Manufacturers' Monthly April 2014 by Prime Creative Media

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

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ADVANCING MANUFACTURING INSIDE News & Analysis >> Laser Welding >> Design Software NMW Preview >> ERP Update>> Endeavour Awards >> Materials Handling

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Inside

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APRIL 2014

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For daily news visit manmonthly.com.au

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

6 News & Analysis

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

■ Reactions to Alcoa plant closure ■ Castech finds success ■ News in brief

Editor: Matt McDonald Ph: (02) 8484 0645 Fax: (02) 8484 0722 matthew.mcdonald@cirrusmedia.com.au Journalists: Brent Balinski Ph: (02) 8484 0680 Fax: (02) 8484 0722 brent.balinski@cirrusmedia.com.au

8 Industry Comment

Alex Heber Ph: (02) 8484 0884 Fax: (02) 8484 0722 alex.heber@cirrusmedia.com.au

■ It’s time to act on workplace relations

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

10 IT@MM

Graphic Designer: Louis Santos louis.santos@cirrusmedia.com.au

■ Five signs a business is ready for ERP ■ BYOD and the growing demand for mobile ERP ■ Key reasons to upgrade your ERP system

Production Co-ordinator: Mary Copland Ph: (02) 8484 0737 mary.copland@cirrusmedia.com.au VIC/Overseas Sales: Michael Northcott PO Box 3069, Eltham, VIC 3095 Ph: 0448 077 247 michael.northcott@cirrusmedia.com.au NSW Sales: Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Ph: (02) 8484 0868 Fax: (02) 8484 0722 Mobile: 0414 644 664 anthony.head@cirrusmedia.com.au

10 Mining ■ Manufacturing for the mining sector: digging for gold

Key Account Manager: 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

18 Endeavour Awards ■ A preview of some of the entries received

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

38 SolidWorks World 2014 ■ Dassault Systemes unveiled a product that will change the way MA 0 4 1 4 _ 0 0 1 _ R E E D

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

Est. 1961 APRIL 2014

42 Welding & Profile Cutting ■ ■ ■ ■

Understand laser welding Eye-viz protection Laser cutting machine Auto-darkening welding helmet

45 Production Line Safety ■ Industrial safety systems ■ Wall mounted ventilation solution ■ Safer air and water use in road and rail

46 Energy Management ■ Putting the sun to work on cool desserts

49 Materials Handling ■ Safe, high-density storage

Multi axis robot energy chains 50 What’s New Automation controller Structural steel fabrication cutting system ■ Energy-efficient pump drive solutions ■ Washdown sensor

■ ■ ■ ■

54 The Last Word ■ It pays to take the right measurements

Behind the cover

Australia’s premier showcase of manufacturing technology and solutions, NMW arms visitors with tools they need to enhance processes, advance technology, build innovative, market-driven manufacturing capabilities and optimise operations. With a revised floor plan giving more ADVANCING MANUFACTURING space to new sectors and technologies 2 0 1 4 - 0 3 - 1 3 T1 3 : 2 8 : 5 7 + 1 1 : 0 0 driving industry growth, NMW will host Print Post Approved PP100007882

39 NMW Preview ■ A round-up of some of the innovative products that will be at the show from sophisticated welding equipment to multifunction portable tools

NMW 2014

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INSIDE

News & Analysis >> Laser Welding >> Design Software NMW Preview >> ERP Update>> Endeavour Awards >> Materials Handling

a record 15 Product Zones. As well as showcasing cutting-edge technologies and sectors, NMW 2014 also introduces an extensive parallel programme of education, dedicated networking events and prescheduled one-to-one business meetings, creating an ideal environment for buyers and sellers to network and do business. Visit www.nationalmanufacturingweek.com

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Manufacturers’ Monthly APRIL 2014 3

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Comment

KEVIN GOMEZ – Managing Editor

Bail out or invest in tech?

NEXTISSUENEXTISSUE • NMW Preview • Heating & Air Conditioning • Metalworking and Machine Tools • Automation & Robotics • Finance, Leasing & Rentals • Additive Manufacturing • Conveyors & Loaders • Pumps Valves M A 0& 4 1 4 _ 0 0 0 _ BOC1

t is indeed a tightrope walk – save the industries we have or invest for the future. With limited funds available, it has to be one or the other. At the ground level, communities and families have to deal with the unfortunate situation that arises when manufacturing plants close down and throw large numbers of people out of work. there is however, a strong case to be made for tax payer funds to be better invested in sectors that will provide jobs of the future instead of bailing out some industries that are likely to forever live on life-support. But is Australia prepared to accept they will have to let some industries go? Whether we like it or not, we are in a state of transition and despite regular news of plant closures, there are currently one million people employed in industries that did not exist 20 years ago. With the decline in miningrelated employment, the challenge is to find meaningful work for twice that number of people in manufacturing over the next ten years – all this while reorienting and upgrading our industrial landscape. A recent article on the Manufacturers’ Monthly website reporting that Sydney has overtaken Melbourne as the country’s manufacturing capital drew a sharp response, as could be expected. But while the two cities duke it out, it is Queensland that is quietly powering ahead. Between 1984 and 2013, Queensland’s share of national manufacturing jobs almost doubled from just over 10 per cent to a little over 20 per cent. Over the same period, the shares of NSW and Victoria slipped from just above the mid 30s to the high 20s respectively – in terms of percentage. Crunching the ABS numbers, we find that the total manufacturing work1 2 0 1 4 - 0 2 - 2 8 T1 1 : 3 4 : 3 4 + 1 1 : 0 0 force has fallen from about 1.1 million to about 950,000.

Queensland has thus seen an absolute, as well as a relative, increase in manufacturing jobs. If technology is to be a driver, we’re glad to see the CSIRO’s Future Manufacturing unit still standing after a major restructuring which will see the loss of over 200 jobs and two divisions at the country’s national science and research agency. Apart from access to advanced technology, the other major gripe among our exporting community is the high value of the dollar. But there have been reports that the Australian dollar could fall to 66 cents by 2016 and if that happens there are no bets on which direction our export graph could be headed. the April issue of Manufacturers’ Monthly is a special one every year as we profile many of the entrants to the Endeavour Awards. And there are many fantastic entries in here. the gala dinner on 13 May in Sydney is shaping up to be a terrific night. Come and be a part of the celebration. Book your tickets soon, if you haven’t done so already (www.manmonthly.com.au/awards). As always, the team at Manufacturers’ Monthly would love to hear from you, so do drop us an email, follow us on twitter and join the discussions on Facebook and Google+. kevin.gomez@cirrusmedia.com.au

A Member of The Linde Group

BOC is your leading partner in manufacturing At BOC, we understand the tough economic challenges facing the manufacturing industry everyday, and how important it is to have a supplier you can rely on. If we can help you increase productivity while keeping costs down, then we’re doing our job. We recognise that for welding, it’s important to use the right combination of BOC shielding gases, quality welding consumables, and state-of-the-art welding machines to help you achieve the results you need. In addition to this, BOC has a wealth of technical expertise available to you through our Welding Specialists located in major regions across Australia. Just as we protect our own people , you can count on BOC’s commitment to help protect yours. We have a comprehensive range of personal protective equipment and workwear specifically designed for your workers. To find out more, call 131 262, visit your local Gas & Gear® retail outlet, or boc.com.au

BOC Limited, Riverside Corporate Park, 10 Julius Avenue, North Ryde, NSW 2113 Australia boc.com.au | 131 262 BOC is a trading name of BOC Limited, a Member of The Linde Group. © BOC Limited 2014. MP13-0350-2|ML|MM|0414

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© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. All other logos, trademarks or service marks used herein are the property of their respective owners.

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Siemens PLM Software provides an immersive decision-making environment that understands the cross-functional dependencies in your product lifecycle process. This gives everyone the right information in the right context to make the right decisions.

Answers for industry.

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News&ANALYSIS In brief... Ageing population hampering innovation Access to capital for more risky firms, especially start-ups with little business history, is likely to become more restricted and expensive, according to Reserve Bank of Australia deputy governor Philip Lowe. This is likely to hamper Australia’s productivity growth and reduce innovation.

Auto suppliers need assistance The Federation of Automotive Parts Manufacturers is urging the federal government via the Automotive Transformation Scheme to assist the sector. FAPMA is looking for a continuance of the assistance programs that are in place to support carmakers and component makers through to 2020.

Security concerns over Industry 4.0 An increasing number of unsecured, computer-guided production machinery and networks in production facilities are evolving into gateways for data theft. Experts claim new security technologies are needed to shield the sensitive data.

Hunter keen for defence contracts The region could push to secure lucrative defence contracts and Williamtown could become a maintenance hub for F-35 Joint Strike Fighters if the region’s manufacturing came together to push for it. Australia’s JSF program would be worth billions of dollars to the Hunter.

Bad headlines don’t tell whole story The RBA’s governor, Glenn Stevens, has said that it’s not all bad news for the country’s manufacturing sector, and that undue emphasis had been placed on the auto industry’s woes.

Emerson sets up in Melbourne Emerson Process Management has opened a manufacturing and service facility in Melbourne for the industry in ANZ. Visit www.monthly.com.au for daily updates

6 APRIL 2014 Manufacturers’ Monthly

Alcoa smelter to close, 1,000 jobs to go

HE five-decade-old Point Henry Alcoa smelter in Geelong will close in August 2014. The smelter, which has been under strategic review by the company since February 2012, will close in August, shedding 500 jobs. Almost 500 jobs will be lost elsewhere as the company closes two rolling mills. “Despite the hard work of the local teams these assets are no longer competitive and are not financially sustainable today or into the future,” said Klaus Kleinfeld, company chief executive officer. An announcement on the company’s website explained that, “A comprehensive review found that the 50-year-old smelter has no prospect of becoming financially viable.” The smelter was granted $40 million in 2012 by the then Gillard federal government and the Victorian government to continue operating until June this year. “Their job prospects are terrible,” the AWU’s Ben Davis said of the workers who will lose their jobs. “Geelong is becoming a manufacturing disaster zone.” At least 800 jobs in Geelong would be lost in the coming months, reported the ABC, and though the demise of the smelter had been expected for some time, the effects would be significant. “You can’t take 800 jobs out of the local economy without having some of impact there,” said the local

chamber of commerce’s Bernadette Uzelac. “We certainly are looking at what other industries we can attract new investment and business to Geelong.” Joblessness has been creeping up in the manufacturing heartland, which has seen its unemployment rate increase to 7.3 per cent from 6.7 per cent for the year to September 2013. The Metalworkers’ Union’s Peter Douglas has predicted that every job lost at Alcoa would see seven related jobs disappear. There was some good news for industry in the region last month, however, with Carbon Revolution, a maker of carbon fibre wheels, named the first winner in a program aimed at helping Geelong’s manufacturers adapt. It has said as many as 300 jobs might be created at the company as it grows. It was named a first-round beneficiary of the Geelong Region Innovation and Investment Fund and awarded a $5 million grant for its Waurn Ponds plant. A proposed 108 jobs would initially be created, according to Carbon Revolution, but after the announcement CEO Jake Dingle put the figure possibly as high as 300 staff once demand increased and industries other than automotive began to seek CR’s wares.

What members of our manufacturing community think about the Alcoa closure ... Mr Sinter Hey, don’t worry about this, have you not read some of the other stories by various University Economic boffins, that this will just make more people start up new industries and we will be able then supply all this high tech stuff they come up with here locally, and open up all these new export markets. So even the person driving the forklift at the Alcoa smelter, or the person who is now putting bolt number xyz123 into place on the current Commodore, Falcon or Camry will have a new career just waiting for them to start up or take up once they walk out the door of their current employer. So be it from the smelter or the car companies, life will be wonderful - just ask those well educated boffins ! ... my 2 cents.

Self employed Bob Yes it is bad luck all these companies are closing shop, most are overseas owned and profits are headed back to their countries. I do not believe the Australian government should be giving grants for overseas-owned business, just to keep you in a pushy job, with all the perks your union provides you with. Try starting your own business and get to see how it really works.

Editor’s note: These comments are as received. Corrections have been made for spelling and grammar only.

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

Callum I hope it does not become like Detroit in the US with all this manufacturing exodus. BrentBalinski So do we. Trying to find something to fill the gap is going to be diabolically hard. I don’t envy any of the people in that community or the policy makers who have to deal with it.

