accumulating and managing manufacturing performance data to identify the causes of product defects, and to implement countermeasures. In the advanced manufacturing workplaces of the future, it will be necessary to gather a wide range of work-related performance data, including manufacturing performance and inspection data and the results of visual checks by workers. It aims to reach new traceability by establishing mutual links among these different forms of product performance data. All of these will be achieved by introducing new manufacturing execution systems that incorporate IoT technologies. The image analysis system uses depth cameras to extract 3-D forms in order to measure worker activities, and obtains positional information on human joints, such as hands, elbows, and shoulders. Then, based on frontline interviews and observations, it derives standard behaviour models that exclude information not directly related to
tasks (e.g., the length of arms and legs). Furthermore, it identifies deviations in worker activities by using statistical comparisons with those standard behaviour models. The system also detects abnormalities in the case of defects in materials and facilities by analysing differences compared to video images under normal conditions. In addition, the system is able to detect abnormalities in the case of welding defects, by combining voltage and current data from existing facilities with light emitting element colour analysis using high speed cameras. In this way, the system quickly extracts only information related to improvements in quality and productivity from huge volumes of video data, and combines this function with data analysis to improve work efficiency and quality stabilization, and to quickly discover defects. By accumulating image data and connecting final products based on individual product serial numbers, the image analysis system can detect production processes which cause defected products, and improve them. When inappropriate operation is detected, it can trace final products based on serial numbers, thus achieving multi-traceability. In the future, starting at the Harima Plant, Hitachi and Daicel plan to install the image analysis system at six overseas plants, and aim to construct a globally integrated management system by aggregating and analysing information via cloud service. Hitachi will make the image analysis system available to the manufacturing industry worldwide as generalized digital solutions by applying ideas and technologies of the IoT platform “Lumada”. (1) Non-defective product ratio in individual processes on assembly and manufacturing lines. The non-defective product ratio for final products can be increased by identifying and removing defective parts from individual processes and sending only non-defective products to downstream processes.
WORKSHOP TOOLS Fire prevention in a breaker Schneider Electric, the global specialist in energy management and automation has launched a new arc fault detection device (AFDD) which will cut power the moment a dangerous electrical arc occurs. This means that the new AFDD will do for fire prevention what RCDs have done for electric shock prevention in homes and premises for many years. Developed following the recent release of IEC/EN 62606, a design standard for the operation of AFDDs, New Zealand is the third country in the world to gain access to the Schneider Electric technology. The range has five devices which cover from six to 25 amps. Integral to each device is a miniature circuit breaker which provides all the protection of a typical MCB. When the circuit breaker is activated by the AFDD, it delivers broader protection against additional risks. “The new AFDD offers distribution board based protection against all significant risks to people and property along with protection of the electrical installation itself and appliances and cords plugged into it,” Schneider Electric’s Simon Grose said. “This type of protection has been around for a long time in medium voltage installations, but now we finally have a device to take care of low voltage distribution.”
“To remove any possibility of these normal arcs causing nuisance tripping we had to design algorithms that would distinguish harmful arcs from normal arcs as they occurred, and isolate the faulty circuit instantly.” Simon says Schneider Electric also carried out further testing on the AFDD in New Zealand to make sure there are no local supply conditions that would compromise its effective operation and cause nuisance tripping. Easy installation “Wiring an AFDD is as easy as installing an RCBO and its pricing is similar. All you have to do on existing installations is remove the MCB from each circuit you want to protect and install the two-pole AFDD to replace it,” Simon said. Simon says while installing an AFDD on every final sub-circuit will offer maximum arc protection, many installation owners will be happy just to have protection on power circuits where the risks and consequences are greater, such as in bedrooms and where old wiring may be installed. The electrical regulator is backing the use of AFDDs and is likely to cite IEC/EN62606 in Schedule 4 of the Electricity Regulations in the next amendment to provide for its use in New Zealand.
The product works by detecting these dangerous arcs in milliseconds, and then activating the MCB before sufficient energy is released to cause a fire. It does this through sophisticated electronics that monitor in real time a number of different electrical parameters in the circuit it protects. “It is designed to pick up any change to a waveform that confirms the presence of an electric arc, and will only trip if the arc is dangerous. Harmless electric arcs appear frequently during normal electrical operation – in the switches, relays, contactors and motors of the various loads plugged in to a circuit.
www.nzmanufacturer.co.nz
/
NZ Manufacturer July 2016
29
ENERGY
Discipline is the bridge between goals and accomplishments. - Jim Rohn
Konecranes’ waste-to-energy technologies help unlock bioenergy potential Konecranes Biomass Handling Crane technologies recognise that many biomass energy plants today use cranes instead of front-end loaders or conveyors. Cranes need less energy, can operate unmanned in full automation, eliminate diesel fumes from inside your plant, and maximize your available floor space, just to name a few advantages.
