Manufacturers' Monthly March 2015 by Prime Creative Media

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

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MARCH 2015

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

MARCH 2015

From car panels to confectionery pallets INSIDE >> 16

IT@MM Technology trends you canâ&#x20AC;&#x2122;t ignore

Safety First Why single use gloves make sense

Compressors & Pneumatics The right compressor for your business

MA0315_000_LAF

If the motor was half the physical size and weight and almost completely silent, would this benefit you?

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er have Do you ev bout the a s concern nsumption energy co ctory? ur in yo fa

And , prod if you w u ere a c tion wou d half ld a mot esiigner or th and e size a that is nd w supe r-effi e cient ight of b be enefi t?

rgy Are ene itive ib h ro costs p you e s u a bec many have so rs o mot ?

Of course you O w would love to get your energy costs down.

If you could have an electric motor that is IE4 efficient, way above the current efficiency standard, and would cut your energy costs to a large degree, would that be of help?

If you answered yes, you are not alone... Lafert Electric Motors Australia can supply the world’s first multi award winning High Performance motor that just might be what you are looking for! A new High-Performance motor intended for the OEM market that offers significant savings on running costs and space requirements that can be engineered to match customer’s applications has been introduced by Lafert. Savings on operating costs are substantial since the motors are far superior compared to standard AC induction motors enabling significant frame size and weight reductions.

motor) combines the technology of both brushless Permanent Magnet Servo Motors and conventional AC induction Motors. The ability to do this is facilitated by the fact the Lafert group has both Servo and AC induction motor “know how” in-house.

superior across the whole speed range.

By combining these technologies, substantial efficiency advantages over conventional Ac induction motors, including IE4*, are achieved. The efficiency is

All these combined features enable engineers to achieve compact efficient motor solutions, particularly for such applications involving pumps, fans and compressors that are

The enhanced performance characteristics of the HP motor also permit Lafert to offer smaller frame size solutions and weight savings of around 50%.

The new Lafert ‘High Performance’ motor (Hp

substantially more compact, lighter in weight and less expensive to operate. All these benefits are provided from one development source due to Lafert’s in-house technology and the ability to harness the best from proven components such as the AC induction motor’s standard stator and the surfacemounted permanent magnet rotor from the brushless servo motor.

Lafert A Australia import and distribute the internationally recognised, high quality brand internat AEG Ele Electric Motors. AEG G spe specialise in manufacturing High Efficiency Cast Iro Iron and Aluminium, three phase IE2, IE3, Nema EEpact and Customised motors. With a w wide range of sizes and speeds, starting from .09 .09kw 56 frame 2,4 & 6 pole up to 315kw 355L fra frame, straight off our shelf, you can be up and runn running nn in less than 24 hours.

Ph: (03) 9702 3707 Visit: www.lafert.com Email: morgan@lafertaust.com.au

Check out our Facebook page

Lafert can deliver drives controlling stand-alone PM motors (HPS range) or drives integrated into the PM motors (HPI range)

Motors also available from AEG ex-factory with exceptional delivery times: • High Voltage • Marine • Super Premium IE4 • Cooling Tower • IEC EX Hazardous Flame Proof Don’t be the last person to switch to AEG and Lafert Electric Motors.

WORKSHOP AND ENGINEERING Lafert Australia also offer quality IN-HOUSE rewinding, repairs and engineering.

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Inside

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MARCH 2015

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For daily news visit manmonthly.com.au

Publisher: Martin Sinclair martin.sinclair@cirrusmedia.com.au

6 Editorial

Managing Editor: Kevin Gomez Ph: (02) 8484 0976 Fax: (02) 8484 0722 kevin.gomez@cirrusmedia.com.au

■ Innovation needs better support

Editor: Matt McDonald Ph: (02) 8484 0645 Fax: (02) 8484 0722 matthew.mcdonald@cirrusmedia.com.au

8 News & Analysis

Editor-at-Large: Alan Johnson Ph: (02) 8484 0725 alan.johnson@cirrusmedia.com.au

12 Comment

Graphic Designer: Dave Ashley david.ashley@cirrusmedia.com.au

■ Don’t write off manufacturing yet

Production Co-ordinator: Mary Copland Ph: (02) 8484 0737 mary.copland@cirrusmedia.com.au

14 IT@MM ■ ■ ■ ■

NSW Sales: Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Ph: (02) 8011 3184 anthony.head@cirrusmedia.com.au QLD Sales: Sharon Amos PO Box 3136, Bracken Ridge, QLD 4017 Ph: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 sharon.amos@cirrusmedia.com.au NSW, SA/NT & WA Sales: Cirrus Media Ph: (02) 8484 0868 anthony.head@cirrusmedia.com.au Published 11 times a year Subscriptions $140.00 per annum (inc GST) Overseas prices apply Ph: 1300 360 126

Cirrus Media Tower 2, Level 3, 475 Victoria Avenue, Chatswood, NSW 2067, Australia Locked Bag 4700, Chatswood Delivery Centre, NSW 2067, Australia Ph: (02) 8484 0888 Fax: (02) 8484 0633 ABN 80 132 719 861 ISSN 0025-2530 www.cirrusmedia.com.au © Copyright Cirrus Media, 2015

What’s next for manufacturing? App for making things Technology trends you can’t ignore When’s the right time for ERP?

manmonthly.com.au

46 Laser Technologies ■ Keeping a close eye on safety

18 Endeavour Awards

33 Composites Engineering ■ CME – the rewards of diversifying

■ ■ ■ ■ ■

Laser engravers offer flexibility 6.0kW laser cutting system Laser vibrometer Laser marking machines High- speed laser marker

20 Management – Exporting

34 Materials Handling

■ Time to chase the tiger ■ Help at hand for exporters

25 Safety First

■ Efficiency and environmental benefits ■ Reach truck ■ Aluminium portable gantry gates

■ Why single-use gloves make sense ■ The temptations of incidental reporting

40 Compressors & Pneumatics

54 The Last Word

■ The right compressor for you

■ Manufacturing’s Holy Grail

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

MARCH 2015

A long-time, Tier 1 supplier to Holden and Ford, Composites Materials Engineering (CME) has a proud history From car panels to confectionery of success in the auto industry. pallets Nearly two decades ago, the company looked into its crystal ball and decided to seek markets other than automotive. 2 0 1 5 - 0 2 - 2 6 T1 5 : 3 0 : 4 1 + 1 1 : 0 0 And the encouraging news for any 16

IT@MM Technology trends you can’t ignore

Safety First Why single use gloves make sense

Compressors & Pneumatics The right compressor for your business

52 What’s New ■ CAD/CAM nesting software ■ Product for on-site maintenance ■ Smart standard drives

Behind the cover

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INSIDE >>

■ Biodegradable lubricant ■ Knowledge can save you power

■ Introducing our 2015 sponsors

Average Net Distribution Period ending Sept ’14 18,688

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■ Snapshot ■ Senate votes down R&D changes ■ Submarine deal still up in the air

Journalist: Brent Balinski Ph: (02) 8484 0680 Fax: (02) 8484 0722 brent.balinski@cirrusmedia.com.au

Printed by Bluestar Print 83 Derby Street, Silverwater, NSW 2128 Ph: (02) 9748 3411

other manufacturers contemplating the death of Australian car making is that its diversification, offering lightweight, technical solutions, has proven a success. Last year a profile on CME said that within a decade it had moved from being 98 per cent automotive-oriented to 50 just per cent.

Manufacturers’ Monthly MARCH 2015 5

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Comment

KEVIN GOMEZ – Managing Editor

Local innovation needs better support

the Greens leader commented that it was a “big win for ENDORS promoting novel solutions into the Ausbusiness”. However, there’s still a $100 million cap on R&D tralian market are often met with the response: spending that’s being retrospectively applied. “... but has this been implemented locally as yet?” Meanwhile in the UK, the State of Engineering report The Australian environment is sometimes considered released in January this year reveals that their so different and unique that it needs a specially engineering sectors contribute 27 percent to tailored solution. that country’s GDP. But the impact is much It was therefore interesting to read about a wider. For every £1 in gross value added manufacturer in Victoria, Australian Tartar(GVA) that is generated by engineering, ic Products (ATP), powering their factory a further £1.45 is generated elsewhere in with grape waste from wineries of three the economy. Thus, an equivalent of 66 states. With manufacturers facing increaspercent of the UK’s GVA can be attributed ingly large energy bills, this ‘Australian soto engineering. lution’ is a welcome development. Currently The UK study also showed that every new bioenergy provides just over 1 percent of Ausengineering role creates an additional two jobs tralia’s total energy generation. in the economy. In an encouraging trend, many sugar mills are NEXTISSUENEXTISSUE All hues of this country’s political spectrum starting to generate their own energy from sugar • Made in Australia must come to the realisation that the best way to cane waste and thus lowering their operating costs. • NMW 2015 Preview secure Australia’s economic future is to take measGiven this need for technology and innovation it • Energy & Power Management ures to support innovation. Not strangle it. was disappointing to see the Federal government • Welding & Profile Cutting As always, the team at Manufacturers’ Monthly attempt to pass a budget proposal to reduce research • Cranes & Lifting and development tax breaks for all companies by 1.5 would love to hear from you, so drop us an email, fol• ERP Systems percent. For a government that came to power with the prolow us on Twitter and join the discussions on Facebook, • Manufacturing for Mining M A 0 3 1 5 _ 0 0 0 _ G R A _ T mise G 4 0to support 1 business, 2 0 1 5 it - took 0 2 -the 2 Greens 6 T 1 5and : 3Labor 1 : 4in7 + 1 1 Google+ : 0 0 and LinkedIn. • Safety in Manufacturing the Senate to vote this down. Commenting on the rejection, kevin.gomez@cirrusmedia.com.au

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Siemens AG. All other logos, trademarks or service marks used herein are the property of their respective owners.

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News&ANALYSIS Senate votes down change to R&D tax break THE Senate has voted down a Government budget proposal that would have reduced research and development tax breaks by 1.5 per cent. According to the SMH, Labor and the Greens joined forces to defeat the bill which the Government had claimed would have resulted in savings of $620 million over four years. However, following a deal between the Government and the Palmer United Party last month, the amount on which companies can claim R&D tax breaks will be limited to $100 million. Opposition innovation spokesman Kim Carr said the change would have had a great impact on small to medium enterprises, which make up a large proportion of those involved in the scheme. “The passage of this Bill in its current form would further degrade the R&DMtax of A 0incentive, 3 1 5 _ 0which 0 0 _is Fone AN the most important mechanisms avail-

Opposition innovation spokesman Kim Carr. diverse economy, and if we do not able in the taxation system to foster build a more diverse economy, we innovation,” said Carr in the Senate. 1 “Without 2 0 1 5 - a 0strong 2 - 1innovation 7 T 1 4 : 2 5 : 1 cannot 5 + 1 1protect : 0 0 living standards and system, Australia cannot build a more we cannot ensure that prosperity is

spread throughout our population.” Carr’s views were echoed by Sukvinder Heyer, National Head of Research & Development Tax, Grant Thornton Australia. “This is positive news for many mid-size businesses for whom the reduction in the rate would have meant an actual cash decrease. In innovation, every dollar counts, so to have certainty that the rates will remain as they are, is very welcomed,” she said in a statement. “What remains to be seen is the impact of the introduction of the cap on expenditure. This measure has the potential to push R&D offshore because the margin provided by the R&D tax offset to large companies is diminished. “This could stifle activity in the local technology, life sciences and manufacturing sectors by taking away opportunities to be involved in leading developments.”

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In brief... Govt contract for Ballarat train maker The Victorian Government will purchase 30 new train carriages from Alstom, a Ballarat manufacturing company which has been struggling to survive. The company currently employs 70 workers and the order should ensure its survival until at least 2016.

RET deal getting closer Agreement on the controversial renewable energy target is becoming more likely as the Government and the clean energy sector continue talks. It appears the final agreement will commit Australia to source about 33,500 GWh of energy from renewable energy sources by 2020.

Forgacs to cut Newcastle jobs Engineering company Forgacs will cut a fifth of its workforce in Newcastle due to a lack of shipbuilding contracts. The company, whose workforce at Newcastle peaked at 900 and now stands at 600, has been warning about the shipbuilding ‘valley of death’ for more than two years.

Labor company tax crackdown The Labor Opposition says its plan to crackdown on tax avoidance by multinationals would save at least $1.9 billion over four years. Most of the revenue would come from changes to the arrangements for how multinational companies claim tax deductions.

Possible new car factory for SA Melbourne-based Ethan Automotive is considering opening a small-scale car factory at Edinburgh Parks in South Australia. The company plans to make prototype vehicles, the first model of which would be a real-wheel drive, in 2017.

Govt won’t change penalty rates The government says it will not seek to change penalty rates or the minimum wage, even if the Productivity Commission’s inquiry into workplace relations makes such recommendations. Both will continue to be set by the Fair Work Commission. Employment Minister Eric Abetz said he was surprised when the Productivity Commission said the review would look at the minimum wage and penalty rates.

manmonthly.com.au

Submarine deal still up in the air PRIME Minister Tony Abbott has pledged to allow local ship builders to bid to build the next generation submarines but it still appears some or most of the work will be done overseas.

Meanwhile, cross bench Senator David Leyonhjelm left no doubt about his feelings on the issue. Echoing former Defence Minister David Johnston, he said he “wouldn’t trust ASC to repair a canoe”.