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Castech finds success

OUTH Australian based manufacturing firm, Castech, has just delivered its first order of specialised castings to defence ship building organisation, ASC. ASC is Australia’s largest specialised defence ship building organisation, with naval design and engineering resources unparalleled within Australia’s defence industry. Castech continues to work closely with ICN in SA to identify and broaden its exposure to procurement officers in the Australian defence sector. “Five years ago, the defence sector for us was unexplored territory,” Castech Business Development Manager Jeff Green said. “ICN, in particular Defence Industry Supply Consultant, David Land, were instrumental in opening the right corporate doors for us.” ICN have been working closely with ASC to identify capable Australian suppliers for part of their Collins Class Sustainment Program. The new castings will be fitted to the Collins Class submarines at the ASC Osborne facility with two more orders now in progress. Castech is a privately-owned company that has forged a reputation as a leading supplier of castings to its traditional markets in mining and engineering. They are now in the midst of one of the most exciting growth periods in the company’s 67-year history. “Up until now we’ve been a silent achiever and relatively unknown outside our more traditional sectors,” said Green. The ASC contract was a major win for Castech. Because of this, they now have access to a new sector and have a strong long-term growth outlook. “Thanks to the support of ASC, we are now in the thick of the action with our first major defence contract and a longterm growth outlook,” said Green. “The strong partnership with ASC has given us the opportunity to maintain profitable business growth as well as give our local sub-contractors ongoing work.” manmonthly.com.au

The ASC contract has given Castech a firm direction for their future. The rigorous standards required in being a defence industry supplier, have also given Castech the opportunity to review and improve their own operations. The results are technical improvements and process improvements as well as workforce upskilling, putting Castech in a good position for future work. “This has generated even greater benefits to the business – not just for our defence prospects, but also right across target industry sectors. It’s been a very thorough process but we’re now on an expansion path that previously was not open to us,” said Green. “With the improvements that Castech have made in their processes to meet defence requirements and the experience that they will gain from supplying to ASC, I believe the next stage is for Castech to grow their defence business and then look at export markets in the defence sector,” said Land. Castech are in discussions with other major companies and see defence becoming a key market for them in the coming years. “With the downturn in the mining sector and in general engineering, the subsequent reduction in demand for our castings meant that the ASC contract could not have come at a better time for us and it has given us a firm direction for our future at Castech,” said Green. ICN www.icn.org.au 1300 961 139 Manufacturers’ Monthly APRIL 2014 7

MA0414_008 - 8 Group 2014-03-19T09:18:24+11:00 es WIllox – Chief Executive, Australian Industry

editor@manmonthly.com.au

Comment

Innes WIllox – Chief Executive, Australian Industry Group

It’s time to act on workplace relations The Fair Work Act is in need of reform. It needs to allow Australian workplaces to be more flexible and more competitive. Inness Willox writes.

e have now reached something of a turning point in the increasingly important workplace relations debate in Australia. It seems the debate, especially the need to review aspects of the current system to boost flexibility and competitiveness, is picking up steam and is back on the national policy agenda. While the current focus has followed what has been a tough time for manufacturing with a series of business closure announcements, the renewed attention is most welcome. We are a high cost economy and if we want Australia to remain a highwage, high-standard of living country, we need to find ways to lift to grow, innovate, create jobs and develop the skills of the future. Cutting costs will only get us so far. That is why this focus on workplace relations is important and essential. An agile and properly functioning workplace relations system goes to the heart of the cost and productivity issues. enterprise bargaining has a role to play in assisting businesses to improve productivity through encouraging parties to negotiate measures to improve productivity; and through ensuring that the enterprise bargaining system does not impose barriers to productivity improvement. The Coalition Government has a yet to be implemented policy requiring parties to satisfy the Fair Work Commission (FWC) that they have discussed productivity improvements during the bargaining process in order to take protected industrial action or have an agreement approved. This policy is very welcome and it should be implemented as soon as possible. However, the enterprise bargaining system in the Fair Work Act imposes some major barriers to productivity and these barriers need to be redressed without delay. There are a number of key

8 APRIL 2014 Manufacturers’ Monthly

changes that need to be made to the Fair Work Act regarding enterprise agreement content, specifically: • Permitted matters and unlawful terms - Under the Fair Work Act, the unions and employees were given the right to take industrial action over a much wider set of issues than previously. The “permitted matters” for bargaining under s.172 of the Act need to be more tightly defined and the “unlawful terms” in s.194 need to be extended. This will ensure that bargaining is focussed on matters which genuinely pertain to the employment relationship, rather than on matters which seriously impede the ability of employers to manage their businesses in a productive manner. • Variation of agreements – the Fair Work Act should be amended to put beyond any doubt the right of an employer to propose a variation to its enterprise agreement. Circumstances sometimes change requiring variations to industrial instruments. • Termination of enterprise agreements after the nominal expiry date - the very high bar which the Fair Work Act and decisions of the FWC have placed on applications to terminate an

enterprise agreement after its nominal expiry date also needs addressing. Many employers are saddled with unproductive enterprise agreements made in far less challenging times. With Ford, GM Holden and Toyota announcing the closure of their Australian manufacturing operations, automotive component manufacturers are facing a potential crisis if they cannot quickly restructure and develop new products and markets. Many of the companies are highly unionised and therefore the support of the unions will be important. The early signs are not encouraging. Over the past few weeks the feedback to Ai Group from our member companies is that during bargaining the unions have ramped up their claims for: • Restrictive no extra claims clauses which the unions are hoping will block employers from proposing changes to their agreements; and • Excessively generous redundancy entitlements of up to four weeks’ pay per year of service with no ceiling on payments. Both claims are short-sighted when many companies need to restructure, and require enterprise agreements which do not impose un-

due barriers to this restructuring. Operating against the imperative for Australian companies to become more cost competitive, is the Government’s gold-plated Paid Parental Leave (PPL) Scheme. The idea that 3,000 companies will be required to fund a scheme for the whole community is unfair. It would undoubtedly have adverse flow-on effects across the whole economy through higher prices and reduced investment. One company told me that the scheme would take over $150 million dollars off their bottom line. The existing PPL Scheme which provides 18 weeks’ pay at the level of the National Minimum Wage was introduced with the support of Ai Group and is working well. Clearly, there are many challenges ahead although all can be dealt with effectively if employers, employees and representative bodies pull together. The Government

“

Operating against the imperative for Australian companies to become more cost competitive, is the Government’s goldplated Paid Parental Leave Scheme. also has a key role in creating the right framework. The Government needs to act quickly to remove the obvious barriers to productivity and flexibility in the Fair Work Act. This should be given bipartisan support in the interests of ensuring a positive economic future for Australia. www.aigroup.com.au manmonthly.com.au

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TechnologyIT@MM Five signs a business is ready for ERP Recognising the time to move the ERP investment decision out of the ‘too hard’ basket and into ‘mission critical’. Kaido Schmidt explains.

aking the decision to invest in better business management software can often fall into the ‘too hard’ basket for SMEs. all too often, companies can often overlook the correlation between their business systems and the success of their business and/or the satisfaction of their customers. So how do you know when the time has come to move the investment decision out of the ‘too hard’ basket and into ‘mission critical’? 1. There are cracks in the foundation systems supporting your business Take a hard look at what you’re using to run your business. an accounting package? Spreadsheets? a different software tool for every different business task, none of which is integrated with another? imagine seeing a real time overview of all this information, all in the one system.

you save if your sales teams had tablets they could use to access up-todate production times, inventory and pricing? 3. Inventory losses due to poor paper trails or double entries are frequent occurrences Total control over inventory including individual items, recipe creations that automatically adjust inventory levels, automated stock reordering at minimum levels, stock taking, multiple cost formulas. With ERP, inventory levels are instantly changed according to deliveries and are linked to your general ledger. keeping track of your stock values and movements is easy thanks to purchase orders, purchase invoices, sales orders, sales invoices, deliveries and receipts all being linked together.

With ERP, inventory levels can be instantly changed according to deliveries.

ponent items with the cost of labour 4. Managing and tracking of exand machine usage. act costs, resources and materials involved in production is difficult or 2. Your mobility is limited 5. Your IT systems are a mess impossible Do your Sales Reps have to ‘get back The upshot of having different as your business grows so too does to’ customers with production times, software tools to manage different the amount of projects and the mastock availability and pricing? Does aspects of your business is typically terials and resources required. But if your Procurement Manager need a creaky and difficult-to-manage iT it’s becoming difficult to keep track travel from stockroom to desk and environment. then you may need an ERP system. back when replenishing stock levels? With an ERP solution you can increased mobility means better MA 0 4 1 4 _ 0 0 0 _ S O U 1 2 0 1 4 - 0 3 - 1 8 T 1 4 : 3 1 : 5 3 + 1Computers 1 : 0 0 crashing, constant and unsynchronised upgrades and combine the exact value of all comuse of time. How much time could

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patches, attempts to integrate or share information from one system to another – these are signs of an iT system incapable of meeting business requirements without interruption. [Kaido Schmidt is Country Manager with HansaWorld Australia, who will be offering free 30-minute introductory consultation at this year’s NMW in Sydney, email australia@hansaworld. com or call 02 8011 1895.]

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BYOD and the growing demand for mobile ERP As organisations seek to improve operational efficiency and customer engagement, mobile access to ERP systems is becoming standard. Craig Charlton writes.

n this age of Bring Your Own Device (BYOD), mobile devices are affordable, mainstream, reliable, secure, and scalable to run multiple applications. With the ability to connect to the Internet and download a wide variety of applications, more and more end users are purchasing mobile devices for their consumer needs. Furthermore, we are now able to prove return on investments from those organisations that have implemented mobile solutions and developed BYOD policies. Mobile user access to ERP and other back office systems has become a core requirement as organisations seek operational efficiency and deepening customer engagement. Without mobile access, system users are disadvantaged by needing to return to a desktop, often after a job is completed, to enter data relating to that job and get information about other jobs. Frequently that information is not entered at all and become more of a hindrance to user adaption of your ERP investment. The majority of ERP workers are growing up with the ability to instantly access information and interact with that information wherever and whenever. These same users

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Working with ERP data on mobile devices, users can provide feedback and make changes to daily. are expecting the same thing with their ERP data and are making this a requirement. User pressure to be able to access ERP data is not the only compelling reason there is to adopt mobile solutions. We also see influence from companies themselves as mandate to gain operational efficiencies and providing a competitive differentiation as drivers. Mobile accessibility is identified to be one of the core drivers of

process realignment, improving collaboration and communication and offering a new channel for products and services to gain these efficiencies and differentiation. Studies have shown a year over year increase in demand for these disciplines to be implemented. During process realignment, this is driving the requirements in mobile application for things such as approvals, notifications, business intelligence, product and contact management and work queue management.

Instead of having to go to a traditional workstation to access these functions, companies are able to see the benefits of moving this functionality to a mobile form factor. Mobile users are quickly able to engage in their day-to-day activities and work more efficiently. Working with ERP data on a mobile device, users are able to provide feedback and make changes to daily issues as they present themselves. By having these real-time transactions in executive hands, there is a shorter time to decisions, which helps organisations gain the efficiencies that are required. In todayâ&#x20AC;&#x2122;s environment, mobile solutions are seen as core drivers of organisations pushing to gain operational efficiencies over their competitors. Enterprise mobile apps have become essential enablers of organisational transformation, by increasing operational efficiency, accelerating time-to-decision, deepening customer engagement, and streamlining workflow processes. [Craig Charlton is SVP and general manager, Epicor Software Asia Pacific.] Epicor Software 02 9927 6200 www.epicor.com

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Technology IT@MM Key reasons to upgrade your ERP system When it comes to business growth, everyone talks about entrepreneurs, start-ups and innovation, however there is one important sector being overlooked - mid-market manufacturers. Mike Lorge reports.

N difficult economic times, the mid-market manufacturing sector punches well above its weight to make a substantive economic contribution. When it comes to IT needs, midmarket manufacturing companies have one thing in common – they have the IT and ambitions of big enterprises but the resources and budgets of small companies. When it comes to strategy and IT purchasing, mid-market manufacturing CEOs still make personal decisions. They are not big enough for business decision makers to be able to hide behind bureaucracy and complex corporate structures. The transformation of the business environment over the past ten years has been greater than over the previous fifty. The internet, the empowered consumer and the way technology has helped to blur the lines between business and personal lives are just a few of the ingredients that have created great opportunities for companies today. Mobile, connected services, the maturity of cloud technologies and social and legislative developments have rapidly changed the way we do business. Further, tough economic conditions have demanded that companies become much more efficient. Mid-market manufacturing companies are focused on reducing their costs and overheads to ensure that profit margins are robust. With this backdrop, ERP systems have solved a number of challenges for manufacturers – from improving internal communication, increasing customer loyalty, streamlining operations and helping companies monitor their data. Today, therefore, there are four key reasons why more companies are

12 APRIL 2014 Manufacturers’ Monthly

considering an upgrade to their ERP platform in 2014:

1. Cost reduction Many business investments are made to achieve cost savings, and ERP is no different. Modern systems can reduce both administrative and operational costs by delivering accurate, realtime information. This enables manufacturers to make better decisions and take advantage of opportunities to cut costs. Businesses with an ERP system can more proactively manage manufacturing processes and prevent disruptions and delays, which allows for a larger cash flow.

2. Streamline processes As businesses grow, operations become more complex, which can become a concern for a mid-sized company. Modern ERP solutions can automate processes which allows endto-end processes to move faster. ERP increases efficiency by helping users through complex processes, preventing data re-entry, which improves order completion and on-time deliveries through improved decision-making, and ERP allows companies to track orders.

3. Manage business growth In addition to cutting costs, many technology investments are made to help businesses grow. Modern ERP software is web-based and allows firms to automate more tasks. This software is scalable to the business, so it can be adapted when the company grows. Instead of companies getting bogged down with new business developments or orders, ERP can be adjusted for growth. In addition, firms can measure their efficiency and continuously

Modern ERP software is web-based and allows firms to automate more tasks. improve processes and reduce costs which fosters growth.