A Konecranes refuse handling crane.
A broad range of lifting and materials handling technologies specifically designed for waste-to-energy (WTE) and biomass applications is being introduced to Australasia by Konecranes as the region develops its bioenergy potential. The technologies – including unmanned full automation, remote operation stations, remote monitoring and maintenance reporting products – are focused on applications such as biomass, refuse and ash/slag. Konecranes Australia National Industrial Equipment Manager, Mr Peter Monaghan says the WTE market has considerable growth potential because these technologies allow customers to save money and run their businesses in a more sustainable manner. “Our WTE cranes can be equipped with Global Technical Support connection, remote monitoring and a computer interface capable of semi or fully unmanned automation or a remote for manual handling, as well as a range of features and benefits to maximise production and minimize running costs,” said Mr Monaghan. Konecranes waste handling cranes are designed with smart features, which manage critical crane functions to reduce structural stress, increase efficiency and prolong equipment life. For example, sway control minimises load sway from bridge and trolley motions, reducing collisions between the bucket and the pit walls or hopper, and preventing equipment damage. It increases operator confidence, reduces training time and allows the crane to operate to its full potential.
experience in the waste and biomass handling applications, Konecranes is able to provide complete crane systems for the renewable energy industry,” says Mr Monaghan. “Cranes play a crucial role in waste-to-energy as well as other modern incineration plants where tight environmental management guidelines are applied. A continuous material handling system with maximum safety and efficiency and minimum downtime is vital.”
Remote Operation Konecranes can replace entirely the crane operator pulpit chair and pulpit itself with a remote operators station or ROS which allows someone to operate the crane via cameras from a central operations room located in the facility. This ROS ensures all personnel are removed from harm’s way.
NZ Manufacturer July 2016
/
The storage is managed by the crane. Every time crane deposits or picks up material, it updates the storage in that coordinate location. The same modular solutions used in Konecranes WTE cranes are applicable to Biomass Handling Cranes. Konecranes refuse handling cranes are designed to meet the demanding loads of waste management plants, where minimal downtime is crucial. Important components like hoisting trolleys, drives and grapples have been engineered to reduce maintenance requirements. Each crane features Konecranes’ advanced integrated rope/cable drum. The vertical power cable for the bucket is wound onto the rope drum and is driven by the hoisting machinery. With this unique solution, savings in maintenance costs are substantial. Konecranes refuse plant cranes recognise the importance of a continuous material handling system, from the reception of the waste to mixing and feeding. If a waste handling crane stops, the whole process is in danger. Konecranes proprietary smart features manage critical crane functions to reduce structural stress, increase efficiency and prolong equipment life.
A Konecranes Remote Operators Station
Waste-to-Energy crane technology
Sway Control minimises load sway from bridge and trolley motions, reducing collisions between the grab and the pit walls or hopper, as well as preventing equipment damage. Sway Control increases operator confidence, reduces training time and allows the crane to operate to its full potential. Their ash (or slag) handling cranes are ruggedly designed for harsh environments. These cranes are used to distribute slag under the conveyor
“As an industry leader in cranes and crane maintenance, with over 50 years
30
Konecranes biomass handling cranes automatically start the working cycle to transfer the material from the reception pocket to the adjacent storage. Likewise, the crane automatically starts the working cycle to fill the hopper from the storage after the reception of the command “fill the hopper” from the sensor of the hopper.
www.nzmanufacturer.co.nz
line to the other areas in the slag bunker 24 hours a day as well as loading trucks during the daytime. Sometimes the ferrous rejects have not been separated from the slag, causing higher requirements for the buckets. To achieve better penetration into the slag, the edges of claws can be provided with special teeth. The Konecranes Main User Interface, or MUI, is Konecranes’ new standard solution for programming waste-to-energy automation. Accessed from the MUI station, the MUI features a computer and 23-inch LED panel screen, keyboard and mouse. This computer is fully integrated with the crane’s PLC system, while isolated from outside networks. It allows the operator to schedule and program a week-long agenda that includes up to 20 different work routines in full automation, giving plant managers enhanced flexibility to manage pit operations for receiving, mixing and burning waste. In seasons where flexibility is not as important, facilities can repeat the Monday through Sunday agenda indefinitely without accessing the crane–except to take it out of automation for scheduled inspections and maintenance. In addition, the MUI monitors crane operations, including usage statistics, error messages and equipment condition. The system also generates summary reports to help managers optimize maintenance and alert them if more operator training is needed. Konecranes waste-to-energy technologies include an extensive range of maintenance reducing software, electrical and mechanical products including TRUCONNECT Remote Monitoring and Reporting.