What members of our manufacturing community think about the submarine project… Shane We have done it here with the Collins class; we can do it here again. Senator David Leyonhjelm’s comments are baseless and searching for some political influence in these desperate vote grabbing times. Of course ASC needs to be part of the tender process so all of these factors, especially financial can be evaluated. It is amazing that foreign delivered projects such as the F35 are expected to have overrun but not local manufacturing. Australia has learnt a tremendous amount from the Collins class and it should be made public knowledge now that they have exceeded expectations in many areas. Leyonhjelm is ill-informed just as he was about opposing Howard’s Gun buy-back scheme. He should refer to Yule & Woolner. By 2006, A$5.071 billion had been spent to build the submarines (excluding the fast track program); after taking inflation into account, the project had run less than A$40 million over contract. Leyonhjelm does not agree with active Government and was wrong about the proven benefits of the Howard guns buy-back scheme and is well advised to read about PMI stimulus and growth which now needs to occur here. [It needs to be] similar to what has taken place with the UK Government’s “Rebalancing the Economy”. We need our politicians to understand the basic economics and benefits of local manufacturing. We have thrown away vehicle manufacture, rolling stock and now possibly shipbuilding which will likely mean the death knell to our steel industry as we will reduce our national steel requirement by 50%.

Apart from pathetic politicians we no longer have faithful locally run corporate allies such as the once fabled Big Australian to repay some of the debt that the country has afforded it, as under the Billiton years they have demonstrated a global interest at our expense where as in previous times they had leadership that considered national interest as being an important part of their identity. The 280 tonne excellent quality stainless steel flagpole on Parliament house could not be made at Wollongong under the present regime as they do not now produce stainless steel in Australia. However we could again under the right influence and stimulus. Reproducing advanced micro alloys for a world class submarine might be a rebirth in an export market? We might save our metals industries and create employment. Wouldn’t that be a good idea, dear politicians of both parties? Let’s get the country back into advanced manufacturing and keep the taxpayers’ dollars here so payroll tax and money spent on local materials can be retained in our economy, not just take the easy path and send it offshore where there will be no value add, just more debt.

more. The Collins was a disaster and still is and these new submarines need to be made at a price and with a guarantee of quality so, if there is a problem, the taxpayer is protected. Wayne (in response to Alfred Arthur Arnold Be) Alfred, fair enough… the unions can be an issue so push the unions out. [Let’s have] direct negotiations with the workers with bonuses on performance and milestones. As Shane said we need to keep this type of manufacturing here so we can adapt to the new manufacturing world and develop our advanced technologies. It’s well and good for the politicians to talk up verbage on change. When you get Christopher Pyne announcing he might cut $120 million from research, what hope do we have? Editor’s note: Comments are as received. Corrections are made to spelling and grammar.

What do you think? Go to www.manmonthly. com.au and make a comment about this or any other issue.

Alfred Arthur Arnold Be You have to be joking, As others have stated we can’t even build a great canoe. The biggest problem we have is not the trades. It’s the unions running the companies with threats, demands for money and general interference. Quotes for this equipment blew that far out it hurt not only the country but the quality of product costing millions

Manufacturers’ Monthly MARCH 2015 11

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Comment

MARK GOODSELL – NSW Director, Australian Industry Group

Don’t write off manufacturing just yet For Australian manufacturing, most of the news in recent years has been negative. However, according to Mark Goodsell, there are still reasons to believe that the sector will survive.

USTRALIAN manufacturing has long been doing it tough, and optimism, it would seem, is thin on the ground. It is difficult to overstate the extent of the challenges the industry has faced over the past decade, which in many ways have been bigger even than the shocks experienced with the wind-down of tariffs from the 1980s, or the recession of the early 1990s. Ai Group’s own Business Prospects Survey, released in January, reported that the majority of manufacturers said business conditions deteriorated notably in 2014 – 60% of CEOs reported business conditions in 2014 as being worse than 2013, while only 18% reported an improvement. Looking M A 1 1ahead, 1 4 _44% 0 0 of 0 _manufacBOK turers expect business conditions to

ing supports including, education, tourism and business services. It will also help offset the fall in national income and the tax base stemming from lower commodity prices.

Fundamental opportunities

worsen in 2015 compared to 2014, versus 24% who expect an improvement. Fortunes, of course, are mixed: business in food and building materials is growing well, whereas metals and 1 machinery 2 0 1 4 - 1continue 0 - 0 8 to T struggle. 1 2 : 5 1 : So where do we look in 2015 to

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find reasons for optimism? Contrary to the prevailing dark mood, there are a number of positive signs to indicate that manufacturing sectors have much to look forward to. 5 4 + 1 1 : 0 0

Gaining from the pain

In response to the difficulties they have been facing, many companies have restructured and now feel quite good about their own prospects, even if industry-level sentiment is poor and the macro-economic environment is unclear. These companies are better positioned to weather currency fluctuations and have used the stress of operating at or above $US parity, with high domestic labour and energy costs and chronic skills shortages, to really lean out their operations. Smaller companies have learnt that you have to sell before you make, and have invested in the capacity to understand customers’ problems deeply and look in strange places and new sectors for customers – skills that were only optional in the old world of manufacturing.

Currency Major currency realignment, especially against the US and China, should offer us a major boost in competitiveness. This will take some time to flow through, but if sustained it should go a long way to boosting sectors such as manufacturing, as well as other sectors that manufactur-

Undeniably, the global centre of gravity is still moving irresistibly towards our region. In the 1970s, the centre point of the world’s middle class consumption could be located somewhere in the Atlantic, but it is quickly shifting east and in 15 years’ time it will certainly have shifted to Asia. Tremendous opportunities are emerging in our region, and these will only become more available to Australian business as we grow more familiar with doing business in Asia and take advantage of a large domestic population with deep knowledge of Asian cultures and languages.

Consumer confidence While consumer confidence has been brittle in recent times, the increase in household wealth in the past few years and the continuation of low interest rates should begin to underwrite stronger household spending.

State governments State governments who have been able to recycle capital locked up in their assets now have increased spending power. Given these developments, and the historically demonstrated Australian capacity to solve problems in the national interest and forge new opportunities, there are plenty of reasons to believe that manufacturers can start to have more positive stories to tell in the future. [Mark Goodsell is the NSW Director at the Australian Industry Group and in 2014 was appointed to the new position of National Director – Manufacturing.] www.aigroup.com.au manmonthly.com.au

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TechnologyIT@MM What’s next for manufacturing? As we move into 2015, it is clear that manufacturers can’t just stick with their old ways. Technology-savvy, alert and agile businesses will come out ahead, Jo-Anne Ruhl reports.

Y 2020, it’s predicted there will be 33 billion connected devices on the planet– nearly three times the 10 to 12 billion estimated today. Manufacturers need to be a part of this growing technology evolution, and take the time to carefully consider their business goals, and focus on market opportunities and pain points that need to be overcome. It’s important manufacturers research the various new technologies available to them, while considering the short-term and long-term benefits of each. Smart organisations need to adopt new technology processes to be successful now and in years to come.

Monitoring in real-time Utilising the information from embedded sensors to transition from preventative maintenance (regularly inspecting and maintaining equipment), to predictive maintenance (such as infrared thermography which monitors equipment’s operating temperature and detects thermal anomalies), is one proven way to lower costs and improve service. Most equipment is still maintained today on a time or volume basis. However, real-time monitoring of equipment performance, which considers factors such as operating temperatures, flow rates and energy usage, is a far better indicator of when equipment is in need of maintenance. This gives you options to service earlier in the cycle, avoiding machine breakdowns, or later in the cycle, lowering repair costs. This flexibility in service scheduling can create new revenue opportunities by taking advantage of demand spikes while also safely re-scheduling maintenance plans. In addition, think of how much time is lost today by multiple engineering visits to remote equipment, first to diagnose the problem and then repair it. Sophisticated self-diagnostic 14 MARCH 2015 Manufacturers’ Monthly

Manufacturers need to be a part of this growing technology evolution.

sensors on equipment make it more efficient to identify the fault immediately, so that the right engineer with the right service pack and repair parts are dispatched the first time.

Making a shift to the cloud “Anytime, anywhere” access to critical business information is a key driver of cloud adoption. Companies that have adopted the cloud are able to move much quicker, with faster time to market, and much faster time to benefit. Organisations are constantly pressed to automate, integrate, and extend their business processes. Cloud solutions deliver new automation, but also come with new integration and

extension models for cloud services. With data available from anywhere with a web browser connection, manufacturers can improve planning and business decision-making. A cloud solution is scalable, easily accessible from multiple locations, and can eliminate costly annual maintenance and infrastructure costs. As the equipment industry learns to better adapt to a global economy, they will undoubtedly also need to better monitor a global network of suppliers, contractors and partners. A complete real-time view of the end-to-end value chain is essential to creating the collaborative and customer-centric approach – which cloud technology can offer.

The ability to scale quickly will be paramount to success in 2015. Rapid response is critical when unforeseen events take place – such as new competition that can come out of nowhere and steal market share within months. On-premise applications aren’t as quick to rapidly structure, expand, and scale up operations, like cloud solutions are, which can put a company at a disadvantage when faced with other fast growing businesses.

Embracing a mobile workforce In today’s environment, users want to be able to work the way they live. Because of this, they have so many options in the marketplace. manmonthly.com.au

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This in turn creates more pressure on organisations to develop clean and beautiful looking interfaces that can be used at a desktop or from a mobile device like seen with Facebook. Applications now should be intuitive, fluid, and natural to use, as well as able to be accessed anywhere, at any time. This is especially important for service engineers who need to be on the road maintaining expensive assets, not stuck in an office. Social and mobile technologies allow service enterprises to boost their workersâ&#x20AC;&#x2122; productivity. Connected devices are making diagnostic data available remotely, delivering the possibility to identify, diagnose and even repair equipment, via software updates and remote fixes. Every avoided trip represents a significant cost savings and a boost to equipment utilisation and profitability. When software anticipates what companies need, it makes everything easier, freeing companies to focus on the bigger picture. As well, business specific applications for the equipment industry allow organisations to boost efficiency by providing more tailored solutions for sales, the floor, supply chain and logistics. Users need to be able to access critical information from their own personal device in order to see results in real-time and make better business decisions.

Encouraging a social business MA 1 0 1 4 _ 0 is0 part 0 _ of SA G Social collaboration the

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growing convergence of business and personal technology. As data continues to explode and decisions have to be made faster and more intelligently, social media has a pivotal role to play in the enterprise, not just for marketing but in the systems which underpin crucial back office functions. Through driving user engagement, empowerment to make better, more informed decisions, and boost productivity, organisations that can successfully harness this trend would be able to focus on what matters most, customers. When employees are able to follow critical data, events, and people, every touch point across your enterprise becomes organised and actionable. Integrated tracking allows users to filter key enterprise data and events between disconnected forms of inoffice communication eliminating obstacles to effective and timely communication that decrease efficiency and productivity. As the manufacturing industry looks forward to 2015, it is clear that the technology-savvy, alert and agile businesses will come out ahead. Embedded sensors, real-time information, mobility and cloud deployment will be major factors that manufacturers will utilise to their advantage. The sooner organisations get on board, the sooner they can reach the next level of customer satisfaction, service innovation and profitability. [Jo-Anne Ruhl is General Manager Australia with Infor] Infor 1800 656 575 1 2 0 1 4 - 0 9 - 1 1 Twww.infor.com 1 4 : 4 3 : 5 5

The cloud-based tool combines 3D industrial and mechanical design, collaboration, and machining in a single package.

App for making things AUTODESK has released Fusion 360, a cloud-based tool that combines 3D industrial and mechanical design, collaboration, and machining in a single package. Now available in Australia, Fusion 360 is said to be the first solution of its kind available for purchase worldwide on the Mac App Store. The tool is designed to meet the changing needs of product developers and entrepreneurs. With Fusion 360, designers and engineers can create products that have both form and function and prepare them for fabrication with one single tool. As a result, users can explore product ideas quickly and get a prototype far faster. The tool also provides a single space for entire teams to collaborate on projects. Built-in and automated data management and sharing ensure all models, designs and information are automatically archived, versioned, managed and can be securely shared with stakeholders. Additionally, the cloud-based nature of the solution means designers and engineers can access the system anytime, anywhere, whether in the office, or on the go. Autodesk www.autodesk.com + 1 0 : 0 0

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Technology IT@MM Technology trends you can’t ignore In response to the need to drive efficiencies and compete on a global market, some clear technology trends have emerged in the manufacturing industry. Carsten Pedersen reports.

USTRALIAN manufacturers often struggle to compete with overseas manufacturers that have lower overheads and easy access to the largest global marketplaces. In a relatively isolated country and with the high costs associated with manufacturing, Australian companies have to find ways to compete more effectively or risk going out of business. Reducing costs as much as possible is only one part of the equation. Australian companies must develop processes that make them more efficient. This can include using software that gives the management team an overarching view of the company and its operations. In response to the need to drive efficiencies and become more productive, some clear technology trends have emerged in the manufacturing industry. While each trend delivers specific benefits, there’s an overarching trend that seeks to leverage the collective advantages of technology, while at the same time avoid the old problem of disparate and siloed information systems.

The rise of ERP Smart manufacturers are adopting new technologies that directly align with and support their business strategies, specifically ERP solutions. ERP can be a powerful business tool that integrates all of the different functions and processes of a business into one complete system. The result is a streamlined and comprehensive view of everything, from financials and staffing to logistics and customer relationship management. For example, an ERP system tracks sales orders and integrates them with logistics, fulfilment, inventory management and customer relationship management systems so that the business gets an instant, overarching view of every customer’s behaviour and every product’s performance. It is the integration of the information that makes ERP so 16 MARCH 2015 Manufacturers’ Monthly

Using cloud solutions to offload application installation, operation and support can better manage costs and improve services. powerful: it removes doubt and error from the reporting process and lets each business function operate in concert with the others. Manufacturing organisations can achieve a competitive advantage if they use the right ERP system thanks to the granular level of reporting that can be delivered. This lets business leaders make better-informed decisions that can help reduce costs and suggest new business directions.

Technology trends There are five key technology trends in addition to the adoption of ERP systems that can potentially increase the manufacturing industry’s competiveness. 1. Cloud technologies. Manufacturers are becoming more decentralised. However, scaling IT resources to every new location or delivering IT support services across time zones and cultures creates a services challenge and cost burden. Using cloud solutions to offload application installation, operation and support across locations can better manage costs and improve services.