4. Growth in global markets As companies grow, they may consider expanding into international markets, and this means they will need sophisticated technology to aid this goal. Many companies will need a higher level of visibility to keep processes moving smoothly. Modern ERP solutions can fit a business with multiple locations in different countries with a single platform. Having all supply chain information in the same place can help separate partners and suppliers stay on the same page throughout the production process.

Advantages Those companies today which have disconnected or piecemeal systems are at a severe disadvantage. They may not be able to quickly get a grasp of the true situation. However, those with ERP systems have a better chance for success. Indeed, those with both ERP systems that support a culture

focused on interconnected data and collaboration among disciplines and partners are likely to have an easier time gaining a competitive advantage. Today’s market for products is global, fast-paced, and subject to volatility based on demand, supply, political and natural events, and new competitors and technologies. It offers challenges, but also opportunities to gain traction in emerging markets and new segments. As the market begins to grow, those companies with a clear strategy plus the right ERP systems in place to take advantage of the new opportunities will be able to grow more quickly than their less-prepared competitors. Designed with manufacturing in mind, ERP software can accommodate the many different types of manufacturing that support your business processes. [Mike Lorgeis is Managing Director of Sage Business Solutions.] Sage Business Solutions 13 72 43 www.sagebusiness.com.au

manmonthly.com.au

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2014-02-28T11:32:47+11:00

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2014-03-19T10:44:19+11:00

ManufacturingFOR MINING Manufacturing for the mining sector digging for gold While media headlines suggest the mining sector is in ‘bust’ mode, manufacturers in the industry know better; but it’s no longer the promised land. Alan Johnson reports.

ITH our car industry soon to be relegated to the history books, many in the devastated sector will be thinking of diversifying and possibly moving into the mining industry. But while the transition for some will be relatively painless, most will struggle and some just won’t be able to make the leap. Robert Trzebski, Executive Officer with Austmine, Australia’s leading industry association for the METS (Mining Equipment, Technology and Services) sector, says anyone thinking of getting into the mining industry must be innovative, and think globally. “They must also think outside the square and be able to adapt their product for the needs of mining companies outside Australia.” Trzebski told Manufacturers’ Monthly that ongoing innovation is the key to success. “Companies must be able to position themselves in an advantage position against their competitors, including cheap competitors, and really diversify. “Companies should also be flexible and adaptable to customers’ needs, because markets change, and market conditions change and needs change all the time,” Trzebski said. And for those who can meet the criteria, he says they should get prepared for the next boom, “because it will come”. Trzebski says they should be prepared in terms of capacity, as well as innovation, utilisation, and collaboration. “They should form alliances with overseas companies, for example in Brazil or Russia, and use their local expertise and local presence to sell their products into markets in those regions. “Austin Engineering, for example, 14 APRIL 2014 Manufacturers’ Monthly

has been buying companies in the US and Peru and Columbia, and setting up a presence in Russia. “They are a good example of a company with a really good product, and through mergers and acquisitions they have become a global supplier. “But they are not alone, we have a lot of expertise here in Australia, and produce some excellent products,” Trzebski said . While he was generally upbeat about the market, he did admit some members are struggling, particularly those in exploration and assessment of new projects, and some engineering companies. “But at the same time there are some manufacturing companies who are not feeling the pinch at all. “It’s very hard to generalise when

talking boom and bust in the mining industry. Those companies that only produce products for the Australian market are suffering the most, because the situation is not as bad in other countries.” Trzebski said there are numerous exporting manufacturers who are doing very well including Hedweld Engineering, MineARC Systems, Russell Mineral Equipment and Xstrata Technology. “They are not experiencing any bad times because they are very diversified as far as their target markets are concerned,” he said. However, Trzebski admits some companies won’t survive the down times. “There are a number of companies in receivership or in administration at the moment, but thankfully the numbers are quite low

at the moment. However, many of our members are asking us to help them with exporting opportunities. “For example in WA, many members are saying there are too many companies in Australia for the few domestic projects, and realise they need to look overseas; to Mongolia, to Kazakhstan, to South America, to Africa for example. “They now realise they made the mistake of just focusing on the local market during the boom time. They didn’t build enough capacity and resources to cater for the export markets,” he said. Like manufacturing in general, Trzebski says the keys to success in the mining industry are innovation and working very close to clients by responding to their needs on the projects, “and to be very flexible”.

Yandina Plastics produces two different grades of core trays; one for temperate climates, and one for temperatures as low as -50degC. manmonthly.com.au

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2014-03-19T10:44:50+11:00

Keech Australia Dr Herbert Hermens, CEO of Keech Australia, a leading manufacturer of ground engaging tools for machines including excavators, shovels, loaders and draglines, believes his company’s successes in the mining industry are due to more than just one element. “It’s multi functional. We have spent a lot of time and effort in improving our production processes, controls and quality, and costs, plus we have invested heavily in R&D, far more than most companies our size, and in our products.” Hermens says it’s important to produce the products companies want. “In the development of our products we have focused on what our customers want; sending our engineers out to our customers and discussing with them what they are looking for, what they want, and try to meet those demands,” he told Manufacturers’ Monthly. Hermens explained that the company has two key competitors; one is based in the US, a global organisation, and one local multinational organisation, “but most of its manufacturing is done offshore”. “However our commitment to manufacturing here in Australia is complete, with 97% of our products produced in Australia.” He believes governments should be aware of what local manufacturers are required to meet; national standards which do incur costs that his competitors don’t, and additional costs such as workers comp insurance, paid leave, sick pay, and holiday loadings. “We can’t do anything about these additional costs, so we have invested heavily in automation and technology throughout our company. “It’s about giving our people the capacity to produce as much as possible in their given time, but that can only take you so far. We have a massive focus on R&D so we can get leading edge technology happening in our products as well. “We have a heavy focus on improving the process, in value and in productivity, but an even heavier focus on the product itself. We have put patents in place. manmonthly.com.au

“We are now selling all over the world, to North and South America, and to Eastern Europe. “For example we are selling product into Kazakhstan where they are operating at -70 deg C, for that you need to have an adaptive technology that will allow you to adapt the product to meet the local conditions. “By being a little smaller than our competitors this allows us to be a little bit more flexible, plus we are able to control our designs, including pattern making, right through to distribution. “For example we were asked by a couple of our key customers in South America to set up in the region. They wanted Keech there because obviously our products were giving them key benefits.” Hermens said exporting is now a key part of Keech’s business. “It wasn’t but now it is, and we will make it more significant. We now have our own sales organisation and warehouse in Chile and are importing from there and distributing to our customers there. That’s becoming an important part of our business. “While I continually hear that the Australian market is too small, there are others who say companies should just focus on the Australian market and build capacity here. “In fact there is truth in both, because if you can’t be competitive in the Australian market, how can you be competitive on the global market. “For me, if you are competitive on the Australian market, then you have the capacity to be competitive overseas, but you need to understand that the competition overseas is not always fair. “We have an open market here with no barriers, but with some South American countries, for example, you need to apply to the local government for orders we place with ourselves. They often limit the number or orders we can place. “Many people don’t realise some of the problems exporters can face.” However, Hermens said many people often ignore the enormous local markets. “By that I mean countries such

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MA0414_016

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2014-03-19T10:45:43+11:00

Manufacturing FOR MINING

55%

CURRENTLY EXPORT PRODUCTS, SERVICES OR TECHNOLOGY

Kadir says with a lot of timber still being used, as well as gal trays, even waxed cardboard, there is a big market out there. “They all have major problems; 21 with the gal trays corrode and react the minerals in the cores and give false readings, while the cardboard trays fall apart very quickly and lose their valuable core. 91 “It’s the same with the timber trays, they suffer from termites and other infestation and have to be replaced in a short amount of time.” Kadir HEAD explained that the company LOCATIONS BY 806 STATE OFFICE FORseries SURVEYED has two different andCOMPANIES is continually upgrading its products to suit the market. “Our original Series 1 core tray is still being used today, while our Series 2 core tray came on board in 2009 with a slow transition. “Some people have switched over to series 2, while others prefer the Series 1. We provide a total package,” he said. As well as quality, Kadir explained that the company competes on its ability to offer a quick turnaround to Australian customers. “But we are also able to

186

$27bn TOTAL EXPORTS ESTIMATED $15bn EXPORTS DERIVED FROM THE MINERALS AND MINING BUSINESS Australia’s mining equipment, technology and services companies are globally focused with a footprint that reaches every corner of the globe. business, but we also need to import as Indonesia, Japan and Thailand. equipment, for that I wish the A$ was We are part of Asian now, and they at $US2. But our overseas business should be part of our market. is encouraging, despite the slowing “We should be working together global economy. to make sure the obstructions into “This year we have committed to the Asian markets are equally fluid even more deeper training within both ways.” our production units and additive While the media is full of the manufacturing technology for boom and bust of the mining prototyping,” Hermens said. industry, Hermens says that kind of talk relates mainly to the investment side of the industry. Yandina Plastics “People see the construction side Tanju Kadir, MD of Yandina Plastics, as the boom time, but the bust is says innovation is the key for actually the production phase. In fact companies thinking of moving into BHP and Rio Tinto exported more the mining sector. CURRENTLY EXPORT iron ore last year than they ever did. “While there aren’t the volumes PRODUCTS, SERVICES “We focus on developing our that would normally justify a OR TECHNOLOGY equipment that fits the construction manufacturer to invest in the market; and the production phases of the if they are clever and innovative, they mining cycle. can develop products to replace a “But saying that, mines have been lot of metal components used in the under enormous pressure to control mining industry with polymer,” Kadir costs so us and our competitors are told Manufacturers’ Monthly. finding it very tough, not because the Based in SE Queensland, Yandina production is not there, but because Plastics is a small plastic injection they are scaling back costs and moulding company with around 20 reducing their inventories to reflect employees. real demand. The major products they ESTIMATED $15 bn EXPORTS “One mine site, for example, had manufacture for the mining industry DERIVED FROM THE MINERALS an inventory of our products that are core trays, with four different would last them over two years. While sizes and the associated accessories AND MINING BUSINESS they can’t afford downtime waiting including lids and core markers. for spares, this is ridiculous as we can “They are very popular in the supply them quickly when needed. mining industry because they are Like many, Hermens describes the the leading product on the market lower A$ as a two edge sword. and are far ahead of the rest of the “We want to grow our export world.”

successfully compete globally, with 40 to 45% of our product going overseas including to South Africa, Phillipines, UK, Oman and PNG. “The fact is people recognise quality. We offer a UV package that was developed in-house, and is far 149 superior to anyone else’s,” Kadir said. “We produce two different grades of product; one for the temperate climates, and one for sub-zero climates, which can withstand temperatures as low as -50degC. 4 “Hence we have an exclusive 142 supply to Oyu Tolgoi copper gold mine in Mongolia. They wanted core 12 trays that last. “The purchasing manager there had bought a couple of containers of core trays from elsewhere that quickly broke because they weren’t designed for such low temperatures. Many people don’t think about the temperatures their products have work in. “That’s what sets us aside. It’s the understanding of what conditions our products need to cope with, and making sure we have designed the product around the end user.” According to Kadir, the Australian

201

55%

149

186 91

201

$27bn TOTAL EXPORTS

16 APRIL 2014 Manufacturers’ Monthly

806

HEAD OFFICE LOCATIONS BY STATE FOR SURVEYED COMPANIES

142 12

The mining equipment, technology and services sector in Australia comprises a diverse range of companies which produce technologically advanced, globally competitive products and services for mining companies worldwide. It operates in every state with capital cities, regional areas and remote locations benefiting from its revenue, jobs growth and exports. manmonthly.com.au

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Manufacturing FOR MINING skilled Australian workers to project manage the quality and certify these products.

market has become too small because of the number of ‘me-toos’, some with no respect for other people’s IP.

Quarry Mining Kari Armitage, MD of Quarry Mining, a specialist drilling equipment company, says the lower the Australian dollar the happier she is. “It discourages my customers from sourcing their products overseas,” Armitage told Manufacturers’ Monthly. “At present we have 30 employees, and manufacture rotary drilling equipment, drill bits, drill rods, adapters, spanners, primarily for the underground coal mines in Eastern Australia and New Zealand. “We also export a little bit to Mexico and the Czech Republic, and could probably export a little more, but we are kept very busy keeping up with demand from local coal mines.” Armitage said there were many reasons for the company’s success M A 0 product, 4 1 4 _ technology, 0 0 0 _ FLI including service, backup and price.