Konecranes specialised Waste-to-energy technologies.
REAR VIEW
Life is a sum of all your choices. -Albert Camus
Brexit highlights export access challenges into the EU - by HERA Structural Systems General Manager Dr Stephen Hicks The big breakaway happened - with a slim 48/52 vote in favour of exiting the European Union (EU). The positives and negatives of the decision have been covered in much detail since it was made – and it seems the immediate effects of the UK’s withdrawal have been limited when it comes to New Zealand.
with the EU strong.
manufactured items.
Adding to this, that we were the first country in the world to sign a free trade agreement with China and the first to sponsor them into the WTO we can see that, while it took a great deal of effort - it’s also gone a long way in establishing our track record and ability to get the job done when it comes to a favourable trade outcome.
Time is money, and we simply can’t afford to wait for others to sort everything out – so with Brexit fresh in everyone’s minds, we thought there’s no better time to remind you of the need to obtain CE marking for your manufactured products to help facilitate export into these regions.
But, for those of our members in the export game or considering entering it (specifically the European one), knowing your options suddenly got very important. While our government plans to launch negotiations for a free trade deal with the EU, looking at your current business model and understanding if there are any tweaks you can make during this time to continue ‘business as usual’ or in fact seize an opportunity should be a priority.
To pursue CE marking, understanding what group your product falls under and if you require a Notified Body is needed. Notified Bodies are the only recognised third-party bodies that can carry out conformity assessments and are mostly based in Europe – which is why we’ve worked hard to develop a relationship with a Notified Body to open access to their support, and as such offer a one-stop-shop for manufacturers wishing to export to Europe.
Putting it into context It’s fair to say New Zealand has come a long way since the UK entered the then European Economic Community (EEC) 43 years ago. Up until that time, much of our exports went to the UK, and since then we’ve become a diverse, creative and proactive economy that has markets spread around the world. The bulk of New Zealand’s exports are sent to Australia and Asia, where we’ve risen to become one of the strongest performers in our respective block, but the advantages of pivoting towards emerging markets is clear and an opportunity to negotiate a trade deal that makes it commercially easy
highways or other civil engineering projects – ensuring our locally manufactured products meet European Standards (Eurocodes) are crucial for market entry. We’re able to assist in achieving this throughout the design phase by developing and managing test programmes and evaluating they meet Eurocode guidelines - preventing costly mistakes when placing products on the market.
What we now have to grapple with, is that these sorts of negotiations don’t happen overnight - and all the while the world continues to need our
Understanding CE marking In New Zealand we’re no stranger to having to comply with standards – so much so that in 2012 we established HERA Verified for our manufacturers wishing to demonstrate their products or services were independently verified and compliant. Not surprisingly, Europe has a similar but more formal approach, calling for CE marking on products traded in the European Economic Area (EEA). They declare that products sold in the EEA have been assessed and meet legal safety, health and environmental protection requirements - while also supporting fair competition by holding all companies accountable to the same rules. As this marking also applies to construction products permanently incorporated into ‘construction works’ such as buildings, bridges and
www.nzmanufacturer.co.nz
So far we’ve helped a number of New Zealand businesses to achieve CE marking including the ComFlor 60 and 80 cold-formed steel decking products developed for use in composite flooring. We’ve also assisted M Metal in Singapore to meet Eurocodes that have been adopted by other countries around the world by designing, managing and extending the application of loaded fire tests undertaken at the renowned Exova Warrington fire facilities in the UK for them. These works allowed them to eliminate the need for bottom reinforcement bars for the composite slabs on the 40-storey CapitaGreen Building they were constructing - resulting in savings of approximately S$180,000. A passport for entry Whilst the UK has decided to exit the EU, it doesn’t change the fact that it remains the largest economy and trading block in the world – which is ripe with opportunity for us in New Zealand. For our manufacturers, gaining CE marking is crucial to gain entry into this market – and through our strong relationships with a Notified Body, a stepping stone in developing new products and exporting them to Europe.
/
NZ Manufacturer July 2016
31
HEADING
The shortest way to do many things is to do only one thing at once. -Samuel Smiles
title text
Manufacturers focused on
SUCCESS Join with...
32 tell us your story www.nzmanufacturer.co.nz publisher@xtra.co.nz NZ Manufacturer July 2016 / www.nzmanufacturer.co.nz