2. Lean manufacturing. While lean manufacturing has sought to eliminate waste and non-value added expenditures from the production process since the 1990s, only in the last several years have the marketleading manufacturing business systems fully enabled this production practice from a technology perspective. For example, manufacturing systems such as Microsoft Dynamics ERP have enhanced project accounting and cost accounting modules with deep integration to both finance and core manufacturing processes to identify waste and thereby preserve value with less work. 3. Supply chain optimisation. There is a continued morphing of manufacturing systems and supply chain management systems into single solutions. This trend is part of a bigger trend in which best-of-breed business applications are being replaced by integrated business suite solutions. Manufacturers are increasingly turning to the supply chain to reduce cycle times, lower inventory, accelerate customer fulfilment and decrease distribution costs.

4. Customer relationship management. Manufacturing companies have a reputation of using customer relationship management (CRM) systems for the bare minimum; essentially as ‘systems of record’ for prospects and customers. However, as customers are now more connected, more informed and have more options, companies must rethink their CRM strategy, processes and software. For example, customers are now more active in requesting ethicallysourced products and want to understand the full lifecycle of the products they believe are right for them. And they’re sharing their findings with others and entire online communities in social networks and Internet forums. To meet these customers where they congregate, CRM software systems have evolved to include social CRM tools which leverage social listening and collaboration apps to better identify and engage social patients where they communicate. 5. Business intelligence (BI). Historically, BI systems have fallen short of delivering (near) real-time information with easy-to-read analytics and actionable insights. But that’s changing. The scope of BI has advanced from simple dashboards on the front-end and sophisticated data warehouses on the back end to also include rapid and selfservice BI. Like all technology trends, this advancement is heavily dependent upon business process and, in this case, knowing what measures impact business performance most. Manufacturers that can identify the most salient metrics, and deliver the right information to the right people at the right time, will empower those people to make better business decisions. [Carsten Pedersen is a senior executive with UXC Eclipse] UXC Eclipse 1300 660 471 www.uxceclipse.com.au manmonthly.com.au

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When’s the right time for an ERP system? A robust, fully integrated business management solution is a crucial piece of capital infrastructure, yet it is frequently overlooked.

UCCESSFUL or growing businesses will experience changes that contribute to both the functional demands and data manipulation requirements put on a small accounting system. The result is that the business’s simple accounting system becomes augmented by a combination of spreadsheets, third-party software add-ons, sticky notes and manual processes. A house of cards can be built, supported primarily by the processes and habits of one or two key staff members who hold it all together. There are signs that let you know your business has outgrown your simple accounting system.

What you should look for • Reports cannot be produced that show live data either quickly or in a usable format • There is consistent duplication of data or replication of effort (e.g. information is entered into more than one system or re-entered multiple times in the same system) • There is a high dependence on spread-sheets to either store data or calculate data (e.g. spreadsheet being used to store additional customer information because it can’t be entered anywhere else) • Key business processes can’t be supported properly or at all by the software • There is a lack of traceability, accountability, accuracy and reliability Ignoring these signs is not a wise idea. It has ramifications. For example, the quality of customer service is likely to decline. In other words, you will have to deal with things like missed or incorrect orders, forgotten backorders, poor communication, irregular or no follow-ups, and inconsistent pricing. Without a solid business management solution, it is also likely that staff will be under-utilised or poorly utilised. manmonthly.com.au

More staff will be required to do the same task. Over-stocking or under-stocking of products become more likely and the business is likely to be run with little or no visibility into financial operational performance. The possible consequences of this include cash flow problems, cost blowouts, profit erosion, declining revenue from certain income streams, and a reduction in production efficiency.

A sound return on investment A single, integrated ERP system that encapsulates all of your day to day business functions will streamline your business and improve your profitability. The return on such an investment is quantifiable: you will have greater control over your data, increased efficiency, greater visibility into the business, and a more holistic understanding of operational or financial performance.

Awareness is the key The requirement for such a change often happens slowly and can creep up on business owners who are often too close to the business to see the writing on the wall: an awareness of the problem and a willingness to address it are the keys to avoiding costly problems. By looking for the warning signs that your current software is struggling you can prepare for change at your own pace. Accentis 07 3256 6875 www.accentis.com.au Manufacturers’ Monthly MARCH 2015 17

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EndeavourAWARDS

Enter online at endeavourawards.com.au

Introducing our 2015 sponsors Now in its 12th year, the Manufacturers’ Monthly Endeavour Awards program enables the Australian manufacturing community to acknowledge the successes and achievements of local businesses.

PLATINUM SPONSOR It is with great pleasure that BlueScope continues their support of the 2015 Manufacturers’ Monthly Endeavour Awards as the principal sponsor. As one of Australia’s largest manufacturers and the leading manufacturer of flat steel products, BlueScope continues to play a key role in Australian manufacturing. Attributes that have built the BlueScope brand, such as world class quality, durability, technical backup and support will continue to encourage innovation and inspire confidence by assisting to minimise risks in the manufacturing industry, says Sarah Deukmejian, Manager Distribution and Manufacturing Markets, BlueScope. BlueScope steel is designed for Australian conditions and utilises world leading technologies – and all with the backing of BlueScope for ultimate confidence. BlueScope is proud to associate with the 2015 Endeavour Awards, acknowledging Australian manufacturers who display excellence and innovation in their work and values the continued support of the manufacturing industry in 2015. BlueScope 1800 800 789 www.steel.com.au

Technology Application

Australian Industrial Product BOC is extremely pleased to be participating in the 2015 Manufacturers’ Monthly Endeavour Awards. These awards are very much in keeping with BOC’s own core values of recognising excellence and innovation in manufacturing and industry, which is why the company is delighted to be continuing its support as a major sponsor. As a leader in the application of technology, BOC is constantly looking for new ways to provide our customers with high quality products and innovative solutions. By continually challenging ourselves to raise the bar we ensure our customers can always count on us to deliver the very best gas-related products and services. BOC 131 262 www.boc.com.au 18 MARCH 2015 Manufacturers’ Monthly

The strategy in 2015, as always at ifm efector is to focus on innovation, quality, and strong customer service and support. For 40 years the company has been researching, developing and producing products and technology to optimise technical processes. ifm continues to invest significantly in R&D, employing 450 development engineers. Thus, ifm continuously optimises technical processes in almost all industries and is one of the world’s leading manufacturers in the automation industry. “Our German engineered products all undergo rigid testing in conditions that far exceed their intended application environments to ensure high standard of quality and safety,” says David Delany, Managing Director, ifm efector. “Our customers count on ifm to be a reliable partner for their automation and control solutions. We pride ourselves on our service and support.” This includes on-time delivery. ifm hold extensive stock at our warehouse facilities in Australia and New Zealand, and our products can be delivered overnight in over 97% of instances. We provide strong phone based and on-site solution focused service and support for your application challenges, knowledgeable and efficient customer service and easy order placement. Through our website, customers can also easily check price and availability, track orders, view order history and purchase ifm products using e-shop. From inductive and flow sensors to pressure and temperature sensors – from individual sensors to a complete system solution – our customers can find sensor and control products to suit their requirements. ifm efector 1300 365 088 ifm efector www.ifm.com/au

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Manufacturers’ Monthly Endeavour Awards Deadline extended to March 18 These are the only awards designed specifically for Australia’s manufacturing industry. All finalists receive two free tickets to the gala dinner in Melbourne. The awards dinner is a great way to meet new customers, make contacts, and raise staff morale. Entering the Endeavour Awards is easy: simply visit the Awards website at endeavourawards.com.au to download an entry form. The deadline has been extended to Friday March 18, so hurry for your chance to be part of the biggest Endeavour Awards yet!

Most Innovative Manufacturing Company

Environmental Solution Atlas Copco, a leading provider of sustainable productivity solutions, was recognised by the annual Global 100 list as one of the world’s most sustainable companies. The list, presented at the World Economic Forum in Switzerland in January 2015, ranks companies that prove they are increasing productivity while using less resources. Atlas Copco is ranked 23rd overall, up from 46th last year, and is number one in the machinery industry. It was the ninth time Atlas Copco appeared on the list. Creating business value through sustainability is at the core of Atlas Copco’s products and service. The Group’s sustainability goals include boosting customer energy-efficiency by at least 20 percent between 2010 and 2020, decreasing CO2 emissions, working actively to eliminate corruption, and promoting access to clean drinking water in countries in need. “Energy Audit is a concrete example of how Atlas Copco creates long lasting value for our customers and shareholders, providing customers with tangible return and opportunity to reduce their operating cost from proven ROI. This expertise applies to all of our solutions, air and gas compression, and vacuum pump or Natural gas generation. Providing sustainable solutions is at the core of Atlas Copco, and this is why we are proud to sponsor the Endeavour Awards for Environmental Solutions, for the past 11 years.” says Alain Lefranc, General Manager, Atlas Copco Compressors Australia. Atlas Copco Compressors Australia 1800 023 469 www.atlascopco.com.au

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One of SEW-EURODRIVE’s core values is service. It’s this proud tradition of providing unparalleled service that forms the cornerstone of the company globally, and why we have a network of state-of-the-art facilities spanning across Australia. It is also the reason why SEW is usually the first address when searching for drive technology to drive this great nation. Many household brands are secure in the fact that SEW is working quietly in the background ensuring a seamless path into the market place. This 4th generation family business, which employs over 16,000 people worldwide, including 550 in research and development, is a company that extends far beyond hardware. Our unique portfolio of drive systems apply to a wide and varied list of applications spanning across the globe. According to Managing Director Robert Merola, SEW-EURODRIVE is delighted and proud to be sponsoring the Most Innovative Manufacturing Company award at this year’s Manufacturers’ Monthly Endeavour Awards. The company wishes all of the nominees the best of luck. SEW-EURODRIVE 1300 739 287 www.sew-eurodrive.com.au

Global Integration ICN makes it easier for you to do business in Australia and New Zealand. For more than 30 years the company has been bringing together the region’s best suppliers and introducing them to the supply chains of national and regional projects. For project managers this means everything from reduced procurement times and costs through to increased value from suppliers and the ability to buy complete solutions. For suppliers, ICN opens up new business opportunities through quality tender information and networking, plus a channel to promote your capabilities and track record to a range of potential buyers. At the heart of ICN’s service is ICN Gateway, an online system meeting point for new procurement partnerships. Suppliers can search projects and register their company’s interest. ICN Gateway also helps project managers to manage the supplier registration process for their projects. There are many success stories where ICN has helped local manufactures win new contracts on projects large and small, says Derek Lark, Executive Director, ICN Limited. Since its inception, ICN has helped local suppliers find $29 billion worth of contracts. Industry Capability Network (ICN) 1300 961 139 icn.org.au

Safety Scheme SICK is proud to once again be part of the 2015 Manufacturers’ Monthly Endeavour Awards sponsoring the Safety Scheme Award. Modern safety solutions offer the optimum combination of safety and efficiency: intelligently co-ordinated emergency stop strategies, zone concepts or muting functionalities that optimise production work flow. Together with SICK’s partners, the investment in the next safety solution is paramount to offering the competitive advantage customers demand. The secret to success is to ensure all sensors work in any automation scenario providing our customers with the freedom to design and create the best possible safety solution, says Jason Mair, Product & Marketing Manager, SICK. That success is what drives the company’s core values as it focuses on the future through the education of Industry Safety Specialists who understand the industry language, the processes involved and the challenges faced. The result is innovative, powerful products and systems that provide customers the highest level of safety while increasing machine productivity and reducing downtime. SICK 1800 334 802 www.sick.com.au

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Management – EXPORTING Time to chase the tiger Exporting, like so many things in life, is all about timing, and with India’s star on the rise, now could be the opportune juncture to go hunting. Alan Johnson reports. (Part I of II).

OT too long ago, India was seen as a basket case; a bureaucratic nightmare plagued by poverty, bad governance , inefficient transport and logistics, unclear legislation, red tape and inequality. However in recent times, especially with the election of Narendra Modi as the country’s inspirational prime minister in May last year, the country is on a slow but steady economic growth path. With GDP growth at around 5.5% for 2014, the International Monetary Fund (IMF) said the post-election recovery of confidence in India provides the country an opportunity to embark on “much-needed structural reforms”, and is predicting GDP growth to rise to 6.4% this year. Nicola Watkinson, Austrade’s Trade Commissioner for South Asia, based in New Delhi, says now is the perfect time for Australian manufacturers to be looking at India. “Under Modi, the Indian Government is moving to open up its market and is inviting new players in, plus the government’s reform agenda means there is a good alignment of settings in India, coupled with a strong growth forecast over the next five to ten years.” She said that as part of Modi’s government’s broader economic agenda, he has promised to make it more attractive for companies to build infrastructure and to manufacture in India.

“Australian business should be optimistic about Modi’s economic priorities because they will make it easier to do business here, thereby helping to lift productivity. “Reducing agricultural waste, addressing water security, improving transport infrastructure and safety, and opening up the mining and energy sectors are the ways forward for India. “Much the same can be said about Modi’s emphasis on creating a skilled, job-ready workforce and increasing tourism by better showcasing Indian history and culture.” However, Watkinson emphasised that this is not a one-sided relationship. “The visit to India by Prime Minister Tony Abbott in September last year, the first Prime Minister to visit India after the elections, focused attention on Australia and demonstrated that we are serious about developing the business relationship. “Modi’s visit to Australia was a significant watershed in our commercial relationship. The first Indian Prime Minister to visit Australia in the past 28 years and one that could provide significant trade, investment, education and tourism opportunities for decades to come. Watkinson pointed out that Australian companies have been successful throughout the world and while markets like China remain the destination of choice, there is no

Time to explore, with India now far more attractive for Australian manufacturers. reason Australian companies cannot replicate their successes in India. “We have the expertise, solutions and an approach to business that works very well in the Indian context.” According to Watkinson, Australian industries such as rail, transport and logistics, agribusiness and food,

India’s global merchandise trade relationships: India’s principal export destinations, 2013:

India’s principal import sources, 2013:

United States

12.3%

China

United Arab Emirates

10.2%

Saudi Arabia

7.8%

China

4.6%

United Arab Emirates

7.1%

Australia

0.7%

Australia

2.4%

11.0%

Compiled by the Economic Diplomacy, Trade Advocacy & Statistics Section, DFAT, using the latest data from the ABS, the IMF and various international sources.