[Alan Johnson is Manufacturers’ Monthly’s former editor. He has researched and written about all aspects of the Australian manufacturing sector for more than 25 years.] Austmine 02 9357 4660 www.austmine.com.au Keech Australia has invested heavily in new manufacturing technologies and training, and is now succesfully selling its products all over the world. because the industry is so depressed, “They are all as critical as one some companies are looking at some another; we have to keep all those of the cheaper drilling equipment balls in the air. But probably the coming out of China and giving them main reason for our success is our a chance. quality products. Australian coal She admits the Chinese are mines demand high quality products. 1That’s 2 0what 1 4 -we0 focus 3 - 0on. 5 T 1 6 : 1 4 : 4 getting 6 + 1 1better : 0 0and better at it all the time, with some companies using “However, we understand that

Keech Australia 02 9648 3100 www.keech.com.au Yandinda Plastics 07 5446 8088 www.yandinaplastics.com.au Quarry Mining 02 4966 5028 www.quarrymining.com

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Manufacturers’ Monthly APRIL 2014 17

MA0414_018r

2014-03-19T16:05:56+11:00

EndeavourAWARDS

2014

Open to all manufacturers, Manufacturers’ Monthly’s

Endeavour Awards program has evolved into the ideal vehicle for Australian manufacturers to highlight their recent successes and achievements.

PRINCIPAL SPONSOR

NOW in their 11th year, the Endeavours are the only awards designed specifically for Australia’s manufacturing industry. With the Australian dollar slowly moving down to a more sustainable level against the greenback, manufacturers are increasingly optimistic about 2014 and entered the awards in record numbers. At the time of going to press, there were well over 100 nominations received. Proudly sponsored by BlueScope Steel, the Endeavours are the only awards program designed specifically for Australia’s manufacturing industry, and are now in their 11th year. Designed to celebrate Australian manufacturers’ achievements and inspire innovation and success, the Endeavour Awards drew in entries from a whole host of manufacturers, large and small, including engineering companies, food processors and chemical companies. Several entries in 2014 focused on companies transforming their businesses, by increasing productivity, innovation and competitiveness. The Australian manufacturing industry is highly dynamic with many unsung companies making a valuable contribution to Australia’s economic output, with product innovation, support of local employment and training our future stars. The Awards dinner will be held on Tuesday 13 May 2014 at the Ivy Ballroom in Sydney. Come and be a part of the celebration - tickets are available for purchase. Check www.manmonthly.com.au/awards

18 APRIL 2014 Manufacturers’ Monthly

Manufacturer of the Year for 2013: Pat Boland, director of ANCA (right) being congratulated by Steve Gregson from principal sponsor BlueScope Steel.

manmonthly.com.au

MA0414_000_BLU

2014-03-18T08:42:30+11:00

MA0414_020

2014-03-17T18:08:32+11:00

EndeavourAWARDS

PROUDLY SPONSORED BY

TECHNOLOGY APPLICATION OF THE YEAR

THOMPSON & REDWOOD SOFTWARE IMPLEMENTATION Thompson & Redwood, an animal feed manufacturer partnered with Siemens Solution Partner, AP Automation, to modernise its manufacturing plant. Initially, the idea was to find a solution that would see the plant grow in line with its modern requirements, become more efficient, consume less energy and comply with food safety regulations of tracking and tracing, while being robust enough to handle the repetitive grinding and batching functions. For Thomson & Redwood, the key attraction of the Siemens solution was its ability to adapt to any grinding or batching application and its advanced diagnostics capability. The solution was based on proven and tested software libraries which can be tailored for any application and consequently provide Thomson & Redwood with the flexibility to produce various product lines efficiently. According to the company, the improvement in efficiencies is due to fine tuning of the new system and reduced down time. As a result, the company has achieved a 7% increase in production and reduced its energy consumption by 2%.

ORORA ST REGIS BATES SOFTWARE IMPLEMENTATION Orora St Regis Bates (Orora SRB) specialises in fully tailored packaging solutions across a broad range of dry powder and granular markets including milk powder, flour, mineral, building and more. The company commenced a major Productivity Improvement Project across three plants in Perth, Sydney and Melbourne. The technology used in the project is the OFS Solution, supplied by Operations Feedback (OFS), a Melbourne based OEE software developer. OFS also delivered execution, implementation and training services for the project. Having a manual production recording and monitoring method meant the company was waiting on information that was usually late and often wrong. The vision was to find a solution that did this work for them. The OFS software suite was deployed to all three manufacturing facilities between December 2012 and February 2013, which included comprehensive onsite training by the software supplier. As a result, labour costs were reduced by 14% and setup/changeover time was reduced by 21%. There was also an increase in AVA and an increase in engagement from the factory floor.

MICHAEL HILL INTERNATIONAL STONE IN PLACE (SIP) Michael Hill Jeweller has invested in 3D printing technology. In conjunction with a CAD programme, it is helping the company close the gap between it and its Chinese and Indian competitors. The project, called Stone in Place (SIP), took around two years to fine tune and develop. The CAD programme is built off the back of Rhino and developed for jewellery design. The particular programme used is called “Matrix”. By introducing this process, the company has reduced labour time by 50% and, in some more labour intensive pieces, by 60-70%. The technology has improved quality by ensuring all stones sit level. This creates a better finish compared to the hand-set technique. When stones are hand set, the setter would find it difficult to get the stones down as low without breaking the diamonds in the process. 20 APRIL 2014 Manufacturers’ Monthly

Being able to sit stones in the soft wax with no direct pressure on the stones (as opposed to pushing the stones into metal) has reduced the number of broken stones and reduced costs.

CYBER TECHNOLOGY USE OF 3D PRINTING Cyber Technology designs and manufactures CyberQuad unmanned aerial vehicles. These are electric ducted fan quad-rotors with vertical take-off and landing capability. Designed by 30-year-old CEO Joshua Portlock, they are used in various applications, including aerial inspection, photography, cinematography, emergency services, law enforcement, surveying and surveillance. CyberQuad Maxi was designed and manufactured using high-end 3D printing, which facilitates rapid change and improvement of the product, without the overheads of tooling. It was designed using multi-disciplinary-design-optimisation and computationalfluid-dynamic modelling. It took three years to develop and has now been in production for four years. The use of Selective Laser Sintering (nylon powder based 3D printing) has allowed the company to rapidly evolve the product, without the expense and time of tooling moulds every change. It has also allowed them to manufacture the light weight and aerodynamically optimised, hollow, compound curved ducts and struts, which would be near impossible to create using conventional manufacturing techniques.

COLLIER & MILLER PRONTO XI SOFTWARE Agricultural engineering company Collier & Miller designs and manufactures equipment for dry land and irrigated agriculture. The company’s core operations are split into two divisions (manufacturing and sales) and management required a single IT solution. They chose Pronto Xi, a solution that combines business intelligence tools with an Enterprise Resource Planning system. They implemented modules including Finance, Distribution, Point-of-Sale, Project Costing, and Business Intelligence to support the business into its next phase of growth. The software has become an integral part of the company. It has improved efficiency across the business by eliminating duplication of data entry; provided a clearer understanding of finances; and most importantly, empowered staff to improve customer service and better sell their services. In particular, Pronto Xi Business Intelligence has given Collier & Miller a clear picture of their business performance, through full visibility into all operations. Visibility in the areas of purchase orders, point of sale and project was previously a major issue. The software has enabled workflows and business processes to become more streamlined.

EDITOR’S NOTE This is a selection from all the nominations received at the time of going to press. Once judging is complete, Finalists will be announced on www.manmonthly.com.au. They will also be individually notified.

manmonthly.com.au

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2014-03-18T16:08:47+11:00

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MA0414_022

2014-03-17T18:08:32+11:00

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ENVIRONMENTAL SOLUTION OF THE YEAR

CRIBBING AND MATTING CO CRIBBING AND MATTING The Cribbing and Matting Co is introducing a high performance recycled plastic cribbing system throughout Australasia and South-East Asia. It is engineered to provide optimum safety and durability when stabilising heavy loads. The lightweight, splinter-free, non-absorbent and environmentally sustainable Dura Crib and Dura Stat ranges were developed to replace older, weaker, less predictable wood cribbing systems which need constant ongoing replacement involving consumption of a finite resource. Being recycled, the products tackle two problems in one. They cut down on waste going into landfill and reduce the use of timber. The matting solutions are also manufactured from recycled plastic and are available in a broad range of styles and colours. Because they are modular, users are not limited to particular sizes or shapes. Applications include industries such as construction and building, rescue and recovery, mining and resources, food processing and materials handling, industrial maintenance and safety, road and rail transport, ports and shipping.

KEECH AUSTRALIA FACTORY UPGRADE For almost a century Keech has supplied Australia and the world with innovative products in mining, excavation, construction, agriculture, rail transport and defence. Owned and operated by the Keech family, the company employs 119 people. The company’s head office is in Bendigo, Victoria and its annual revenue is $50 million. Over the past four years the company has transformed from a foundry to a global provider of innovation, services and products, resulting in 60 per cent growth. To remain competitive and viable in the Australian manufacturing and mining industry, Keech needs to be a sustainable business, in terms of business operations, the environment, staffing, health and safety. To this end, the company undertook the transformation of its Number 2 foundry, implementing quick change-over tooling to improve flexibility compared to its competitors. The factory transformation began in 2012. The company hopes it will reduce manufacturing costs, reduce its carbon footprint, boost product quality and improve workplace health and safety.

LEUSSINK LEUSSINK GLOBAL WORMING When challenged to raise an 8-storey building’s green rating from 4-star to 5-star upon completion, Leussink didn’t focus on the usual areas of air conditioning, sunlight control, and so on. Instead, the engineering/manufacturing SME took the radical step of eliminating organic waste collections in favour of manufacturing its own composting worm farms. What transpired is Leussink Global Worming – where the company uses its traditional manufacturing skills base to make customised compost worm farms for any level of compost management (commercial, industrial or bulk domestic). All organic matter, including paper, cardboard, food waste, and cloth is 22 APRIL 2014 Manufacturers’ Monthly

no longer taken away in skips. Instead, it is turned into fertiliser for the site’s decorative gardens. Industrial strength worm farm enclosures are sized and manufactured at the company’s plant in Unanderra. They are manufactured according to the volume of waste output of the client. In this case, they have proved ideal for an ATO office which constantly produces paper waste.

LONGWARRY FOOD PARK PLANT UPGRADE Longwarry Food Park is a dairy business based in Gippsland region of Victoria. Its products are sold in major Australian supermarkets and exported to over 30 countries. The company had an opportunity to buy the Longwarry dairy plant from Bonlac Foods Ltd in 2001. The plant was sick and had been closed down. The company has increased the plant capacity to 6.0 MT to reduce the cost of production and increase productivity. This was achieved by in-house innovation and process optimisation. It involved about 20 innovations like viscosity control, preheat, humidity measurement, and cleaning time reduction. A grant for reducing energy consumption from AusIndustry helped the company match best practice. This project has been completed and has made a significant impact on productivity and energy consumption. The company has installed and is marketing two new product lines. It is now struggling to meet the demand for these products.

AIR SPRINGS SUPPLY INFLATABLE PIPE STOPPERS Air Springs Supply distributes a broad range of Pronal inflatable stoppers suitable for all types of pipelines including concrete, cast iron, steel, stainless steel and PVC. As one of the most urbanised and coastal-dwelling nations on Earth, Australia is increasingly sensitive to accidental spills of chemicals and other potentially harmful materials in the workplace. One method of stopping and sealing pipelines involves inflatable pipe stoppers that can be easily deployed, easily transported and widely applied in urban, remote, temporary and permanent industrial situations. According to the company, sometimes such stoppers are permanently located in pipelines for instant remote inflation with compressed air or other gas. This is particularly the case in situations where there is a risk of toxic runoff at different stages of production, or where spillages occur. In addition, they can be used to seal off sections of pipe where leaks are occurring. This enables the pressurisation of that section so leaks can be detected, then protects those working in the pipeline from any product flows while they fix the problem.

manmonthly.com.au

MA0414_000_ATL

2014-03-17T19:26:38+11:00

Cut Energy bills. Atlas Copco can show you how.

Based on an audit of your production processes, Atlas Copco energy consultants can suggest quick wins for your compressed air installation, with an eye on maximum availability at lowest possible operating cost. Fact: Anyone can buy a compressor Fact: We will explain to you total cost of ownership Fact: We are committed to showing you how much you can save We are so passionate about our environment and what it means for our future, that we are once again proud to be the major sponsor for the Environmental Solution of the Year award at the 2014 Endeavour Awards We wish all the finalists the best of luck! Atlas Copco Compressors Australia 1800 023 469 www.atlascopco.com.au/compressorsaustralia

MA0414_024

2014-03-17T18:08:32+11:00

EndeavourAWARDS

PROUDLY SPONSORED BY

AUSTRALIAN INDUSTRIAL PRODUCT OF THE YEAR

ACTRONAIR HERCULES PACKAGED AIR CONDITIONING UNIT Designed for large commercial applications such as convention centres, airport terminals, and shopping centres, the Hercules air conditioning unit has been engineered to better match the thermal load of typical commercial buildings. The range includes three models – the PKV1400 with a capacity range from 35kW to 140kW; the PKV1700 with a capacity range from 42kW to 169kW; and the PKV2000 with a capacity range from 48kW to 194kW. The units benefit from the latest generation of inverter compressor technology. Two variable speed compressors closely match the thermal load requirements of the building – simultaneously ramping up or down to reduce compressor cyclic degradation and maximise system efficiency. With a system turn-down ratio of 4:1, unit capacity can be adjusted from 25% - 100%. This is intended to offer improved part-load efficiency to reduce energy consumption. Other key features of the units include high efficiency EC condenser fans and EC evaporator plug fans; improved indoor and outdoor heat exchanger surface area for better efficiencies across a larger operating range; and flexible configuration.

K-TIG K-TIG WELDING The K-TIG welding process involves a specially controlled high current arc which opens a full-penetration keyhole in the join between the two surfaces to be welded. K-TIG keyholes have extremely high stability and operate over a wide range of welding currents, travel speeds and setup is extremely straightforward. The process uses self-induced effects to generate a plasma jet. There is no orifice, making the process extremely simple to manage and optimise. Just one welding gas is used, and its flow rate is not critical. It is a low distortion process. Unlike plasma, laser and electron beam welding, it is tolerant to imperfections and creates a highly stable, self-correcting fullpenetration keyhole across a wide range of metals. K-TIG provides results across a wide range of exotic and conventional materials including titanium, zirconium, stainless steels, hastelloys, niobium, ferroniobium alloys, inconel, incoloy, nimonic, cobalt alloys, nickel alloys, super alloys, monel, bisalloys, andcarbon steels. The welding system can capture detailed weld data for every weld performed. It stores this information in the cloud for complete weld data traceability, monitoring and maintenance.

TECHNOFAST POWER GENERATION TECHNOLOGIES EZITITE TR & CAMNUT TURBINE CLOSURE SYSTEMS The bolting of heavy rotating equipment used in power generation presents a range of difficulties. Fossil or nuclear fuelled equipment necessarily operates at elevated temperatures; for example ultra supercritical steam turbines have inlet steam temperatures in excess of 600°C. As steel bolts have reduced tensile properties at such temperatures, bolts have to be very large, numerous and placed closely together to be capable of resisting the massive forces attempting to separate the two shell halves of the turbine casing.

24 APRIL 2014 Manufacturers’ Monthly

Technofast’s products replace the existing nuts with custom fasteners which allow the use of hydraulic pressure to precisely elongate the bolts and fix them in place. Depending upon the application, either an EziTite TR Hydraulic Nut or the CamNut system can be used. For large steam turbines, CamNuts are recommended, and closure of a steam turbine half-joint can be accomplished in around six hours. The use of Technofast’s EziTite TR fasteners is intended to reduce service times and therefore increases availability and electricity production. According to the company, large GE 7FA series turbines have been completely bolted in ninety minutes using this technology.

LIQUIP API800 SERIES LOADING COUPLER The API800 series loading coupler is a bottom loading dry-break coupler with automatic latching that is used to load the compartment of a road tanker from a fuel terminal. It is intended to represent the next generation of loading coupler. The loading coupler can be used on a range of fuels and has been developed so that the base components can be easily configured to suit a range of operations, either by changing the material of the O-rings or changing the length of the operating handles to suit geographical market needs. It is intended to increase site safety by minimising product leakage during disconnect (less than half of the specified standard allowance). It is designed to deliver fast in-field replacement of all seals on or off the loading arm, as well as quick and easy maintenance without removing the coupler from the loading arm. It features a face seal and poppet seal combined in one seal assembly. This is intended to facilitate inspections and preventative maintenance. It also has a stainless steel collar and hard anodised body for increased service life and durability.

MODULAR WALL SYSTEMS ACOUSTISORB Modular Wall Systems’ AcoustiSorb panels are designed, manufactured and tested in Australia to ISO9001 quality standards. According to the company, it used its knowledge of composite modular practice to develop the first complete absorption and structure solution. The panels are environmentally sound, with a core made from Expanded Polystyrene (EPS) and absorption from recycled PET plastic. PET’s are manufactured from thermally bonded polyester fibre. The perforated outer skin (to the noise source side) uses Australian made Steel with a minimum open perforation to achieve the desired noise absorption coefficient. Coupled with a prefinished external skin or FC sheet, it enables all-inone installation.

manmonthly.com.au

MA0414_000_BOC

2014-03-17T19:39:47+11:00

Supporting innovation and success BOC is the proud sponsor of the Australian Industrial Product of the Year category in the 2014 Manufacturers’ Monthly Endeavour Awards. It is fitting that we are supporting the category which recognises innovation in new industrial products, as it is something that is very close to our hearts at BOC and an important hallmark of our own business. At BOC we aim to be admired for our people, who provide innovative and sustainable solutions that make a difference to the world. These awards

reflect and promote the same kind of spirit, and we acknowledge the terrific efforts of all entrants who share our passion to excel. BOC wishes all finalists the very best of luck in the ninth annual Manufacturers’ Monthly Endeavour Awards and encourages all businesses, big and small, to strive for continuous improvement with commitment, courage and creativity.

BOC Limited

Riverside Corporate Park, 10 Julius Avenue, North Ryde, NSW 2113 Australia boc.com.au |131 262 BOC is a trading name of BOC Limited, a Member of The Linde Group. © BOC Limited 2014. MP13-0350-3|ML|MM|0414

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A Member of The Linde Group

MA0414_026

2014-03-17T18:08:32+11:00

EndeavourAWARDS

PROUDLY SPONSORED BY

BUSINESS TRANSFORMATION

ACTRON ENGINEERING Actron Engineering was formed on 1984 at Winston Hills in Sydney’s North West. The head office and manufacturing facility, located at Bella Vista in Sydney’s northwest, covers more than 2 ha. The 10,500m² world-class manufacturing facility includes a sheet metal fabrication line, powder coating facilities, commercial and residential assembly lines, and a world-class R&D facility. To overcome these challenges, ActronAir began setting and implementing a strong and focused five-year corporate strategy. The strategy provided clear objectives, key strategic project deliverables linked to all projects, and transparent Business Performance Indicators (BPI) implemented across all areas of the business. With a strong and clear strategic direction established, the next step was to remove the imported overseas brand from our product offering. This allowed them to refocus on our ActronAir branded products, with an emphasis on delivering technologically advanced, innovative, energy efficient products. The decision was also made to refocus on the channels to market, with an emphasis placed on strengthening relationships and working more collaboratively with industry experts and a range of suppliers.

FPC FOOD PLASTICS FPC was established in 1998. The company has two sites located in Tullamarine and Campbellfield with 40 employees. FPC was limited by large competitors in a low margin and mature market that requires intense capital. In order to compete against very large companies FPC focused on improvement to manufacturing cost base and to identify profitable opportunities. Food Plastics undertook an Enterprise Connect Business Review in March 2011 and the Enterprise Connect Continuous Improvement program in November 2013. Recommendations from original business review in March 2011 were to improve manufacturing cost base of blow moulding products, grow through building strong brand and product expansion, improve leadership and organisational effectiveness, and business site relocation and capital investment plan. In the three years since the first review, business expansion was 54.0% and FPC had diversified their market to a point where we now have products and markets with higher value added margins and profit.

CHEM-SUPPLY Chem-Supply is a chemical supply company formed in 1989 in Adelaide, SA, with two divisions. The Laboratory Division is one of Australia’s leading importers, manufacturers and suppliers of Laboratory reagents. The Specialty Division is a niche provider of imported and locally sourced specialty chemicals for markets such as agriculture, food, beverage, consumer & home care, wine, defence, general industry and plastics. The main challenges lay ahead in the pending retirement of one of the owners and with company morale that plateaued despite good business performance. Chem-Supply underwent a significant transformation of its Vision, Values, Culture, Policies and Procedures. This was done in the context of day to day operations and strategic leadership. This process commenced in 2011 with a strategic review which identified Culture, Values and Vision as well as Leadership and Succession as two key areas requiring attention. The Company Visions and Values, whilst existent but implicit were drawn out, 26 APRIL 2014 Manufacturers’ Monthly

clarified and documented. The results have seen morale and staff satisfaction reach new high levels, staff turn-over and absenteeism have reduced and efficiency in key areas like production and warehouse are increasing.

ARMSIGN Armsign signage manufacturer located in NSW’s Northern Rivers at Goonellabah, with over twenty seven years of experience. The company’s main clients tend to be government-funded bodies from all parts of Australia, such as National Parks, Marine Parks, Landcare Groups, Councils, Botanical Gardens, historic societies and other agencies. Other main products seld to these clients have been long lasting outdoor signage. Although Armsign was a respected and experienced company the business had started to flat-line, with a number of issues that had to be addressed. Continuous improvement and lean manufacturing methods were able to work through issues in small steps. Stripping the factory of three truckloads of rubbish, un-useable stock and historic data created in the region of 25 percent more working space. New KPIs and other measurements were brought in. Results have included an increase our turnover of 35%, profits up from 2.2% to 17.7%, reduced our lead times from four to six weeks down to three weeks. The number of jobs taken on increased by 10%.

THE SHOTTON GROUP The Shotton Group was established in 1977 with eight staff and today employs 90 people, spread over three rented premises in Dandenong South, Victoria. Its sales are spread over four distinct market segments: Sheetmetal Fabrication and Design (62% of sales this year); Home and Small Industrial Passenger Lift design, manufacture and installation (18%); Mortuary Equipment design, manufacture and installation (18%); Dry Goods Material Handling Equipment design, manufacture and installation (2%). Shotton employed Enterprise Connect to conduct an independent assessment of all aspects of the business. Establishment of the other divisions provided the company with a form of insurance in the event of a downturn in the core fabrication business. Enterprise Connect provided the company with information including customer feedback, product definition, and marketing. The last six months saw the development of new logos, employment of more sales staff, and the beginning of Dry Goods Handling product sales and manufacture. Shotton is on track to achieve total sales of $17 million this financial year - an increase of 28 percent on 2012/13.

manmonthly.com.au

MA0414_000_DEP

2014-02-28T11:36:02+11:00

2014EA-MM04

Give your business a competitive edge. Success in business has a lot to do with making powerful connections and getting the right advice. Our experienced, independent Business Advisers work with you to review your business potential. They help you make the right connections and build a more productive, innovative and globally competitive business.

131 791 | enterpriseconnect.gov.au

MA0414_028

2014-03-17T18:08:32+11:00

EndeavourAWARDS

PROUDLY SPONSORED BY

EXPORTER OF THE YEAR

COOK MEDICAL AUSTRALIA Cook Medical Australia is a Brisbane-based company which is part of the world’s largest privately owned medical device company. In 2013 Cook achieved export sales of goods and services of $105.5 million, equating to 91.2% of Australian manufactured products exported overseas. This is an overall growth of 31.1% on by value on exports the previous year. Cook differentiates its offering by exporting patient-specific products designed to address anatomical limitations and hence improve patient outcomes. In 2013, Cook became the first company in the world to secure FDA approval to sell Fenestrated Endovascular Grafts in the US. In the past year, they have also laid groundwork for expansion into Indonesia, Vietnam and the Philippines. Recently Cook has spearheaded a campaign calling for the introduction of an Australian Manufacturing and Innovation (AIM) Incentive to support Australian exporters. The incentive has secured support from the Export Council of Australia, Ausbiotech, and the MTAA, and generated positive media discussions around the need to encourage the retention of Australian IP and local production.

RØDE MICROPHONES Founded in the early 1990s, RØDE originally focussed on the burgeoning home music studio recording market. Founder Peter Freedman quickly realised that owning the manufacturing capabilities would provide increased economies of scale and ensure a barrier to entry for competitors. RØDE Microphones is based in Silverwater, in the outer suburbs of Sydney, where its product design and manufacturing facilities are housed alongside supporting business functions including the company’s in-house marketing department. Just over a decade ago the company acknowledged an emerging market in home video editing and entered the broadcast audio market segment, subsequently becoming the defacto standard for on-camera audio around the world and growing its export business to be over 90% of all manufacturing. All of RØDE’s products are designed in Australia, and over 85% of products are manufactured here. RØDE has previously been named 2012 NSW Exporter of the Year award and Australian Export Awards’ Manufacturer of the Year 2013. With total revenue growing by more than 20%, this Australian company is an international success story.

For Australian manufacturers as a whole, Micreo’s continuing success has proven that industry can remain viable even in difficult economic times.

LONGWARRY FOOD PARK Longwarry Food Park is a dairy business based in Gippsland region of Victoria. The company converts fresh milk from the region into various products for domestic and export market. Their products are sold in all three major supermarkets in Australia (ALDI, Woolies and Coles) and exported to over 30 different countries around the globe. From purchasing a sick plant in 2001 and being a one-product company with with a turnover of $1 million that year, Longwarry has grown into a multi-product company and projects a $85 million turnover in 2013-14. The plant’s obsolete, uneconomical technology has been converted to an energy efficient, increasingly productive growing site. The plant has been upgraded from 2.3 MT/hr to 6.0 MT/hr using inhouse technology. Longwarry’s products are Full Cream Milk Powder (Export), Cream Cheese (export), UHT Milk (Export and Domestic) and Fresh Pasteurised Milk (Domestic). The last three production lines were installed over last two years and was motivated by the desire to diversify and to produce value-added products.