20 MARCH 2015 Manufacturers’ Monthly

mining and resources, medical and health, and financial services are recognised by Indian business as being amongst the best in the world.” She said Australia is presently sitting in a very good place in India. “While Australia is a small market, we are having a moment in the sun with India, and now is the time, especially for SMEs, to take this opportunity and come and have a look at India.”

India is no China For exporters thinking that exporting to democratic India will be a similar experience to exporting to communist China should be delighted with the differences between the two most populous nations in the world. While India is the second most populated country in the world with manmonthly.com.au

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NOMINATIONS HAVE BEEN EXTENDED! This is your final chance to nominate so get in quick Nominations for the 2015 Manufacturers’ Monthly Endeavour Awards have been extended until Wednesday 18th March 2015.

WHY NOMINATE?

• Exposure and publicity • Recognition for your hard-working team members • Valuable networking opportunities with key industry leaders

THE CATEGORIES ARE • Technology Application of the Year • Environmental Solution of the Year • Safety Solution of the Year • Industrial Product of the Year • IT Application of the Year • Global Integration Award • Exporter of the Year • Young Manufacturer of the Year • Lifetime Achievement Award • Most Innovative Manufacturing Company • Manufacturer of the Year

PRINCIPAL SPONSOR

SPONSORS

FOR MORE INFORMATION PLEASE EMAIL: AWARDS@MANMONTHLY.COM.AU OR VISIT: WWW.ENDEAVOURAWARDS.COM.AU .

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Management – EXPORTING over 1.3 billion people, that’s where the similarities end. China and India are very different economies, mainly because they have had totally different histories; China is essentially a centrally controlled economy, while India is more a mix of different states and regions that have only been pulled together as a nation in modern times. So the way the two countries’ economies are structured is quite different. Watkinson explains that the state governments in India have much more control and more discretion on how they set up their business environments and what they choose to do in terms of infrastructure to support businesses than in China. “And being a democracy means there is always a healthy debate regarding a particular strategy the state government wants to put forward. Meaning the benefits are measured to the rural community as opposed to the urban community and wealthy as opposed to the under privileged, and the skilled versus the unskilled. “And because of the very small tax base in the Indian market, where just 3% of people pay tax, there is a lot of competition for the very small amount of government funds that are available.” Watkinson says all these elements mean that India is working in a far different context to China, which has traditionally made India a more fragmented and complex market for Australian companies wanting to do business here – “but not now”.

Signs of change Watkinson says manufacturers should take note of what Modi is doing, now that he has come into power. “He was previously leader of Gujarat state, which he turned into one of India’s most successful states in India.” Gujarat now has a much higher per capita income and a much higher level of investment, with a quarter of foreign investment in India going into Gujarat. Gujarat is India’s 5th largest economy and amongst India’s most industrialised states. Its strengths include engineering and automotive manufacturing, food and agribusi22 MARCH 2015 Manufacturers’ Monthly

A modern factory in Kerala, South India. ness, textiles, gems, jewellery, minerals and mining, port and shipbuilding, chemicals, petrochemicals and pharmaceuticals. Watkinson explained that the authorities there have adopted the philosophy that if they create the right environment to attract new investment, both international and domestic, the state will become

Australia is having its moment in the sun with India, and now is the time, especially for SMEs, to take this opportunity – Watkinson. competitive, and benefits will quickly flow to other parts of the population. “Modi is now taking that experience and his track record on one state and applying that at the national level. “He is doing what he can at the central government level to simplify the approval system and the regulatory environment that companies coming into the market have to deal with. “Plus he is taking a much stronger

partnership role with the states, offering support for reforms they believe are needed to make them competitive. “Already, we have seen a couple of states start to enter legal reform programs, which for India is quite radical, and something unthinkable before Modi cam e to power.” Watkinson says Modi’s reform program offers the prospect of a major reassessment of trade and investment ties between Australian and India. “The Australian government’s announcement last year that it wants to finalise a free trade agreement with India within a year will only add momentum to this prospect. “Already the signs of change are there in India and they should encourage Australian business to explore opportunities in the hope the market becomes more transparent and efficient”. According to a number of recent surveys, business confidence is up in India and the reforms are hot topics in boardrooms throughout the country. Watkinson believes India shows all the promise of achieving its much talked about “economic star” status. “Its middle-class is growing rapidly, delivering increased disposable income, high mobile phone usage and strong capital inflows.” But without the types of reforms Modi’s government is keen to push through, Watkinson admits these bright prospects will fade. “But for now, at least the path to reform is getting paved.” In recent months, announcements

have included changes to fuel subsidies, labour law regulation and the rules governing foreign investment in sectors such as rail and defence. The Indian government has also foreshadowed coal market liberalisation, and continued to implement measures to promote financial inclusion, with 70 million Indians given bank accounts in the last few months. Watkinson said that finalising approvals for stalled projects has also been a priority. “For good reason. Of the 460 projects before government, over 150 have now been cleared across the energy, mining, manufacturing and renewable energy sectors.” She says India’s vast and fabled bureaucracy is also changing. “The public sector is adjusting to reformminded, pro-business officials being appointed to senior positions. “Transparency is seen as a key to efficiency, with biometric finger scanning allowing the public to see online when their officials are arriving and leaving the office. See April issue of Manufacturers’ Monthly for part II of this article. [Alan Johnson is Manufacturers’ Monthly’s former editor. He has researched and written about all aspects of the Australian manufacturing sector for over 25 years.] Austrade 13 28 78 www.austrade.gov.au manmonthly.com.au

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Help at hand for exporters Manufacturers are facing some tough conditions domestically, however there are a number of great opportunities for expansion in overseas markets, as Andrew Watson reports.

OR manufacturers looking to grow overseas, the journey to expand export operations can be challenging. Finance is one of these challenges but it doesn’t need to be. There are a range of options available for SMEs exporters looking for support, and a number of great Australian success stories, to prove this is the case. We know from the companies we speak to on a daily basis that established exporters often come up against challenges in accessing the finance they need to achieve their export ambitions. According to our recent SME Exporter Index in December 2014, half of all SME exporters expect access to finance to become more difficult over the next twelve months, a figure that’sMmore since A 0 3than 1 5 doubled _ 0 0 0 _ B A this C time last year.

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warranty bonds or additional capital Whether it be working capital to purchase raw materials to fulfil an to manage the day-to-day strains of export contract. running a business to bonds to fulfil export contracts, accessing finance can be a major barrier to exporters’ Performance bonds success. Manufacturers that export or are part Much of this difficulty in accessof an export supply chain may asked ing finance may be related to the to provide bonds or guarantees as fact that SMEs’ often don’t have the part of a contract. security that financial institutions This was the experience of ATP, require. a WA-based engineering and proAs Australia’s export finance curement company, when it was agency, our role is to help Australian awarded two prime contracts as part SMEs grow internationally and of the Ichthys LNG Project in achieve export success. We can assist Darwin to provide a Wireless Local SMEs to access the finance they Area Network package for the proneed through a range of specialised ject. solutions. The package would allow the faCommonly, this finance can be cilities operator, Inpex, to keep track the key to securing export contracts of all of the equipment and personnel which may require substantial at the Ichthys onshore facility in real 1financial 2 0 1 commitments 5 - 0 2 - 1 0up T front 1 1 : in 1 9 : 0 time. 3 + 1 1 : 0 0 the form of performance bonds and While ATP’s bank was very sup-

portive of this contract, it required 100% cash security before it could provide a bank guarantee to fulfil ATP’s contractual obligations. ATP needed to provide a performance bond and a warranty bond until practical completion of multiple project milestones. Performance bonds give the buyer of a product or service assurance that if the supplier doesn’t meet their obligations under a contract, the buyer can call on the bond to reduce their losses. Warranty bonds ensure buyers are protected from loss if the exporter doesn’t meet contractual warranty obligations after the contract is completed. The performance and warranty bonds that we provided allowed ATP to continue tendering for other contracts in the mining services industry >>

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Management – EXPORTING through reducing the strain on its cash reserves. As ATP’s experience indicates, performance and warranty bonds can assist manufacturers that are part of the supply chain win more contracts and also help to unlock working capital that can be used to finance additional export contracts.

Additional working capital Another common challenge faced by SME exporters is providing the security that their bank requires to approve further working capital finance. A working capital guarantee can be especially useful where a contract requires a large upfront investment, such as purchasing raw materials or packaging for a high-volume manufacturing run. This was the case when Astec Paints, a South Australian paint manufacturer, needed funding to meet increased demand from a number of Japanese clients for the company’s elastomeric coatings, a product in high M demand A 0 5 1due 4 _to0 it0 meeting 0 _ P I JaE pan’s strict building codes.

24 MARCH 2015 Manufacturers’ Monthly

Despite Astec being an established exporter, with around 75% of its turnover derived from exports and their bank being supportive of plans to increase production, the bank required additional security to approve the funds Astec needed to increase production. We were able to provide a working capital guarantee to Astec’s bank, allowing it to approve the additional funds, which enabled Astec to increase production and meet this extra demand immediately. By offering these and other similar products, we’ve helped many Australian exporters take advantage of new contract opportunities that may otherwise have been out of reach. There are many exciting export opportunities for Australian manufacturers and we want to make sure access to finance does not hold businesses back from realising these. [Andrew Watson is Executive Director, SME, EFIC] EFIC 1 2 0 1 4 - 0 4 - 0 3 T 1800 1 0 :093 0 724 8 : 5 4Source: + 1 1 :EFIC’s 0 0 SME Exporter Index December 2014. www.efic.gov.au

Most important export markets for SMEs

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The latest safety information and innovations

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SafetyFIRST Why single-use gloves make sense The safety of workers is something all responsible manufacturers need to prioritise. And in many jobs suitable protective gloves are a must.

T is a widely accepted axiom that a job is done best when the ‘right tool for the job’ is used; meaning that work is conducted more efficiently when a worker’s equipment is designed specifically for that task. Equipment that suits its task streamlines processes, thereby allowing the work to be done faster, with a reduction in fatiguerelated injuries. This principle holds true for Personal Protective Equipment (PPE) as much as for any other item a worker will utilise in the course of their work day. This may be particularly so with hand protection, since maintaining a degree of grip and dexterity needs to be balanced with keeping workers’ hands safe from oil and other chemicals. This industry principle has been formalised in Work Health and Safety guidelines and legislation. However, there can also be the perception by industry leaders that costs need to be kept at a minimum and consequently specialised safety equipment can be overlooked by PPE Managers who might prefer to procure only one kind of glove for all types of work.

PPE as an investment

Ensuring the safety of workers is of paramount concern in most industries today. Mining sites and industrial facilities are stringently regulated by safety guidelines that apply to aspects including tools, work practices and PPE for workers. It is widely accepted that it is the responsibility of workplaces to reduce the impact of injuries to workers. In part, this is due to the link between keeping workers protected and increasing their efficiency in their jobs. It can be argued that it is more cost effective to invest in PPE and thereby avoid delays caused by accidents on the production line, as well as avoiding costly Workers’ Compensation claims. Allowing production to continue smoothly can 26 MARCH 2015 Manufacturers’ Monthly

Microflex single-use gloves by Ansell. be one step toward improvements in overall efficiency and output by workers. To assist with these improvements, PPE is becoming increasingly tailored to suit specific applications. In industries where skilled and dexterous tasks are performed by workers, for instance, providing the correct type of protective glove to suit the job being done can make a significant difference in worker protection and efficiency. In today’s economy, of course, industries can find themselves under pressure to reduce costs wherever possible; and the integral industry area of PPE can be an area where these reductions are sought.

Specialised protection

Job security can be tenuous at times when the mining industry in general is under pressure to reduce costs while simultaneously increasing efficiency. Many roles can be eliminated and employment numbers decrease across the industry under such conditions. Individual employees can find the need to prove that they are adding value to the company. Cost increases that cut into company profits are unwelcome to company owners and shareholders, and the drive to reduce costs can

contribute to the pressure on managers and industry leaders to cut jobs instead of ‘cutting corners’: the necessity still exists to comply with Work Health and Safety guidelines and regulations. Indeed, it can make greater sense to provide specialised PPE since this can promote efficiency through extra grip and flexibility when a glove has been designed for use in slippery tasks requiring a high degree of dexterity.

Single-use gloves

Innovation in the area of PPE by Ansell has led to the introduction of new single-use gloves that provide a solution for a range of tasks which require higher degrees of tactility for workers undertaking dexterous tasks. These offer a protective solution that considers the need to keep operating costs down. Ansell is a brand with a strong history of product development to meet a variety of applications at levels of high quality. For these reasons, they are a recognisable and trusted name in gloves and other PPE. The single-use range of Microflex gloves by Ansell are able to be worn as protection during a task and then discarded after the task has been completed. They are easy to slip

on and to remove, and have a high degree of strength before breaking. The Microflex range is built with a textured grip for use in slippery applications, and also offers a high-visibility option for situations where improved safety is ideal. Ansell also offers a hand protection consulting service free of charge. This service, called Ansell Guardian, considers on behalf of the client the total cost of a hand protection program. It includes in its calculations the numbers of lines stocked, the total cost of worker injury, and the cost of procurement of PPE. It can be a worthwhile resource for industry leaders to utilise when making decisions relating to protective equipment. Protecting workers from injury is a responsibility for employers that can also make good economic sense. There are many factors that contribute to the total cost of worker injury, and also many different solutions to the challenge of finding affordable but effective protective equipment. With a trusted name in the industry, based on years of reliable operation, Ansell continues to innovate to meet the demands of industry. Ansell 1800 512 746 www.ppe.ansell.com.au manmonthly.com.au

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Stop Guessing â&#x20AC;&#x201C; Start Knowing Introducing Kemppi Arc System 3 for Total Welding Quality Management Created specifically to improve welding quality management, operational productivity and reduce risk, the Kemppi Arc System 3, is a modular software product system that can be tailored to your needs. It offers a choice of Arc modules that work seamlessly together or which can be integrated with your existing welding systems to let you monitor and control the quality of your welding operations to achieve welding excellence. With Arc System 3, every weld is traceable, including the welder, his qualifications, welding procedures, all settings and hardware that is used. It allows you to effectively plan, monitor and control your entire welding production process to ensure the desired quality is achieved and minimise risk. Welding parameters can be specified and any deviations by the welder can be altered during the welding process to meet the required quality and eliminate the need for rework. Plus, Arc System 3 automatically collects and analyses data, and outputs reports and documentation for complete peace of mind. A part of Total Welding X Management (TWXM), the Kemppi Arc System 3 lets you manage and control critical welding operations like never before so that you know your welding operations meet all the necessary requirements. For more details call 1300 Go Kemppi or email Info.au@kemppi.com.au

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Safety FIRST

All companies in Australia keep statistics relating to the number of injuries recorded during a given time period.