ENWARE AUSTRALIA Enware Australia is a manufacturer and distributor of a wide range of high quality products in the specialist plumbing, health & safety, adaptable living, environmental, water metering and washroom systems markets. Enware is 100% Australian owned and managed, with three local manufacturing sites and sales offices throughout the country. Enware is represented in major regions throughout the world including Asia, the Pacific, Middle East and Europe. The company has the capability and capacity to design and build high quality products that meet harsh Australian conditions, and are compliant with local and international standards and regulations. The company’s facilities are certified to standard ISO9001 and many products WELS (Water Efficiency Labelling Standards) rated. Enware recently successfully carried out on a project to design, manufacture, surface protect, supply and deliver over 700 safety shower units and associated equipment for the Ma’aden Aluminium Refinery project in the Kingdom of Saudi Arabia. This was, according to Enware, done “with very little disruption to our normal day to day manufacturing... a great testament to the company as a whole.”

MICREO LIMITED Founded in 2002, Micreo is a specialised designer and manufacturer of high performance microwave and photonics sub-system products for defence. Micreo is the only manufacturer of such products using bare chip technology in Australia. In the last year, Micreo has demonstrated success as an exporter with two key contract wins: a repeat order from Micreo’s first ever customer for over $2m for 3 different products. The company also won a new design and manufacturing order from a US customer which was won by Micreo bidding against eight US based competitors. The latter has the potential to grow Micreo to more than three times the current company size when it reaches the production ratesforecast by their customer. Micreo currently exports over 85 percent of its production, mostly to the United States but also to Europe and the Middle East. 28 APRIL 2014 Manufacturers’ Monthly

manmonthly.com.au

MA0414_000_EFI

2014-03-13T13:27:50+11:00

CONGRATULATIONS TO ALL ENDEAVOUR AWARDS FINALISTS

Export Finance and Insurance Corporation (EFIC) is the proud sponsor of the Endeavour Exporter of the year Award. As Australiaâ&#x20AC;&#x2122;s export credit agency, we support the growth of Australian companies in their international activities by providing tailored financial solutions when banks are unable to. We assist a variety of Australian-based businesses: exporters, subcontractors to Australian exporters and those looking to invest overseas. To find out if EFIC may be able to help you, contact us on: 1800 093 724 or visit our website: www.efic.gov.au

MA0414_030

2014-03-17T18:08:32+11:00

EndeavourAWARDS

PROUDLY SPONSORED BY

GLOBAL INTEGRATION

CABLEX Founded in 1985, Cablex is Australia’s leading, globally recognised manufacturer of custom cables and harness assemblies, serving industries including defence/ aerospace, transportation, telecommunication, and electronic. Cablex is AS9100C, ISO 9001:2008 and ITAR compliant, a highly accredited ‘one stop shop’ for both complex and standard cable solutions, and a proven, low risk, established global supply chain partner for International primes such as Northrop Grumman, USA; Eurocopter, France; and Airbus Military, Spain. Its manufacturing and customer support centres are located in Melbourne (Headquarters- ITAR specific project work), Bangalore, India and incorporated in the US. Currently, over 50% of Cablex’s manufacturing is exported. In 2003 Cablex took the strategic decision to expand its capabilities into highly specialised wiring harnesses in Defence and Aerospace, and invested in new capabilities, up-skilling resource and procuring high end innovative equipment, providing a competitive edge which complimented our expertise in the transportation, telecommunications and electronic industries. Within a couple of years Cablex seized on various Aerospace/Defence opportunities including the contract to develop, manufacture and supply aerospace grade harnesses to Northrop Grumman, USA for the Australian Wedgetail program and the Airbus Military MRTT platform. Over the last 10 years Cablex has established various strong and successful long term partnerships, and are now looking to support the JSF (Joint strike fighter) project which will engage them with four additional global companies.

MICREO Micreo is a specialised designer and manufacturer of high performance microwave and photonics sub-system products for defence. Micreo is the only manufacturer of such products using bare chip technology in Australia. Micreo’s key to success in the microwave Electronic Warfare sub-systems market is reliability of supply. Micreo, a start-up company of 17 people in 2002, has grown to 72 in 2014 (with 14 design engineers and over 40 manufacturing and technical staff), and has achieved nearly 20% compound annual growth in that period. Micreo has transformed itself into a world-class designer and manufacturer with ability and reputation to successfully compete internationally. Micreo has had a substantial amount of export sales since the company was started in 2002 and over the past four years the proportion has risen to over 85%. mostly to the United States but also to Europe and the Middle East. Micreo was one of the first SMEss to become involved in the Defence Materiel Organisation-sponsored Global Supply Chain Program and recognised that participation would increase their visibility to major international defence and aerospace prime contractors and have access to program opportunities. By directly engaging with the international supply chains of key defence systems integrators, Micreo has won two key design contracts. One of these has so far provided over five years of follow-on production, and the other more recent design win has the potential to provide substantial revenue growth with similar long-term production prospects.

RPC TECHNOLOGIES Established in Australia for over 30 years, the RPC Technologies Group (RPC) offers an integrated, engineered and manufactured range of composite products for clients in the infrastructure, environment, resource, energy, transport and defence industries. It has four Australian manufacturing facilities and overseas factories in Indonesia and Malaysia. RPC offers a selection of materials and processes, full design service, mock ups, develop pre production prototypes and paint GRP composite ballistic proof cabins. It also offers a complete ‘modularisation’ of front ends and driver’s cabs that lead to significant cost and time savings for passenger rail car builders. Processes include resin infusion, carbon fibre, contact mould, closed mould and meet standards EN 12663, EN 15227, BS6853, NF F 16-101, AS1530.3 and EN 45545-2. RPC’s Batam, Indonesia plant was tasked with providing composite components to our Broadmeadow NSW facility for the Sydney Trains Waratah drivers cabin. Their Glass Reinforced Plastic (GRP) Composite experience with the Sydney Trains Waratah Ballistic Proof Drivers Cabin enabled RPC to bid and win GRP based product contracts and government support for further projects. Other projects include the Bombardier Queensland FLexcity-2 Gold Coast Tram contract, Victoria VLocity carriage vanity modules contract, production of Sydney Cricket Ground 2 new grandstand roof components, Queensland Coal Seam Gas composite pipe contract, Sydney, Melbourne and Brisbane Desalination plants pipe supply and maintenance, Thales Hawkei next generation vehicle in Australian protected mobility vehicle GRP light weight components supply contract, and successful new product introduction of carbon fibre composite mine ventilation pipes.

MARAND PRECISION ENGINEERING The US$400 billion F-35 Joint Strike Fighter program may well be the largest single global defence program in history. Marand’s contribution to the F35 program has been aa “Best In Class”, competent and proven Tier 1 supplier/exporter of highly engineered complex equipment, systems, ground support equipment, tooling and automated solutions. Lockheed Martin first meet Marand in 2002 and recognised Marand’s unique mix of multi industry knowledge, breadth of experience, people/skills, especially in aerospace and automotive. Marand have expertise in dealing with high precision and high volumes. Over the last 10 years, Marand’s exports exceeded AUD$100 million. The company is the global sole source, design authority and manufacturer of unique, complex GSE for F135 engine removal and installation trailer. Marand remains Australia’s only privately owned aerostructures business.

30 APRIL 2014 Manufacturers’ Monthly

manmonthly.com.au

MA0414_000_ICN

2014-02-26T11:01:33+11:00

All the right connections for the manufacturing industry. When it comes to finding new business opportunities, one of the biggest challenges can be breaking into new or existing supply chains. Industry Capability Network (ICN) is an organisation that introduces local companies to the supply chains of major projects. Even if you’ve never imagined your business supplying goods and services to a major state or national project, ICN could uncover an opportunity that’s just right for your business. With more than 29-years experience helping Australian and New Zealand manufacturers find opportunities in major projects, ICN is a great place to start when looking to expand your business. ICN consultants have a thorough knowledge of existing and planned projects. So, if you’re looking to expand your business opportunities go to www.icn.org.au or call your local ICN office on 1300 961 139

ICN0316_MM_Press_Feb14_V2.indd 1

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MA0414_032

2014-03-17T18:08:32+11:00

EndeavourAWARDS

PROUDLY SPONSORED BY

MOST INNOVATIVE MANUFACTURING COMPANY

SEELEY INTERNATIONAL Founded in 1972, Seeley International is Australia’s largest air conditioning manufacturer and global leader in developing energy-efficient cooling and heating products. Their vision is to lead the world in creating climate control solutions which continue to be highly innovative, of premium quality and inspirational in their delivery of energy-efficiency. Recent innovations include the world’s first “Super-Six” ducted gas heater (the most energy-efficient conventional ducted gas heater in the world) and Australia’s first touch screen MagIQ Touch Controller for the evaporative cooling range of products. Seeley’s success in delivering on that commitment has been recognised by many awards and an expanding global presence, exporting to over 120 countries worldwide. In 2012, Seeley International launched the world’s first six star ducted gas heater and the world’s first five star non-condensing ducted gas heater from Braemar and in 2013; the company launched the world’s first ‘Super-Six’ ducted gas heater. Today, Seeley International is the largest, most vertically integrated, manufacturer of air conditioning appliances in the southern hemisphere.

KEECH From its traditional foundry beginnings, Keech Australia now employs the latest technology in design, research and additive manufacturing to produce carbon neutral steel castings for the global mining industry. Its annual revenue is $50 million, and 60 per cent growth has been achieved over the last four years as the company has transformed rom a foundry to a global provider of innovation, services and products. Opened May 2012, Keech’s Innovation and Quality Centre is where it researches and develops solutions. The centre is a hub where metallurgists, scientists, innovators, patternmakers and QA specialists work together developing new products to combat customer issues in the field and continuously improve products and processes. Keech employs six full-time staff in its innovation division and five in its QA team, under the leadership of international metallurgy and foundry specialist Dr Bala Hebbar. It invests over 7 percent of sales revenue every year on R&D through the Innovation and Quality Centre. Over the next five years aims to grow the value of this centre and ensure that 50 percent of the products sold are less than two years old.

AUSTUBE MILLS Austube Mills began in the 1930s, and its Somerton site founded in 1995. It currently employs 300 in Australia and 95 per cent of its products are locally made. Austube Mills is the largest Australian manufacturer of a broad range of highquality structural steel pipe and tube products third-party certified to Australian Standards. Its Somerton site manufactures structural steel tubular products and is also home to the only inline galvanised cold roll profile mill in Australia. The employees at the Somerton site have an operating model that is based around high performing self-managed teams. To counter the downturn and boost morale, an internal ‘people’ strategy was

32 APRIL 2014 Manufacturers’ Monthly

undertaken that would later be known as The VIBE, led and developed internally by members of the site lead team. This drove massive benefits in terms of attendance (43 per cent reduction in hours off work), quality (67 per cent reduction in customer complaints, 2 per cent increase in yield), and productivity (20 per cent improvement across plant). Over $1.5 million dollars to the site’s bottom line annually.

MODWOOD TECHNOLOGIES ModWood was set up in 2001 with its first manufacturing plant located in Reservoir, Victoria. We were the first wood plastic composite manufacturer in Australia. ModWood is committed to conserving the Australian environment, as it avoids the use of imported tropical rainforest decking and diverts waste from landfill. Ninety percent of the board weight is made from reclaimed wood fibre and recycled plastic milk containers. As ModWood was the innovator this required a lot of product development to ensure the product would perform in the harsh Australian environment. Both the machinery and the chemistry were evolving as the business was growing. Recognising both the gap in the market and the longer-term potential for future growth of bushfire-resisting building products, ModWood set out to develop a sustainable, innovative timber-like fire-resisting WPC board. To maintain ModWood’s market leader status in Australia, and to strive towards the goal of a “Utopia” board, ModWood is also continuing to innovate its product range, exploring board finishes, scratch protection, and development of ancillary products such as railings.

SEVAAN GROUP Sevaan Group formed in 2011 when a new management team bought and amalgamated two longstanding Australian fabrication companies, Proline Technologies and Wisby & Leonard, both then struggling. The amalgamation under Sevaan returned solid profits, saw the development and patent of successful industrial/consumer products (domestically and in export markets). At a time when a lot of fabrication companies are downsizing, Sevaan expanded by setting up its own blast room facility and spray booth facility (each at a standalone address), high tech CNC machines and milling equipment, world class benders and more apprentices. The company has publicly thrown out the challenge that its ROI can almost always be a better return than going to cheap labour countries offshore, primarily due to speed of turnaround and adherence to strict Australian Standards. The innovation comes through the business intellect of the management group, and it works very closely with its bank in planning and plotting an organised course with a constant eye on industry changes.

manmonthly.com.au

MA0414_000_SEW

2014-03-05T13:22:48+11:00

Gearmotors \ Heavy Industrial Solutions \ Electronics \ Decentralised Systems \ Services

Proudly sponsoring the ‘Most Innovative Company’

No Matter What You Move: We Drive It SEW’s energy saving solutions can help your plant reach its energy saving potential, all the while lowering overall production costs. SEW’s energy saving solutions are based on the proven SEW modular concept, from high efficiency AC motors coupled with highly efficient gear units, to premium efficient mechatronic drive systems. While one individual energy efficient drive component can achieve satisfactory energy balance, it’s only the optimised combinations adapted by SEW’s professional engineering team which can turn energy efficient drive components into impressive energy savers. Energy efficient solutions from SEW-EURODRIVE. Another way SEW delivers. SEW-EURODRIVE- Driving Australian Industry

MOVIGEAR® • Motor, gear unit and electronics are combined in a single housing • Compact design • IE4 Super Premium Efficiency class • Optimum efficiency due to precise matching of all drive components and the use of permanent magnet motor • High degree of protection

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sew mm 4.14 fap movigear conveyor NEU.indd 1

4/03/14 4:50 PM

MA0414_034

2014-03-17T18:08:32+11:00

EndeavourAWARDS

PROUDLY SPONSORED BY

SAFETY SCHEME OF THE YEAR

BOC SOCIAL MEDIA PLATFORMS In 2013 BOC implemented a comprehensive social media program aimed at increasing its interaction with customers by providing industry and product updates, technical tips for the work place and most importantly, a safety resource for its customers. The program consists of promoting retail catalogues through a dedicated e-catalogues tab on Facebook as well as the weekly development and publication of short YouTube videos covering everything from safety tips to specific products and their applications. The YouTube videos are promoted through the company’s Facebook page. To date the most popular video on YouTube has been “How to set up a basic MIG/MAG welder” with 1132 views. Other videos such as “Tips for welding Stainless Steel” and “Heat Affected Cylinders” are also proving popular with our online audiences. BOC has also posted a range of safety oriented videos with topics including footwear protection, cellar and cool room safety, respiratory protection, checking gas hoses and fittings and more.

EHI AUSTRALIA CHILD SAFETY FLYSCREEN From 2011 to 2013, almost 50 children aged nine or younger were hospitalised in NSW after falling out of windows. In response, Sydney-based company Elite Home Improvements (EHI) developed the Child Safety Screen – a locally designed and built insect screen for windows that is capable of holding 250 Nm or 25 kg of force for a minimum of 10 seconds. According to the company, apart from the obvious desire to save children’s lives, their Child Safety Screen was developed to comply with new safety codes. NSW building safety codes now require any window that is more than 1700mm off the ground to have a safety screen that can withstand holding 250 Nm or 25 kg of force for a minimum of 10 seconds fitted. The new codes also require that these screens be regularly tested. EHI has partnered with a local testing laboratory that is certified to carry out the regular testing of the screens.

HYDRATIGHT IN-LINE WELD TESTING AND ISOLATION PACKAGES In-line weld testing and isolation packages from Hydratight are designed to reduce system downtime during maintenance and increase worksite safety by minimising pressure test volumes. The full turnkey testing packages, available throughout Australasia and the Asia-Pacific, are designed to save time and reduce costs by limiting the test area to only new welds or welded components tested during routine maintenance and maintenance shutdowns such as Christmas/New Year. Localised pressure testing is a means of verifying the integrity of a welded or formed joint or flange installation/weld which has been made on a piping system. Typically these are made as a repair or modification of part of a process piping system which is undertaken during plant shutdown activities, says global joint security specialist Hydratight. The company provides certified and experienced technicians to perform the job safely and provides operators a full turnkey testing package, delivering a first-class maintenance solution for facility assets. 34 APRIL 2014 Manufacturers’ Monthly

Hydratight’s qualified and professional technicians provide a safe, reliable and cost-effective means for the localised pressure testing of piping.

KONECRANES TRUCONNECT REMOTE SERVICES TECHNOLOGY Crane service organisation, Konecranes is introducing its Truconnect Remote Services for enhanced safety, reliability and efficiency to Australia. The service provides users with a clear view of their crane’s usage through continuous data collection. For the customer, this means improved safety and higher efficiency because crane maintenance can be planned according to the crane’s actual usage. Usage data is collected from the crane through a remote connection and compiled into web views and customer reports that are available through a secure online customer portal. The portal offers easy access to the historical data of the crane involved, with important crane-specific key figures collected in real time. Overloads, emergency stops and other safety issues are captured and clearly brought to the user’s attention for possible corrective actions, such as operator training to improve the safety and productivity of the worksite. As an additional value-added service, safety alerts, such as hoist overloads, can be delivered to the customer by email or text message shortly after each occurrence.

BRANAGH MANUFACTURING LEVELLER SPREADER Branach has engineered a height safety solution that is intended to reduce the number of ladder fall incidents by providing a base that is three times the size of a ladder footprint. The Leveller Spreader is attached to the foot of the ladder. A quick release mechanism extends the legs. The legs can then be independently deployed to whatever angle is required. This is intended to increase the margin of safety when working on uneven ground and into tight corners. The system can also be utilised in day to day work because of its high level of stability. Users report that, when in use, it feels like the ladder is bolted to the pole, tree, or whatever work area is in use. The leveller spreader was originally a design concept. Then a joint project with Lend Lease saw it used as part of a system for roof access to switch boxes. It is currently in low volume production, with plans to move to full production in three months time.

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TiM5xx: BECAUSE GOOD THINGS COME IN SMALL PACKAGES.

Modern area monitoring systems are complex. Works of art need to be protected, pallets detected, AGVs guided, and buildings kept secure. And as soon as an unimportant object in the monitored area moves, everything needs to be reset. It's enough to drive you crazy! Fortunately TiM5xx clears the air. A territory of 10 metres in a tiny package not even ambient light can confuse, a choice of configurable fields or raw data, insanely easy networking - and in such a small package. We think thatâ&#x20AC;&#x2DC;s intelligent. For more information please visit www.sick.com/TiM5xx or call 1300 405 807.

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EndeavourAWARDS AUSTRALIAN STEEL INNOVATION AWARD

K-TIG Headquartered in Salisbury, SA, and using technology developed by the CSIRO, K-TIG is the only Australian manufacturer of welding systems. K-TIG is a high speed, single pass, full penetration welding technology that eliminates the need for wire, edge beveling or skilled operators and produces flawless welds up to 100x faster than TIG welding in materials up to 16mm in thickness. K-TIG designs, manufacturers and markets its equipment. The company has unique expertise in advanced physics and materials science which has enabled it to develop a technology which has eluded even the largest companies in the $20B welding equipment market. K-TIG has been formed with the sole purpose of commercialising the keyhole TIG welding system, and is developing a high caliber international distribution network and has fulfilled orders in 6 countries including Australia, UK, Norway, United Arab Emirates, India and China and will fulfill orders in Malaysia shortly.

MODULAR WALL SYSTEMS Modular Wall Systems is the industry leader in innovative and cost-effective acoustic & boundary walling solutions. The company, based in Caringbah NSW, has gone from strength to strength over the past 15 years to become the national market leading manufacturer in its sector. As the original inventors of the modular boundary wall concept and with more than 8,000 projects completed across

Australia, Modular Wall Systems is the national benchmark company in the industry. The AcoustiSorb panel is the latest addition to the company’s commercial range and is an all-in-one composite panel, prefinished and ready to install. The AcoustiSorb Screen provides a minimum NRC rating of 0.9 and acoustic RW28 + capability. Modular Wall Systems purchases all steel required for manufacture from OneSteel and BlueScope Australia.

TECHNOFAST INDUSTRIES Technofast is a privately owned, Queensland registered company with its headquarters and manufacturing facility located in Richlands, an industrial precinct in the Western Corridor of Greater Brisbane. The company designs, manufactures and distributes its proprietary range of bolt tensioning and industrial fasteners both nationally and globally via a network of representatives. Technofast has a strong history of innovation, and maintains a core of intellectual property consisting of Australian and international patents, registered trademarks and designs. It has achieved notable success with the development of products such as the “HydraNut” High Temperature Hydraulic Nut and the “Cone Nut” System. These products were introduced by Technofast for use in the global Commercial Nuclear Power Generation markets, and are now marketed internationally by the CurtissWright group.

YOUNG MANUFACTURER OF THE YEAR

PHILIP WYSOCKI Philip Wysocki works at ANCA’s Melbourne Head Office as an Electrical Systems Engineer and Project Manager. From the start of his career Philip has excelled. He came to ANCA with a 1st Class Honours in his Bachelor of Engineering (Scholars) Degree in Mechatronics Engineering at the University of Wollongong. He came first in Mechatronics and was on the Dean Scholars List in his second and third year. Philip has delivered on all the projects he has undertaken and provided the company with significant cost savings and quality improvements. He implemented new software and processes that significantly improved the development of new products in his section. He is currently project managing an important new product that is anticipated to be very successful.

ANDREW BEAL Andrew Beal is a Senior Electronics Engineer who has been a part of the engineering team at Hydrix for over three years. Andrew is responsible for many aspects of the product development lifecycle, from initial stakeholder discussions through to architecture, design, regulatory compliance and manufacture. Andrew is solely responsible for the manufacture and production of the complex and highly sophisticated Radio Interface Unit. The $3m RIU device, designed, manufactured and to be supplied by Hydrix, forms a key part of the high profile Digital Train Radio System project being built by for Siemens and the Victorian Department of Transport. Originally from an automotive background, Andrew has designed and manufactured many products across many industries, including automotive, biomedical, consumer and rail, many of which are visible in the market today. 36 APRIL 2014 Manufacturers’ Monthly

JOSHUA PORTLOCK Joshua Portlock brought the original CyberQuad intellectual property to the company and spent many late nights optimising CAD to best utilise the exotic selective-laser-sintering manufacturing method until the desired structural and aerodynamic shape was achieved. This involved extensive flight testing and experimental load analysis to find the optimal balance between toughness for durability and lightness for maximum flight time endurance. As well as designing prototype CyberQuads and developing production grade systems, Josh also endeavored to assess and approach the market throughout the process, to ensure customer acceptance and satisfaction. He was promoted to CEO in early 2013 at the age of 29, in recognition of ability to successfully commercialise the CyberQuad UAV (unmanned aerial vehicle) technology.

EMIN BOYNUKISA Emin Boynukisa is one of Cablex’s most talented young Project Engineers, and his initiatives and contributions have resulted in Cablex’s increased international standing through the development of a variety of new and unique manufacturing solutions. He has been able to increase efficiencies throughout the Cablex manufacturing process, which has resulted in a reduction in manufacturing time of approx 5% and a reduction in testing time of around 8%. He was responsible for Cablex’s increased cable production capabilities. Cablex describes his contributions and “pivotal to the success” of various programs and general process improvements. Boynukisa has developed and implemented several innovative manufacturing techniques and methods for the production of leading edge cable technologies for the global F35 Joint Strike Fighter program. manmonthly.com.au

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EndeavourAWARDS O RE YA CO HF I ET VHEEM YE EN AT R LC IAFTEET GI M

GEORGE HELLYER George Hellyer began with the company as a patternmaking apprentice and as he developed he became wood patternshop foreman. Through a series of promotions he eventually became a director of the company. In 1955, Hellyer manufactured sand production tooling for the tap industry and entered it to the Apprentice of the Year awards. His success in this program was as a result of him being the first apprentice of the year. Hellyer won the Victorian Overseas foundation Scholarship and, on his return, the company had begun to direct its attention to automated automotive foundry tooling work. Bell’s persistence culminated in it being the first company in Australia to produce automotive high volume pattern tooling. The success of this, together with George’s overseas knowledge, assisted the company to grow and develop. By 1972, A.W. Bell had nearly 85% of the Australian car engine tooling market. George grew with the company and was heavily involve in apprentice training, probably training some 100 wood and metal apprentices in his time. One of his protégés won the silver medal for patternmaking at the Japan Skill Olympics. He has also trained approximately 100 apprentices, many of whom began their own businesses, was on the RMIT foundry and pattern school advisory committee, and has written many papers assisting the apprenticeship commission on training requirements.

JOHN GUEST John Guest is the managing director of Jubilee Springs, one of the few remaining spring companies in Australia. He started in 1973 after his father died and after finishing year 9 at school. He became a fitter and machinist and worked his wat through the company, starting at the factory floor. Among his milestones are decentralising the company from Sydney to the Central Coast, where he managed the building of three new factories. He oversaw the taking over of several companies including 4 Slide Forming, Peerless Pegs, and C&K springs. He has seen Jubilee grow from 5 employers to over 40 employees, and the company is still going after 75 years of manufacturing within Australia. It has an ongoing commitment to investing in Australian apprenticeships and retraining. Jubilee is proud to be the longest standing spring manufacturing company in Australia, and is a multi-generational family business with the third generation now heavily involved in the business. Guest’s overall dedicated service to the business runs to 41 years. Other accomplishments along the way include reintroducing an innovative Australian-made mouse and rat trap to the industry after Standfield closed, being Vice President of the Australasian Wire Association for 5 years, President of AWIA for 2 years, and helping to establish the AWIA spring training course. He is the current present of AWIA since Oct 2013.