Temptations of incidental reporting In industries where safety is key, there’s huge pressure to keep the stats looking good. But what happens if data can be manipulated to suit business needs? Ben Hagemann looks at the temptation to twist the numbers through a little creative classification.

MAGINE there’s been an incident at your plant, with machinery affected by a series of unfortunate process deviations. Alarm bells sound and, inevitably, production will be affected. What do you do? Do you switch the alarm off, hope no one heard it and try to carry on without recording the events that led to said loss of production? No, of course you don’t. Quite apart from the fact that your job might be on the line for such a grievous neglect of duty, you wouldn’t do these things because you would want to know exactly what went on, and how you could prevent it from happening in the future: You wouldn’t want anyone else to make the same mistakes. Unfortunately this kind of administrative

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behaviour is found all over the nation, and in various industries, when it comes to something far more important: the physical safety of our workers. Admittedly, Australian industry has some of the most stringent administrative safety processes in the world. However, there are problems with the system. All companies in Australia keep statistics relating to the number of injuries recorded during a given time period. Often these come as an injury rate per hundreds of thousands of hours worked. This kind of lagging performance indicator certainly makes for interesting reading, but contributes far less to preventative action. The other most popular measurement, the one we see on boards in factories and at mine site

entrances, relates to Lost Time Injuries, or LTIs. “No LTIs for 160 days,” for example, will be proudly emblazoned with stick-on numbers, ready to increase on a daily basis until that fateful day (may it never come). But it will come. The safety culture of Zero Harm is a noble goal, but also an imaginary, impossible construct. In BHP inductions, new workers are told “You have to BELIEVE in Zero Harm,” which makes the safety officers sound alarmingly like some kind of bizarre cult, rather than the realists you expect to ensure processes are safe. And many companies have similar, branded names and logos to demonstrate their commitment to safety on site for workers. manmonthly.com.au

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By placing importance on the statistics, like LTIs or injury frequency, there’s a clear motivation to keep these statistics as low as possible, and with that motivation comes temptation. Safety staff are expected to keep things safe, and that is all good and well, but what if the collected safety statistics reflect on the performance of safety staff? Is there a temptation to record fewer severe injuries by reclassifying those injuries to register a lower impact on periodic safety report? What happens when you have to take down the numbers on the LTI board and start again from double zeros? Picture this: A man seriously injures his back at work, lifting an object at the instruction of his supervisor. He is taken to medical care, treated with pain medication, and returned home. Within 24 hours he gets a visit at home from the site safety officer, who is concerned about his condition and wants him to come back to work. The next day he visits again, but this time he says there are suitable duties for the injured worker in the office, and that it would be better to get back to work rather than push the time at home into the realm of a LTI. This would seem to be an unprofessional impropriety which may leave the worker feeling pressured to take the hint and show up for some paper shuffling simply to keep the LTIs down, but this kind of behaviour takes place all the time – The problem is we don’t know how often because of the lack of reporting.

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This particular example is a real anecdote which cannot be properly described for legal reasons, but the worker in question was pressured into returning to work despite being on prescription opiates, after the safety officer told him that another worker didn’t “co-operate” after his back injury and that things were not looking good for his future employment. Despite there being a zero tolerance to testing positive for drugs on site, a worker who was inebriated by painkillers was allowed back on site by the site manager, who said this was fine because a doctor had prescribed the pills. This is an example of a chronic breakdown of the administrative safety systems on site, where the motivation to avoid reporting a serious injury by getting the worker back on site was valued more by safety and management staff than the actual recovery and ongoing safety of the worker. Health and safety officer Goran Prvulovic wrote in a recent op-ed that there exists in Australian industry certain practices and behaviours aimed at undermining the reported severity of injuries, practices which result in the loss of opportunities for improvement to overall organisational safety performance. “In some cases, these practices can also create further damage to injured persons and as a result increase adverse legal exposure for the senior decision makers,” Prvulovic said. The temptation for occupational health and safety staff is to try to influence the type of injury recorded, or if possible, avoid recording it at all.

Unfavourable safety satistics can sometimes paint those charged with reporting them, safety staff, in a bad light. manmonthly.com.au

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Safety FIRST

Keeping a close eye on employee safety Many people may think of CCTV cameras primarily as a security solution, but the benefits are much broader. Organisations are increasingly recognising the value of surveillance cameras to help address workplace compliance and work, health and safety policies. Christian Dorau writes.

ORK, Health and Safety Legislation states that employers and selfemployed persons are to ensure the health and safety of all people in their workplaces. According to WorkCover NSW, the total direct costs due to slips, trips and falls in NSW alone is approximately $110 million. The laws in this regard can vary for different industries, but with the average cost of a workers compensation claim being approximately $18,900, potential litigation costs can have a major impact on a business. Having camera footage on hand to verify incidents or check an employee was following company policy and safety procedures can be a valuable resource, particularly for workplaces operating in hazardous environments or working alone in remote areas. While CCTV cameras can be a vital resource for monitoring staff safety and compliance, companies must also consider the CCTV Code of Ethics. As CCTV becomes more common in the workplace, before installing a CCTV system, businesses must consider the ethical use of cameras to ensure they comply with Australian privacy laws. The law requires employers using CCTV cameras to inform staff that the cameras are in use and explain the M A why 0 3 1the 5 cameras _ 0 0 0 _are BI T reasons

60mm x 210mm Horizontal 1/4

With the average cost of a workers compensation claim being approximately $18,900, potential litigation costs can have a major impact on a business. in place. CCTV cameras should not watching out for lone workers who to be installed purely for the sake may be located in isolated or remote of observing staff â&#x20AC;&#x201C; there must be areas. justification for the presence of It is a companyâ&#x20AC;&#x2122;s responsibility to cameras, for example monitoring ensure all staff members understand Work, Health and Safety Policies, the risks and hazards in their workoverseeing the operation of machinplace environment and know how to 1ery 2 1 5avoid - 0 2the - 2risk 7 Tof0injury 8 : 5or4 : 2 manage 9 + 1 1 them. : 0 0 It is also important for to0help

a company to consult on and communicate their surveillance policy and procedures so that employees fully understand how the CCTV footage is being used. If installing surveillance for the first time, consider involving staff in the initial stages of installation to ensure they feel a part of the process

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and understand the reasons why a monitoring system is being installed. Signage must also be clearly visible in and around the areas where cameras are present.

Installation

Before installing any surveillance system in the workplace, firstly identify what issues are to be addressed. This determines the type of CCTV system required, ensuring the right level of image quality for purpose. For instance, are finer details such as facial recognition or vehicle number plates important? This is where a professional security expert can help. A professional security consultant will assess the workplace environment and provide advice on things that a business owner can easily overlook such as the level of lighting and the positioning of the cameras. The types of video surveillance that can help business address Work, Health & Safety and compliance may include: • Security cameras: full line of closed circuit television cameras and lenses for M varying A 0 3 surveillance 1 5 _ 0 0 0needs. _ T RO Specialty cameras such as infra-red,

Businesses must consider the ethical use of cameras and ensure they comply with Australian privacy laws. low-light and night vision cameras management systems with high level can be installed. PTZ (pan-tilt-zoom) access control integration. cameras can also feature new tech• Security monitor screens: a full nology such as facial recognition line of monitor types, sizes, resolucapabilities. tions and formats are available that • Digital video recorders: soluinclude LCD, flat panel and touchtions offer scalability from basic, screen capabilities. single camera installations through • Remote viewing: solutions range to large scale enterprise level from IP-based cameras to web1 multisite 2 0 1 5deployments - 0 2 - 1 1that T 1feature 4 : 1 4 : 2 6based + 1 1 browser : 0 0 software utilising sophisticated video analytics and cloud based platforms.

• Touch screen systems: touch technology is intuitive, accurate, fast and easy to use. ADT provides the latest touchscreen equipment for greater efficiency when using CCTV systems. It can also monitor customer and general public behaviour and provide evidence of fraud, such as slip and fall verification. Integrated systems using access control technology can also be used to enhance compliance. This is particularly beneficial for factories and businesses that operate hazardous machinery. Access control can help workplace compliance by ensuring that machinery is only being operated by authorised staff and its operation is backed up with monitored CCTV footage should an incident occur. [Christian Dorau is the Director at ADT Security] ADT Security 131 238 www.adtsecurity. com.au

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Improve your production line reliability and productivity through...

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CompositesENGINEERING CME reaps the rewards of diversification The looming end of Holden, Ford and Toyota is a huge issue for the car makers’ suppliers. Brent Balinski spoke to one auto parts maker whose ‘diversity beats adversity’ attitude sees it well-placed to adapt.

LONG-TIME, Tier 1 supplier to Holden and Ford, Composites Materials Engineering has a proud history of success in the auto industry. Nearly two decades ago, however, it decided to seek markets other than automotive, and its diversification into other markets, offering lightweight, technical solutions, has proven an intelligent move. “Brian [Hughes, who has run CME since 1989] the managing director has always been very conscious to ensure we are progressing with the times and developing our new products as well,” Bryce Cameron, CME’s sales manager, told Manufacturers’ Monthly. “So we’ve really identified industries here in Australia which we can supply and [in] which we can be competitive.” Cameron said the half-centuryold company has had great success in supplying the construction and logistics industries in the last few years, and been able to compete with imported products by offering solution based proposals. CME has five main brands – CME Compression Moulding, CME Coatings, Akril, Barrington Roof Tiles and CME Trays. These brands cover industries including building and construction, food manufacturing, pharmaceutical, automotive, electrical, solar, rail and defence. It manufactures at three sites – Bayswater North, Bayswater and Dandenong – and is in the process of consolidating operations at the two non-Dandenong locations. It employs roughly 80 people. “We have been supplying the electrical and industrial markets for a long time with a range of different products, but in the last four years we’ve had a real push into building products,” said Cameron. Last year a profile on CME said that within a decade it had moved

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Composite Materials Engineering has three Australian manufacturing sites. from being 98 per cent automotiveoriented to 50 per cent. It is currently well-placed to survive and prosper despite the end of car manufacturing in Australia in 2017. However, it remains a valued supplier to Holden, earning GM Supplier Quality Excellence Awards in the past two consecutive years, 2013 and 2014. It can also boast the title of the only composites OEM supplier to the local auto industry. One of the major successes with GM Holden has been the spare wheel tub in the back of Commodore vehicles. This replaced pressed steel and reduced weight – an increasingly large role for composite materials in cars – by 5 kilograms. It was the result of an estimated $8 million investment by CME and a world-first for General Motors. “As well as offering a weight reduction, CME could incorporate many features into the moulding that could not be done with steel.

The end result also included fitment of the jack package, which was then supplied directly to General Motors production line for installation into their vehicles,” explained Cameron. Other solutions where composites have provided a lightweight, corrosion-free alternative to steel include in underbody shields, and three-panel SMC (sheet moulding compound) tailgates on the HSV Maloo ute, and structural load floors in the Ford Territory SUV. Composites’ properties have been successfully applied in the other industries in replacing materials including metals, concrete and timber. As a replacement for timber, the CME Starch Tray product has seen international success, exported (mainly to confectioners operating high-speed automation lines) to over 35 countries. The trays will not splinter and are more heat resistant than timber. “The products we manufacture for the food industry would be our

largest export item with year on year growth” noted Cameron. In recent years, the firm has been aggressively pushing its construction and industrial offerings which, in the current environment, obviously have stronger long-term prospects than automotive. Hughes has said before that the business operates with a cycle of diversification and upheaval every four or five years. Cameron, who has been on-board for almost five years, says this is accurate, and has seen the shift into industries such as building and construction in his time at the business. CME’s Akril, which makes substitutes for painted glass, last year released at least one new product every quarter. They even threw in a kitchen sink (Literally. In the fourth quarter. And a BBQ.) Although not a major factor, the dollar’s drop in recent months has been a relief in particular for CME’s export business. Though it’s a mixed blessing, with the company importing raw materials, the decline in the AUD is a net positive. Another plus is that the housing boom doesn’t look to be slowing. “We anticipate a very busy year ahead with the launch of new products into the building industry and logistics industry, as well as continuing the growth of our CME Trays business,” he said. [Brent Balinski has been a journalist at Manufacturers’ Monthly since 2012. He is particularly interested in 3D printing and innovation. Find him on Google Plus at https://plus.google. com/+BrentBalinskiCirrusMedia]. Composite Materials Engineering 03 8720 7600 composite.com.au Manufacturers’ Monthly MARCH 2015 33

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Materials HANDLING Efficiency and environmental benefits What’s new in forklifts? Hartley Henderson takes a look and finds that the latest developments promise to be kind to both the environment and your bottom line.

HERE have been significant developments in forklift offerings in recent times, particularly in operating systems, but also in areas such as attachments and safety initiatives. According to the Managing Director of Lencrow Materials Handling, Ross Grassick, the area that has changed dramatically in forklift development is the improved efficiency of electric units with the change to AC operating systems. “This has extended battery life and made these units a very viable alternative to fossil fuels machines because they produce less air and noise pollution, thereby improving workplace health and safety, and reducing industrial carbon footprints,” he said. “The use of AC operating systems in electric units has also improved their duty cycles with smoother operation and step-less controls. Market and user demands have also led to developments in the shape of forklift attachments and we now have more materials handling attachment options available that reduce damage to products as well as increasing safety. “Developments in safety programs now include after-market systems that constantly monitor the equipment condition for operational and environmental effects. “Operation is controlled from the time an operator sits in the seat and includes the ability to log which driver is in control, as well as factors such Toyota’s 3.5 tonne 8-Series unit features SAS stability control.

34 MARCH 2015 Manufacturers’ Monthly

as hand brake operation and idle time, speed, braking and any impacts. Information from these forklift units can be sent remotely or through download facilities to allow real time monitoring and can be configured to cover any parameters required. “Also, remote control forklifts have improved and are a great alternative for repetitious operations. We have not seen the market expand in Australia, but these units are very popular in Europe.” Grassick says that as forklifts are one of the causes of workplace injuries, it is important to ensure that operators are licensed and trained in the type of equipment they need to operate. “We are still constantly hearing of accidents involving operators who were not educated on the type of equipment they were using,” he said. “There is a need to be mindful of the nature and layout of individual workplaces. For example, there are many warehouses operating with insufficient working space, and with obstructions that can cause damage to products as well as injury to people. “Maintenance of equipment is also important, although I am

constantly surprised that people pay a lot of money for their equipment but then fail to maintain it. The cost of servicing is very little when it comes to ensuring safety and avoiding the cost of major repairs. “The industry has invested a lot in adding safety features to forklifts, and we can fit the latest monitoring technology, but if proper attention is not given to key factors such as appropriate operator training and forklift maintenance then safety will always be a problem.” Lencrow recently became the Nissan by Unicarriers dealer for Eastern Australia which the company says gives it a range of equipment to cover all requirements in manufacturing industry. The range of products includes internal combustion forklifts from 1500kgs through to 30,000kgs (LPG, petrol and diesel), electric forklifts and reach trucks with lift heights up to 12,000mm, as well as electric order pickers and all-directional forklifts. Grassick says the 2500kg DU range unit has a fully fuel injected engine that will reduce the use of fuel and improve emission levels. “Other features that come standard with these models include electronic weight gauge, together with speed limiting that doesn’t affect the unit’s performance,” he said.

Stability control Toyota Material Handling Australia offers as standard on several of its forklift models the System of Active Stability (SAS) which uses intelligent technologies to protect driver and machine as well as driving down

Lencrow recently became the Nissan by Unicarriers dealer for Eastern Australia.

overall forklift operating costs. According to Toyota, forklift incidents are a significant contributor to total workplace accidents in Australia, often resulting in serious injury, including permanent disability, or even death. The company advises that its SAS was the first system in the world to monitor and control the forklift through a combination of advanced sensors linked to an on-board controller, enabling excellent load handling performance with greater safety. SAS acts automatically to help prevent sideways tip-over which, according to Toyota, is the cause of over 30 percent of serious forklift accidents. In the event of instability, the Swing Lock Cylinder automatically locks the rear axle to improve the forklift’s stability and significantly reduces the risk of a sideways tip-over. The SAS system also helps to avoid damage to goods through Mast Front Tilt Angle Control, Mast Rear Tilt Speed Control, and Fork Levelmanmonthly.com.au

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ling Control. Both load and forklift are prevented from tipping dangerously forward by constant monitoring of load height, weight and mast position, and if necessary, automatically limiting the mast angle. If loads are tilted backwards too quickly the Mast Rear Tilt Speed Control senses the risk and can reduce the mast speed accordingly. With Fork Levelling Control, the forks are levelled at the push of a button, which can be of particular benefit when loads are at a substantial height. Toyota emphasises that while SAS provides innovative ways to create a safer work environment, it is important that this in no way overrides the value of professional training, and strict adherence to safety features and the forklift manufacturer’s instructions. The company claims that in 2014, battery operated forklifts accounted for just over half of Toyota forklift deliveries and says that it will soon release new models onto the market including a new range Mof A Toyota 0 3 1 58-Series _ 0 0 0battery-electric _ CRO 1 sit down reach trucks.

Recently, Toyota launched a versatile new reach truck designed to operate on outdoor surfaces. The new BT Reflex O-Series has a ground clearance of 145mm and super-elastic tyres. This means it can operate on rugged, loose surfaces while the specialist tyres provide secure grip on wet or high temperature asphalt. [Hartley Henderson has been a regular contributing writer to Manufacturers’ Monthly for the past eight years, covering industry developments in Victoria and South Australia. Prior to that, he held senior positions in government, semi-government and business enterprises and was National Program Director with the Productivity Promotion Council of Australia].

Toyota recently launched the BT Reflex O-Series of versatile reach trucks designed to operate on outdoor surfaces.

Lencrow 1300 536 276 www.lencrowforklifts.com.au Toyota 2 0 1 5 - 0 3 - 0 3 T 1 0 : 1800 1 7 425 : 2438 4 + 1 1 : 0 0 www.toyotamaterialhandling.com.au

CONNECT. MANAGE. ACHIEVE. With InfoLink ™, you have a real-time, wireless connection to your entire fleet, virtually regardless of truck brand, giving you the operator and forklift data you need to ensure your operation is running as efficiently and safely as possible. We build it to your specs and customise it to your facility. Designed, Developed and Supported by Crown. All your do is use it to ensure your get the most out of your operators and your fleet every day. To see how Infolink helped Steelcase reduce their fleet size by 30%, call 1300 909 827 to book your demonstration today.

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Manufacturers’ Monthly MARCH 2015 35

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Materials HANDLING Aluminium portable gantry cranes

Comply with Australian standards. ALUMINIUM portable gantry cranes from Phoenix Lifting are available with a capacity of 500 kg-5000 kg working load limit (WLL). Each is designed to provide flexibility with lifting heights for different applications. Each Gantry Crane is easy to assemble giving user’s maximum flexibility. They of M A are 0 3 available 1 5 _ 0 0in0a_range SUM adjustable spans and heights from

Reach truck MLA Holdings, exclusive supplier of Mitsubishi forklifts in Australia, has released a new reach truck. The warehousing and distribution industry has long desired a reach truck that’s unproblematic to operate yet productive. The RBF14-20CA reach truck from Mitsubishi is simple but does not compromise on performance. Hydraulics, travelling, and power steering functions on the reach truck have been integrated into one AC control system, which makes it smoother to operate. The simplicity of the controls allows the operator to be more focussed and productive. 2.5 metres to 6 metres with lifting Visibility is also significantly capabilities of 500 kg-5000 kg. enhanced. The free lift cylinder is The Gantry Cranes are equipped mounted diagonally and away from with castor wheels for easy movethe mast symmetry, allowing for unfments. lawed forward view. They are tested at 150% capacity Performance standards were and a test certificate is issued with not compromised when making the every crane. They comply with Ausreach truck. AC motor technology tralian Standards. Phoenix Lifting delivers a smooth and powerful 1 2 0 1 5 - 0 2 - 1 0 T 02 1 09894 : 49007 0 : 3 drive, 9 + 1 while 1 : 0360° 0 steering gives the www.phoenixlifting.com.au truck a tight turning radius, creating

MATSU . COM . A U | 1300 CHILLERS

38 MARCH 2015 Manufacturers’ Monthly

The reach truck features AC motor technology. space efficiency in busy warehouse environments. It is available in three different models with a maximum lift height of 10m. MLA Holdings 131 652 www.mlaholdings.com.au

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Compressors& PNEUMATICS The right compressor for your business Compressor technology has come a long way in recent times. But choosing the right machine isn’t a one size fits all game and it pays to choose wisely. Matt McDonald reports.

OMPRESSED air is something a lot of manufacturing operations can’t do without. But the thing is, it uses a lot of energy and therefore costs a lot. So it makes sense for manufacturers to seek out the latest and best products. So what are the latest products? One is the KHE series ‘2 Stage’ rotary screw air compressor from Southern Cross Compressors. “It’s a two–stage compressor as opposed to a typical compressor used in industry which is a single stage compressor,” Mark Ferguson, CEO of Southern Cross Compressors told Manufacturers’ Monthly. “A single stage compressor takes air at its atmospheric pressure, boosts it to its final discharge pressure which means you have a very high overall compression ratio.” In contrast, 2 Stage technology works by dividing the overall compression ratio between two distinct screw air ends, rather than one; and cooling the air in between the stages. “That means that the compression ratio over each of those stages is significantly reduced (less than half) which has the effect of significantly improving the efficiency of the machine,” added Ferguson. “So what you’re getting is a lot more compressed air from the unit for the given power than you’re putting into it. And that’s typically around 15-20 per cent at full load.” To put this in perspective, a 15% power saving based on replacing a conventional 200kW compressor with a 2 Stage unit could realise annual energy savings of around $40,000. 2 Stage technology is not new but the significant thing about the KHE Series is its wide range. Southern Cross Compressors have extended their range to cover capacities from 17.4m³/min (75kW) up to 70m³/min (355kW) and with pressures ranging up to 13 barg. Ferguson said that, by incorporating a variable speed drive into the 40 MARCH 2015 Manufacturers’ Monthly

A ‘2 Stage’ high pressure airend from the KHE Series. system, potential savings are even greater. “We’re getting almost linear reduction in power with demand. In a plant where the demand varies considerably, throughout the day, the night, what have you, these machines will actually respond proportionally to give the required amount of air for the plant at any given time with proportional absorbed power,” he said. “These start at 75kW which covers medium to large manufacturing organisations, chemical plants, the oil and gas industry, mining applications, really anywhere a customer needs a high volume of reliable compressed air.” Asked what the next compressor developments will be, Ferguson said he expected to see an expansion of permanent magnet motor technology and different methods of control.

“

A lot of it comes down to the skill of the people that are making recommendations… But he added, “We aren’t seeing a new mouse trap out there yet.”

Making the right choice He stressed the importance of manufacturers choosing the right compressors for their businesses. He said that, by finding the right machine, you can maximise efficiency and keep costs as low as possible. “There’s not a one size fits all ap-

proach because every application is different,” he said. He added that a lot of this comes down to the skill of the people that are making recommendations. They need to interpret what a customer’s usage looks like and make a recommendation based on that. “I’ve seen plenty of applications where customers have bought a variable speed drive compressor for applications where they use air constantly. There’ just no benefit and in fact there’s a penalty to be paid because of the cost of running the variable speed drive,” he said. According to Jim Rohner, Managing Director of Boge Compressors (Australia), cost savings can also come down to your purchasing behaviour. “All major manufacturers do oilinjected screw compressors. Some of them do oil-free screw compressors and most do a variation of sorts of a piston compressor,” he told Manufacturers’ Monthly. “Boge is a little bit different to that. We do all of those products then we also do oil-free piston compressors - very small ones which are suitable for hospital applications. We do nitrogen generators, oxygen generators, the BC converter...” He explained that Boge aims to provide a total solution. Instead of going to one supplier to buy a compressor, then another to buy another component, then a third supplier to buy drying equipment (such as desiccant dryers and carbon absorbers), you can purchase everything from Boge. “We supply everything,” he said. “When it’s a total package it’s more cost efficient you’re only dealing with one person. Which saves time.” The company’s list of specialised products includes a Nitrogen Generator, which has applications in the food sector. For example, it can be used to prolong the life of fruit such as apples and plums. manmonthly.com.au

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As Rohner explained, if such fruit is left in an oxygen-rich atmosphere it goes off. But, by pumping nitrogen into the refrigerator or holding bay, you can preserve it. “We have nitrogen generators where you can regulate the purity, you can measure the flow,” he said. “And your ability to produce nitrogen can continue to grow just by adding modules.” There is no need to replace the whole system. You can just add to it. Boge also recently released a catalytic converter called the BC Converter. When positioned after any brand of compressor, this product takes all of the contaminants that are drawn into the compressor and leaves you with class 0 oil-free air. The BC Converter is suitable for applications within the food and pharmaceutical sectors, as well as in other areas such as CD manufacturing. Rohner explained that, within these sectors, there are two disadvantages associated with using an oil-free compressor. “It still takes in whatever is in the ambient air and that comes back at the other end. So if there are contaminants

in the air like silicon you will get those same contaminants coming out the other end, he said. And the second disadvantage is the fact that oil-free screw compressors are so expensive. “It’s a false economy to make them too small so generally speaking they start at around 60 horse power and they’re well over $100,000,” Rohner said. So instead of buying an oil-free screw compressor you can purchase a BC Converter at a fraction of the cost. He cited the example of Melbournebased yoghurt maker, five:am. Though a successful business, it didn’t have the budget for an oil-free screw compressor. It simply wouldn’t have been able to make enough yoghurt to make it pay. “They’re a typical example of a plant that would have had to spend $150,000 to buy an oil-free screw compressor.” Instead, he said, they bought two Boge model C30s and a BC converter at about 25% of the capital outlay. [Matt McDonald, a Manufacturers’ Monthly journalist, writes on a broad range of topics. His special interests include Safety and Industrial Relations. Contact him at google. com/+MattMcDonald28]

2 0 1 5 - 0 2 - 1 8 T1 5 : 5 1 : 5 1 + 1 1 : 0 0

Complete BOGE Air Center, Direct Drive, Dryer & Air Receiver. 5.5hp, 19cfm to 20hp, 79cfm.

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Southern Cross Compressors (Australia) 1300 098 901 southerncrossaircompressors.com.au BOGE Compressors Australia 03 5940 3266 www.boge.net.au

Discover the BOGE edge: www.boge.net.au The BC Converter is suitable for applications within the food and pharmaceutical sectors, as well as in other areas such as CD manufacturing. manmonthly.com.au

BOGE AIR. THE AIR TO WORK.

For your nearest BOGE distributor call (03) 5940 3266 Manufacturers’ Monthly MARCH 2015 41

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Compressors & PNEUMATICS Biodegradable lubricant A new lubricant for rotary screw air compressors not only promises new standards of biodegradability but also enables compressors to maintain peak performance across the full range of operating temperatures for much longer periods.

CCORDING to its manufacturer, Australian owned and operated company Anglomoil, BIOPAG CL 46 lubricant is 96% biodegradable. What’s more, within 28 days of it being disposed of, there are almost no traces of it in the condensate. Tests have shown that, unlike petroleum based fluids, traces of the lubricant which end up in compressor condensate in waste water sewage systems are broken down and transformed into carbon dioxide, nitrogen, mineral salts and water, none of which is harmful to nature. This “green” feature introduces a whole new dynamic to the compressor industry because now it is no longer necessary to have oil/water separators on equipment. The lubricating fluid can be removed along with the water. The name itself comes from its ultra-high biodegradable qualities (BIO); the unique 10W20 polyalkylene glycol and polyol ester based formulation (PAG); the fact that it is a lubricant designed specifically for rotary screw air compressors (CL); and its viscosity rating (46).

BIOPAG CL 46 lubricant is 96% biodegradable. 42 MARCH 2015 Manufacturers’ Monthly

“

The lubricating fluid can be removed along with the water... According to the company, the fully synthetic blend enables compressors to maintain peak performance across the full range of operating temperatures for much longer periods. It also allows service intervals to be extended to as much as 8000 hours. Apart from the environmental advantages, the lubricant is intended to contribute to improved reliability, performance, equipment life span and safety. Unlike conventional hydrocarbon oils it is non-varnishing and will not oxidate. It dissolves any varnish left behind by other lubricants. The “green” formulation is resistant to sludging (unlike petroleum based products), is non foaming, has a high viscosity index (173) and a higher flash point (271°C) and ignition point (388°C) than hydrocarbon fluids. The lubricant outperforms other synthetic fluids with excellent seal compatibility with natural rubber and synthetic seals. It offers strong thermal conductivity to keep compressors running cooler and corrosion protection. James Williams from PremiAir Hire said the adoption of Anglomoil products has led to major improvements for his company. “Premiair Hire has

Available in 20 litre and 200 litre containers. 13 depots located across Australia and a fleet with hundreds of compressors and since we began using Anglomoil not one service manager has rung through with a problem,” Williams commented. “In my role to not hear a single comment in all this time is outstanding. The added bonus is that Anglomoil products are competitive on price.” Quantum Compressors founder and director Chris McQuade made the change to Anglomoil compressor oils after experiencing a lot of costly mechanical issues caused by his previous supplier. “With the other lubricants the compressors kept running hotter than normal. This created carbon buildup on the internals which in turn

caused the operating temperatures to increase even higher and led to a number of break downs,” McQuade explained. “We had to bring the compressors back to our workshop to have them stripped down and hydrostatically cleaned to remove all of the carbon deposits before rebuilding them. “To put it quite simply since we changed to Anglomoil’s compressor oils we don’t have any more dramas.” Anglomoil BIOPAG CL 46 is available in 20 litre and 200 litre containers through the nationwide Anglomoil distribution network. Anglomoil 02 9457 8566 www.anglomoil.com manmonthly.com.au

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Compressors & PNEUMATICS Knowledge can save you power The cost of running a compressed air system can account for a considerable amount of manufacturer’s operating costs. So how can manufacturers reduce the impact to their bottom line?

NOWLEDGE gained through compressed air training may well be the key to unlocking the energy savings potential of a compressed air system, said Jeff Coyle, the Engineering Manager at Kaeser Compressors Australia. “It is well documented that electricity prices have risen sharply over the past decade in Australia. Once seen as a relatively low fixed cost, energy has become an ever more important variable cost that impacts on company profits,” Coyle said. “Often considered the fourth utility, compressed air is commonly one of the largest single energy consumers within a manufacturing facility and, depending on utilisation, electrical power can Compressed air accounts for a high percentage of energy account for up to 90 percent of the total costs of usage in many manufacturing facilities. compressed air production. savings can be found and many existing com“In addition, the energy costs of a typical compressed air users could be hiding an energy savings pressed air system can account for almost three potential of 30 percent or more. quarters of its lifetime costs. It therefore makes According to Coyle, anyone wanting to use comsense to keep the power consumption of a compressed air energy efficiently must consider the pressed air system to a minimum.” a whole understand Coyle M A 0added 3 1 5that _ 0 compressed 0 0 _ A T Lair -is one 1 source 2 0 1 5 - compressed 0 2 - 2 4 Tair 0 9system : 3 3 as : 1 0 + 1 and 1 : 0 0 0315 HPAtlas CopcoManMonthly.pdf 1 20/02/2015 3:35:54 PMthe numerous correlations and interactions within of energy where significant and sustainable energy

the system and its integration into the operational environment.

2015 Compressed Air Seminar Series Kaeser Compressors Australia has released details of its 2015 Compressed Air Seminar Series. These one day seminars are designed to equip end users, operators, supervisors and consultants, with the knowledge to assist them in optimising the productivity and energy efficiency of a compressed air system as well as controlling associated operating costs. From the fundamental principles of compressed air to the operation and maintenance of air compressors, control systems and air treatment, the seminars provide participants with the knowledge that can ultimately assist them in optimising the energy efficiency of a compressed air system. The one-day Kaeser Compressed Air Seminars are running throughout Australia in 2015. Seminar dates and venues are available from the company. Kaeser Compressors Australia 1800 640 611 www.kaeser.com.au

CMY

ATLAS COPCO SERVICE ONE SINGLE POINT OF CONTACT Air and Gas Compressor

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Nitrogen

1800 023 469

44 MARCH 2015 Manufacturers’ Monthly

manmonthly.com.au

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LaserTECHNOLOGIES Laser engravers offer more flexibility Laser engravers have been around for quite a while now, but which laser technology is best for which application?

HETHER a manufacturers’ finished products are hard or soft, there are laser engravers to suit a whole range of materials of differing hardness’s including wood, aluminium, leather, acrylic and many more. Laser engraving machines also offer precise engraving depth and a range of different finishes by simply varying the machine’s speed and power parameters, regardless of the material being engraved. According to Simon Scott, Business Manager with Gravotech (Australia), a global leader in engraving technology, choosing a laser engraving machine means far more flexibility for the user. “Lasers are the perfect tool for signage, personalisation, part marking and traceability. And with the advent of QR codes, lasers machines can directly mark codes on parts and materials that can be integrated with scanning systems to provide total traceability in a manufacturing environment. “The machines can be customised to fit the user’s need, whether in a stand-alone work station or integrated into a production line,” Scott told Manufacturers’ Monthly.

There are laser engravers to suit a whole range of materials including wood, aluminium, leather, acrylic and many more. “Since its first demonstrated use in the 1960s, laser technology has spread through all types of industry. Advancements have multiplied and today there is a laser for every application.” Scott says CO2 lasers are currently the most common type of laser engravers, mainly because they are fast, quiet and work with a wide range of organic and man-made materials. “However CO2 is not the only

laser type available, with Fiber, YAG and Green the preferred choice for delicate, sensitive and uncoated materials.” The types of laser engraving machines include: FIBER – Utilising fiber optics to stimulate the laser, the long lasting laser source has a lower maintenance cost over the life of the machine. Plus its higher than average power allows text and graphics to be applied faster. YAG – Similar to the fiber in design, the YAG laser uses pumping diodes to stimulate the laser. This allows a smaller beam width which will attain greater detail and smaller characters. Not sensitive to reflected light, the YAG laser is ideal for marking shiny or polished materials. GREEN – Half the wavelength of a YAG laser, the Green laser features a new type of marking, “cold marking”. Minimal heat is applied to the material which reduces the mechanical stress and distortion to parts.

Positioning systems

Laser engraving machines offer precise engraving depth and a range of different finishes. 46 MARCH 2015 Manufacturers’ Monthly

When deciding on what the right technology is for different applications, Scott says manufacturers should consider the differences

between Gantry and Galvanometer positional systems. “Gantry systems are best described as XY plotter systems because they move the laser above the material to be cut or engraved. He said Gantry systems are best utilised in wide format applications, 600mm or above, when cutting thicker material substrates, 1/64” for example, and where tight tolerance cutting is needed or when large area engraving is required. “They are made in sizes from 24” x 36” up to 6’ x 10’ and are an excellent choice for cutting and large engraving applications,” Scott said. Scott went on to explain that Galvanometer (Galvo) systems are based on moving mirror technology similar to what is used to create laser light shows. “The mirrors make small adjustments in mirror angles to move the stationary laser beam in different directions within a specific cutting or marking area.” Galvo systems use a range of laser types including sealed CO2 and Fiber laser technologies so users can choose the best positioning method plus the correct laser light for the job. Scott says the main advantage of Galvo systems is their speed. “In fact Galvos can be up to 10 times faster than a Gantry based system but have limits on the work area; usually limited to 24” x 24”. He pointed out that a Galvo system can mark a QR code for part marking or traceability purposes in less than a second, depending on the substrate being marked.

Laser features explained Scott says lasers are the easiest engraving and marking systems to use, with no mechanical skill required to understand cutter geometry and material resistance. “However, when purchasing a new machine, it’s important to understand some of the technical terms we use.” manmonthly.com.au

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

Non-destructive destructive Leak Testing for flexible packaging

QR codes can be engraved in less than a second, depending on the substrate. Automatic focus (auto-focus) – The table raises itself automatically until a sensor detects the part to be lasered, without any manual intervention. This function is driven from the software and can be deactivated. Motorised Z-axis table (up/down movement) – This function enables the auto-focus function and is also extremely useful when cutting through thick material in several passes. (The table will be automatically raised between each pass to optimise cut quality). Red dot pointer – LED light than

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can be used to visually simulate the lasering or to locate the area to laser. Automated moveable home position – For items that are not easily positioned in the machine, the red dot pointer can be used to define the position of the area to laser. This is achieved using the machine joystick, making it fast, easy and precise. The XY coordinates are displayed on the machine LCD screen and can be entered in the software. Air assist – Programmable through the software, air assist >>



Pressure sensors



Colour sensors



Thermal Imaging Camera

Underwater testing to determine leak location

Bestech Australia U14, 44 Garden Blvd

MEL.: 03 9540 5100

Dingley VIC 3172

SYD. : 02 9624 4233

Enquiry@bestech.com.au The Technifor green laser is designed for high marking quality in demanding applications. manmonthly.com.au

www.bestech.com.au Manufacturers’ Monthly MARCH 2015 47

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Laser TECHNOLOGIES >> blows air directly onto the item at the point of lasering. It is designed to improve finished quality by reducing heat at the point of lasering as well as blowing away fumes and particles.

Latest products Gravotech has recently released a number of new machines including the Technifor TG400 green laser engraving machine designed to mark materials that in the past were difficult to mark with typical lasers. Plastics and reflective metals like copper, silver and gold can now be permanently marked with this machine. With its specific wavelength (532nm) and a beam twice as thin as a YAG laser, the Technifor green laser is designed for high marking quality in demanding applications. Its cold marking process marks without heating the material and eliminates burning effect or part surface damage. Applications include plastic marking, 2D marking on reflective metals, such as copper, silver and gold, ceramics, removal M A 0 thin 3 1 5coated _ 0 0layer 0 _ G RA_ L a on anodised, painted material, epoxy,

The new wide format LS1000XP machine can cut and engrave at high speed on objects of all shapes and sizes in group series or individually. labels, day and night marking on part series production. backlit panels, and micro marking The new wide format Gravograph on small components, wafers etc. LS1000XP machine can cut and enMarkets include automotive, medical, grave at high speed on objects of all electrics, aerospace, solar, jewellery, shapes in group series or individually. electronics, and plastics. To reduce production time, the Gravotech has also developed a machine features an integrated cutversatile and accurate CO2 laser ting table with detachable blades, for to2offer sengraving e 2machine, 2 0 1 said 5 - 0 - 2 a6 T 1 5 side : 3 and 2 : front 2 7 +opening 1 1 : 0 hatches 0 pass through of large materials and new dimension for prototyping and

one the fastest execution speeds on the CO2 table laser market. Suitable for a wide variety of materials including plastics, wood, acrylic, ceramics, glass, cardboard, foam, the machine can be used for sign making, letter cutting, design and fabrication of models, POP displays, engraving and cutting of synoptics and front panels, mass production of plates and labels in matrix mode, and engraving of bulky objects. To automate part of their engraving process, Gravograph has released an automatic plate feeder (APF) accessory for several of its CO2 laser engraving machines. The plate feeder is designed for the processing of production and batch quantities of machine plates, tags, ID plates and other product identification label media. Loaded in a magazine, tags or plates up to 120 x 100mm can be fed to the engraver for marking. At the minimum thickness stacks of identical tags can be processed in quantities up to 195 at a time. Gravograph Australia 02 9684 2400 www.gravograph.com.au

• Personalisation • Customisation • Permanent Marking • Traceability • Signage

Call us for an onsite demo or email sales@gravograph.com.au

gravograph.com.au | 02 9684 2000 SYDNEY • MELBOURNE • BRISBANE • ADELAIDE • PERTH

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48 MARCH 2015 Manufacturers’ Monthly

Total Engraving Solutions 24/02/15 3:11 PM

manmonthly.com.au

MA0914_000_LMC

2014-08-12T11:28:56+10:00

BySprint Fiber 6000 6.0 kW Fiber Laser cutting

Full lights out automation Automatic nozzle changing CutControl-cut quality monitoring ByPos Fiber-automatic focal control

Fast Efficient Profitable

Available in 3.0 x 1.5m or 4.0 x 2.0m www.bystronic.com

31-33 Sullivan Street Moorabbin Victoria 3189 Tel: (03) 9555 5525 Fax: (03) 9555 2970 Web: www.lmclaser.com.au Email: sales@lmclaser.com.au

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Laser TECHNOLOGIES 6.0kW fiber laser cutting system LMC Laser has released the Bystronic Bysprint 6.0kW fiber laser cutting system. According to the company, fiber lasers have many advantages over CO2 laser machines, with lower operating costs, higher energy efficiency and cutting speeds, reduced maintenance plus the ability to easily cut aluminium, copper and its alloys. The advantages, especially when cutting thin materials with HP N2 as the assist cutting gas, are due to the laser’s focus spot size, which is approximately 10 times less in diameter than the focal point of a CO2 laser. While CO2 lasers (in theory but not in practice) can be focussed to 10.6 micron diameter, fiber lasers with a wavelength of approximately 1.6 micron can produce energy concentrations unachievable by CO2 lasers. Such small diameter focal points can provide high cutting speeds on thin materials. However, one disadvantage with fiber lasers, according to LMC Laser, is that they struggle to cut carbon steels with O2 as the assist cutting gas (as well as CO2 lasers), the reason being that the fiber small diameter focal point cannot provide a kerf width wide enough for the exothermic reaction.

The standard fiber laser machine can cut low carbon steel up to 20mm, stainless steel up to 15mm, aluminium up to 15mm, brass up to 10mm and copper up to 10mm. To overcome this situation machine manufacturers defocus the focal point so the fiber laser produces a beam diameter similar to that of an equivalent powered CO2 so cutting speeds and thickness’ are about the same. Having made that point, LMC Laser says the release of the Bysprint 6.0kW has opened a new range of fiber laser cutting, a standard 6.0kW

fiber laser machine can cut low carbon steel up to 20mm, stainless steel up to 15mm, aluminium up to 15mm, brass up to 10mm and copper up to 10mm. To improve the performance of the machine even further, a Power Cut Fiber (PCF) option allows the machine to cut low carbon steel up to 25mm, stainless steel up to 30mm, aluminium up to 30mm, brass

up to 15mm, and copper up to 12mm. The company points out that with carbon steel the maximum thickness, edge quality and cutting speeds depend on the quality of the material, with high silicon content, mill scale, rust and paint reducing cutting performance. LMC Laser 03 9555 5525, www.lmclaser.com.au.

Laser vibrometer for process control POLYTEC’S Industrial vibrometer combines a robust integrated single-box design with the clear advantages of non-contact, laser-based vibration measurement. The IVS-400 industrial vibration sensor measures structure-borne noise of objects reliably and without contact. The vibrometer is non-contact, wear-free and does not require servo-mechanisms or noise protection for performing measurements. The acquired data provides valuable information on manufacturing quality and compliance with a product’s acoustic emission limits. Direct integration of the vibrometer into a production line makes up a real-time quality control system which enables automatic PASS/FAIL decisions on the basis of structure-borne vibration.

50 MARCH 2015 Manufacturers’ Monthly

According to the company, meaningful input data from the vibrometer enhances proper classification dramatically. Thus, besides sustainable assurance of product quality, it substantially increases the cost efficiency of the production process. The vibrometer is easy to integrate into test setups and existing control systems. It offers reduced impact from surface features due to its DESPEC technology. It covers acoustic measurement range up to 22 kHz frequency response and it includes automatic PASS/FAIL decision with optional QuickCheck software. Warsash Scientific 02 9319 0122 www.warsash.com.au

Simple to install and operate.

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Laser marking machines TROTEC has released the ProMarker series of high-speed laser marking machines, developed for users who wish to laser mark large numbers of parts within shortest time, but without complicated production processes or voluminous software packages. The printer driver software DirectMark, which is included in all systems, enables the operator to work in the daily graphics, CAD or label printing software and to control the laser with a simple printer window. Importing, converting or time consuming data exchange is not necessary. A material database helps to find the right machine settings and can be extended by often recurring jobs and materials. The closed class 2 compact desktop marking The laser class 4 system ProMarker 100 station is designed for the fast marking of often abstains from a housing and offers maxichanging parts. mum flexibility concerning part sizes. The fiber laser is designed to mark every piece of metal or plastic, irrespective of how big or bulky in might be. The system includes a robust Z-post or as an option an electrical Z-axis for precise focussing. Also in the series is the ProMarker 300, a safe, closed class 2 compact desktop marking station for the fast marking of often changing parts. The system is suitable for small to middle sized products, but can be optionally equipped with a passthrough in order to mark long and bulky work pieces (the system is then classified as class 4 system because of the open side panels).

High-speed laser marker AS part of the new SpeedMarker Series Trotec now offers a laser class 2 workstation for marking of big parts and large lot sizes in trays: the SpeedMarker 1300. According to the company, safe laser class 2 marking of big and bulky parts has often been a major challenge, since the parts rarely fit into a closed workstation due to their size or simply have been too heavy. To overcome this problem, Trotec developed a compact closed marking system, with marking fields up to 1120 x 635mm (with X- and optional Y-axis) able to be processed. This offers the opportunity to mark big parts as well as large lot sizes in minimum time without the need of any extra safety precautions such as a special laser safety room.

The laser class 2 workstation is designed for marking of big and bulky parts in large lot sizes. Trotec Laser 08 9240 2122 www.troteclaser.com.au

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What’sNew Polymer that can be recognised by metal detectors

The product may be left in place for future maintenance.

Product for on-site maintenance PT Hydraulics now offers serv-Clip, a product designed to enable on-site servicing to be carried out faster and cheaper. It offers a range of pipe measuring points and sensors suitable for tubes operating at pressures up to 630Bar (9100 PSI). Fitted to pressurised or non-pressurised systems in approximately three minutes, the product can be used on 10-65mm tube or 3/8” - 2” tube in working temperatures from -40 to +120 °C. The product requires no LOTO (Lock Out Tag Out) and no cutting of tubing. It is simply installed by screwing the clip onto a cleaned pipe/tube surface. Once securely attached to the tube, a specially shaped steel needle is inserted through the wall of the tube above the screw head. The screw head is then screwed back slightly to reveal a small contained hole allowing the pressure to be analysed immediately without interrupting the hydraulic system operation. The system is leak proof and the possible contamination of hydraulic fluid by inserting new pipe into the system is eliminated. Once installed, it can be left in place for future maintenance without compromising the hydraulic system. PT Hydraulics Australia 03 9562 8800 www.pthydraulics.com.au 52 MARCH 2015 Manufacturers’ Monthly

PLASTIC bearing expert igus has developed a polymer material that can be recognised by metal detectors for a wide array of industries such as packaging, sports equipment, food processing, and automotive manufacturing. The complete igubal range includes lubrication and maintenance-free rod end bearings and clevis joints, flanged units, press-fit and pedestal bearings. Both the housing and spherical balls are made from detectable plastic. Standard metal-detection systems can detect all potential plastic residues, even down to the tiniest particle, and then select these for rejection. The self-adjusting bearings are manufactured completely from tribo-optimised polymers. They are easy to install, adjust to all angular misalignments and can replace metallic components in many applications. The bearings are up to 80 per cent lighter than traditional metal bearings, allowing machines and systems to work more efficiently and the number of duty cycles to be significantly increased. The detectable bearings are dry

Suitable for use in many applications. running, unaffected by dirt and dust contamination, can operate in liquids and a variety of chemicals, and are corrosion resistant. Application temperatures can range from 4°C to 80°C. In addition, the components can absorb very high forces due

to the fact that the plastic material of the two-part combined bearings can absorb vibrations, in contrast to their steel counterparts. Treotham Automation 02 9907 1778 www.treotham.com.au

CAD/CAM nesting software SIGMANEST is a CAD/CAM nesting software offering with more than 16,000 instillations world-wide. Powered by an advanced nesting engine, it is a comprehensive software solution for nesting, NC programming and cutting of steel sheet, plate, tube/ pipe, and wood. Because it is both powerful and flexible, all cutting machines (plasma, laser, punch, oxyfuel, waterjet, router, knife, punch, combination) can be driven by a single scalable software solution regardless of type or brand. The software is intended to ensure effective material utilization, machine motion optimization, and maximum part quality balanced with cutting speed, work flow integration, material handling, accurate estimates and information management. It offers a split window allowing different areas of the work-space to be

The software is intended to ensure effective material utilization. viewed simultaneously. Users may also manually nest parts across the split windows and onto other sheets. This provides quick nesting of parts onto multiple sheets without

having to select the layout from the list. Sigmanest 07 3246 5213 www.sigmanest.com

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Hanging onto old accounting software?

Smart standard drives TEAMED with advanced inverter electronics for smart control functionality, standard asynchronous motors providing IE2 or IE3 efficiency and permanent-magnet IE4 synchronous motors can deliver servo-level dynamics and agility. Based on state-of-the-art frequency inverters for motor-mounting, wall-mounting, or cabinet installation, NORD Drivesystems implement highly precise positioning tasks, safety applications, and sophisticated functions such as synchronization, coordinated multi-axis operation, winding control, and flying shear. The frequency inverters feature a realtime microprocessor (cycle time 10 ms) and support free programming of drive-related functions according to IEC 61131 to relieve the workload of external PLCs. 200% overload reserve capacity ensures high operating safety, for instance in crane and hoist systems. Employing field-oriented control technology, these controllers achieve excellent consistency under flexible loads and from near standstill up to the motor’s rated speed, even without an encoder. Furthermore, the drives provide high starting torques and speed feedback can

Dynamic, coordinated drives with built-in intelligence manage complex handling assignments. also be implemented. The top-of-the-range frequency inverter SK 540E from the control cabinet line integrates a universal encoder interface for SSI, BISS, EnDat profile 2.1, and Hiperface. The company’s line-up of distributed inverter technology covers the performance range up to 22 kW, while cabinet devices range up to 160 kW. NORD Drivesystems 03 9394 0500 www4.nord.com

Mesh pressing METAL pressing experts, Swift Metal Services, have broadened their metal pressing capabilities to include pressing steel mesh and perforated sheet. There are a number of challenges when pressing mesh and perforated material, including deformation where holes or apertures are. Experienced and qualified tradesmen at Swift combine The company can press a wide range of thicknesses and sizes with the latest technology of perforated material. machinery to ensure the mesh is pressed consistently and uniformly. The company can press a wide range of thicknesses and sizes of perforated material, from small mesh components through to 3m sheets. Materials range from aluminium mesh, stainless steel perforated sheet through to custom punched material. Swift Metal Services 1800 626 525 www.swiftmetal.com.au manmonthly.com.au

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The last WORD Manufacturing’s Holy Grail Brent Balinski spoke to futurist and bestselling author Michio Kaku about wall paper, babies and how manufacturing might look in the long-term.

HE future could see all money digitised, purchases made by literally blinking your eyes, and anything able to be created, molecule by molecule. Dr Kaku, who holds the Henry Semat Chair and Professorship in theoretical physics at the City College of New York, said that the current trends involving mass customisation and 3D printing would accelerate. “I think there’ll be a mix between mass production, customised production, and small-scale production on 3D printers,” he told Manufacturers’ Monthly, speaking about the nearterm future. Additive manufacturing would continue to rapidly gain in popularity, as others such as research firm Gartner have predicted, but would not replace mass production for cheap items any time soon. “Mass production is still very efficient – one size that fits all,” he said. “But for customised work, for customised things, then we can start to use 3D printers.”

As computing power and chips became cheaper and cheaper, computers would be seen in more and more places. The next step after the Google Glass and similar eyewear would be contact lenses containing a microchip and able to present images and information to the wearer. “You’ll simply blink and you’ll be in the Holodeck,” he said, using one of several analogies borrowed from Star Trek to illustrate his predictions. “You will blink and be able to create any imaginary scenario you want. If you’re an architect you can walk through the building you’re designing. Move objects around and have them immediately printed out on a 3D printer.” Wallpaper would be replaced one day with flexible screens, able to present whatever the owner wished to see. Further off, but probably within the 21st Century, the “Holy Grail of nanotechnology”, the nanobot (or molecular assembler, or Replicator) would come about.

Physicist and futurist Michio Kaku (Image: www.flickr.com/photos/campuspartybrasil/6856978097/) 54 MARCH 2015 Manufacturers’ Monthly

According to Kaku, there are reasons to believe nanotechnology is set to improve.

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nanotechnology will create a nanobot by which we’ll be able to order not just mass produced parts, not just 3D printed parts, but anything you want,” he said. Other predictions included unprecedented information available to consumers, and businesses trying to counter this through means such as data mining, targeted marketing and branding. “In the future, when you walk into the store, your contact lens will scan everything and tell you who has the cheapest, who has the best product,” he said. “You will know exactly what things really cost.” Kaku, the keynote speaker at the second day of SolidWorks 2015, explained to the audience that his predictions were based on extensive interviews with elite researchers in various fields. For his Physics of The Future book (published in 2012), for example, he interviewed 300 leading scientists. Kaku has written multiple titles that have made The New York Times bestseller list, most recently 2014’s The Future of The Mind. He has also a regular guest on US TV and radio news programs and has appeared in many documentaries. Manufacturers’ Monthly attended SolidWorks World 2015 as a guest of Dassault Systemes.

Mother Nature can take a bunch of hamburgers and french fries and turn them into a baby in nine months – Michio Kaku... “A Replicator allows you to create anything you want, simply by asking for it... And we know it’s possible because Mother Nature does it. “Mother Nature can take a bunch of hamburgers and french fries and turn them into a baby in nine months. That is amazing. In nine months, turn a bunch of french fries into a baby. “And how does nature do it? Nature does it with a molecular assembler called a ribosome.” Nanotechnology was currently primitive, noted the famous science communicator, with carbon nanotubes and graphene not finding their way into mainstream products. However, there were reasons to be hopeful that improvements in slicing, dicing and reassembling molecules could eventually be a reality. Nanomedicine was promising, and “just on the horizon”, and a Star Trek-style Replicator able to manufacture anything was an eventual possibility. “Perhaps late in this century

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2015-02-26T15:30:00+11:00

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