RAKESH AGGARWAL Rakesh Aggarwal is the managing director of Longwarry Food Park, buying and transforming a sick milk powder plant in 2001 and turning this into a thriving enterprise, with production beginning in 2006. He not only grew business but expanded capacity and diversified. Longwarry expanded capacity from 2.3 MT/hr to 6 MT/hr with innovation and in-house work. It diversified from one product (Full Cream Milk Powder) to four products (UHT, Cream Cheese and Fresh Milk). Aggerwal was responsible for engineering, innovation, expansion plans and investing his own funds. Improvements such as energy cost per unit production being cut by 70%, water usage cut to 0.8 L/Litre (compared to industry average of 1.55 L/Litre), and major projects including production of UHT milk, fresh milk and cream cheese, a coolroom, two large warehouses and MVR building were completed. Labour costs were reduced with automation and now Longwarry Food Park is probably the most labour efficient plant in the country. Longwarry has received awards including Exporter of the year 2011, Governor of Victoria export award; BRW’s fastest growing business in 2008; and My Business magazine’s Business of the Year. Longwarry has also contributed significantly to the local community through assistance to local clubs and social organisations, and educational seminars for the region’s farmers.

MIKE RICH Mike Rich started in manufacturing with what is now Fonterra (the world’s largest diary company), then in meat processing and the oil industry where he learnt computer programming. Armed with a commerce degree, he moved into smart manufacturing developing software that has helped over 30,000 SMEs, including manufacturers, improve business performance. Attaché is one of the most successful local smart manufacturers, twice winning Software Product of the Year. Mike’s been the managing director and major shareholder for 27 years, moving into the cloud several years ahead of others. Now in his 60s, he recently received two Business Leader awards and, to give back to society, he funds the M Institute which aims to double the number of medium-sized firms, growing jobs and GNP in the process. Mike confirmed that the average SME has 12% or more of its cash flow locked in inefficient processes and systems, restraining growth. Rich is Attaché’s managing director, major shareholder and ‘chief engineer’ behind its business transformation process, plus the voice behind the M Institute that aims to double the number of medium-sized firms.

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DesignSOFTWARE A brand new concept The big news at SolidWorks World 2014 was a product that the software company hopes will change the way its customers get their projects underway. Brent Balinski reports.

echAnicAl conceptual was, as it was last year, the main announcement at SolidWorks World, but the 5,000-plus attendees this time around got something that 2013’s guests didn’t: a release date, at least for north America and europe. “We were really surprised, almost four years ago, actually, to find out that customers - okay we knew they did conceptual, but we realised they didn’t use SolidWorks to do conceptual, even if they had SolidWorks in-house,” explained Kishore Boyalakuntla, director of product management for next Generation Products at Dassault Systemes SolidWorks. The popular mechanical engineering software, which claims well over 2 million customers worldwide, believes that its users specialising in industrial machinery will benefit hugely from the release. According to SolidWorks, 31 per cent of project time is spent in the concept phase, averaging six different iterations during this. Mechanical conceptual - SolidWorks’ first product using parent company Dassault’s 3DeXPeRience platform - aims to supercharge productivity in conceptual design. how? collaboration. “if you buy SolidWorks Mechanical conceptual you can create, let’s say, Project A - you can create a community with just two of you on it. And all communication between both two of you is confidential,” Boyalakuntla told Manufacturers’ Monthly. “Then you can create a community with your marketing. You can create a community with your director. You can create a community with your educators, you can create a community with your supply chain. You can create a community with your procurement, and with your end customer.” Mc enables real-time sharing of designs and ideas. Stakeholders only need a subscription and a robust internet connection. 3G speeds are 38 APRIL 2014 Manufacturers’ Monthly

sufficient, says the company, so long as the connection is reliable. “Stakeholders can take advantage of the same tools that have built social networks,” explains a white paper from SolidWorks, with instant messaging, chat, “like” judgements etc. used to give feedback during the process. Social innovation during product development allows feedback from a market way before anybody has even thought of, say, prototyping. The company predicts this to be “game changing”. The upcoming release is complementary to SolidWorks, and not a replacement, the company repeatedly stresses. With around 2.2 million users, many of whom are very happy with their product, SW doesn’t want anybody to think their favourite 3D design software is going to disappear. There are similarities and differences between Mechanical conceptual, which uses Dassault’s cGM kernel for catia software, and SolidWorks, which uses Siemens’ Parasolid kernel. Some have raised concerns about translating models from the new product to SolidWorks. SolidWorks believes moving from one product to the other is simple, with many of the features in SolidWorks 2014 added with Mc in mind. “For example the viewing tool in SolidWorks 2014 when you hit the spacebar and you get this nice cube and you click, that comes from Mechanical conceptual,” explained Boyalakuntla. This switch between products wasn’t that big a jump to make, with only “porous walls” to move through. “Today in aerospace companies they have, for example, for machine design they use SolidWorks and they use catia for systems,” he noted. “We have customers who do that today - a mixed environment... Mechanical conceptual makes it really easy to open catia files, because it’s the same format… So we see a mixed

FASTFACTSFASTFACTS

Mechanical Conceptual • Complementary to SolidWorks and not created to replace it. • Uses certain social media principles to promote innovation at the concept stage, with models shared in real time. • The first SolidWorks product to run on parent company Dassault Systemes’ 3D EXPERIENCE platform. • Uses DS’s CGM 3D kernel, with no associativity between the new offering and SolidWorks. environment, depending on what the customer is doing.” Another major consideration is cost. There has been no price given for Australian users yet. The US price on the April 2 release date will be $US249 per user per month. Assuming a similar price, would Mc be attractive to an Australian business that might benefit from it? “it’s the old price/value equation and i don’t know how much it will cost to do a conceptual design and share that on a monthly basis,” Mark DeereJones, director of sales & marketing at intercad, told Manufacturers’ Monthly. “But i would see the ROi to be very quick.” he added Australia, with its geographic spread and distance between many stakeholders within some businesses, could be an environment where a such remote collaboration tool might be very attractive. “in Australia one of our penalties is distance, so i think that’s a huge benefit and opportunity for the customer,” he said. “And from where i see some excitement is i think it will bring a lot of new people into the 3D cAD space.” Asked about whether the price might be too much to bear for potential Australian customers, SolidWorks ceO Bertrand Sicot also talked price vs value. “You have to understood that

Mechanical conceptual is aiming... where all the innovation happens, where if you do a big mistake, you take the wrong option, it costs you a lot of money down the road,” he told Manufacturers’ Monthly. “i understand your question when you look at the price. But the challenge for us is to make sure the customer understands the value in front of that.” Besides the automatic saving of ideas, there was another saving to be recognised through cloud-based Mc. “We are moving part of the cost to us,” said Sicot. “Because you can basically run Mechanical conceptual from a desktop... much cheaper than the one you have to buy with a big graphical card etcetera so cost of ownership has shrunk.” And like any other new product release, the price was a result of careful consideration. “There is a reason we have come out with $250 a month,” said Sicot. As for when Australian users might be able to add Mechanical conceptual to their armoury of design products, when the question was asked during SolidWorks World 2014, Sicot said Dassault had yet to establish a local cloud for Asia Pacific, and was looking for suitable locations to host it. “i would say late Q3. it’s a question of having the local cloud available for Asia Pac. The project is ongoing. We are looking at places either in Taiwan or hong Kong to host it. So that’s exactly where we are.” Manufacturers’ Monthly attended SolidWorks World 2014 as a guest of Dassault Systèmes SolidWorks. [Brent Balinski writes for Manufacturers’ Monthly on a broad range of topics. He has a special interest in 3D Printing and innovation. Contact him at google. com/+BrentBalinskiCirrusMedia] manmonthly.com.au

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NMW Preview 13-16 MAY 2014

Sydney puts high tech future on show National Manufacturing Week (NMW) is constantly evolving to reflect the latest trends. The event is designed to showcase technologies that help businesses build innovative, market-driven manufacturing capabilities. NMW 2014 takes place in Sydney from 13-16 May. Here is a selection of what visitors can expect to see this year. 1

DGS 3D - Stand 1429

Hurl Nu-Way - Stand 2622

DGS 3D will be exhibiting their eco-friendly 3D Hurll Nu-Way has been importing top quality products to Australian manufacturers for printer, the Mcor Iris. over a hundred years. It builds low cost, durable, stable models in Today the company’s product range includes blowers, compressors and air knives; countless colours from regular A4 copy paper. pumps, mixers and meters; heaters, air handlers, split systems and cooling fans; gas, oil It uses very little electricity and is office friendly, and process burners as well as boilers. classroom friendly, quiet, non-toxic and safe. It Visitors will see their compression product range, including Hitachi screw delivers no noxious fumes, no excessive heat, air compressors, GE Roots blower packages and Secomak air knives. and no loud noises. Models/prototypes can be Hitachi screw compressors are new to the Australian market disposed of in your ordinary recycling bin. and are currently available in the range from 7.5 to 55 kW. Launched in Nov 2012, this 3D printer has been Main features of these compressors are energy efficiency creating waves worldwide, including being named and ease of maintenance. Adobe’s 3D printer of choice for their Creative Cloud. Roots blowers are presented both as bare shaft The Mcor Iris uses patented SDL technology – Selective Deposition Lamination – to models to retrofit on existing base and complete blower build precise, eco-friendly, full colour, fully recyclable models at a resolution of 0.1mm. packages designed to suit any application. Vacuum, presM A3D 0 is 4 the 1 4sole _ 0Australian 0 0 _ Kchannel E E -partner 1 for 2 Mcor 0 1 4Technologies. - 0 3 - 0 7 T 1 6 : 1 1 : 5 sure 7 + and 1 1high : 0pressure 0 DGS blowers are available.

Australian-made products for underground or open cut mining Your expensive equipment is working day in and day out in high impact, harsh conditions – so protect it and extend its useable life with high quality wear components. Keech Australia designs and supplies innovative ground engaging tools for machines including excavators, shovels, loaders and draglines, along with crusher and ore bin liners. Choose Keech for increased productivity, reduced downtime and simple, safe installation. • Increase productivity, reduce downtime and improve loader availability with super tough WearpactTM bucket edge system • Increase nose strength, integrity and bucket life with SidelockTM adaptor and tooth systems • Use ArmourtechTM to protect the tray lip on dump trucks from harsh scraping and damage • Protect your crusher, ore bin or anything else that needs abrasion protection with a KeelinerTM flexible wear system

For more information about Keech’s Australian-made products, call 1300 4 KEECH or visit www.keech.com.au Keech Australia australias-mining-monthly-210x122mm.indd 1

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NMW Preview 13-16 MAY 2014

Obara Australia Pty Ltd/ Coral S.P.A - Stand 1448 3

The Obara name is known throughout the world’s automotive manufacturing industries. Obara Australia provides local support, assisting Australasian companies with their welding/metal joining, fabrication and extraction requirements. While Obara is known for welding equipment, the company continues to look at and focus on new ways to improve and support customers. For many years Obara Australia has been representing Coral, a European manufacturer of dust and fume extraction systems. In addition, they represent Depureco s.r.l (Industrial vacuum cleaners) and Filcar (Automotive engineering). Visit stand 1448 to see demonstrations of Coral portable fume/dust units and Depureco industrial vacuum units. Obara Australia looks forward to assisting manufactures with products and services to meet the ever changing welding/metal joining and OH&S environment.

Sheffield Blades - Stand 1345

Sheffield Blades is now the sole Australian distributor of the Euroboor range of Portable Industrial Tools, including a full range of magnetic based drills and annular cutters. Euroboor recently launched a battery version of the magnetic base drill which will be demonstrated at the show. The company will also promote the Sterling and Alpha brands of cutting tools and power tool accessories. The Sterling range provides complete cutting tool solutions in utility knives, cutters, blades, safety cutting, tape measures and related tools. The Alpha range provides drill bits, driver bits, taps and dies, countersinks, hole saws, SDS masonry drills, wood drills and related power tool accessories. Sheffield Blades recently launched the Maxabrase range of Abrasive products including cutting discs, flap discs, flap wheels and fibre discs.

Staetite Fasteners - Stand 2438

Staetite is Australia’s largest private Australian owned manufacturer of cold forged components, certified to ISO/TS16949. The company services a range of industries - from automotive, transport, mining, building, manufacturing, and agricultural through to general hardware and industrial supplies. Staetite can custom make products to a variety of specifications, in a range of materials and surface finishes. In-house capabilities include tool manufacture and design, forging, rolling, sems assembly, vision sorting and heat treatment. Value added services such as kit assemblies are also available. Their capabilities are further complimented through licensed products such as MAThread and the agency line Pratley DIY and Industrial adhesives.

Ubeeco - Stand 1708

Ubeeco Packaging Solutions is a provider of products and solutions to the industrial manufacturing and supply market segments. Because it has operated for more than 43 years the company can offer customers fit for purpose solutions to their packaging requirements. The company has exclusive distribution rights on the premium plastic pallet and crate offering from MSI and Eco Pallets for the Australian Eastern Seaboard. These products fit with the wider industrial packaging range they offer. At NMW, Ubeeco will showcase Ubeeco-1100, the standard in plastic export pallets which is rated at 1000kg and requires no quarantine. Also on display will be Ubeeco-1160, one of the only plastic pallets in the market built to Australian Standard Size; and Ubeeco-OzCrate which boasts a 750L capacity, 1000kg safe working load, replaceable sides and 4-way entry.

Tesuco – Stand 1331

25-year-old Australian company Tesuco supplies gas equipment to the industrial, scientific, medical and beverage industries. Their range includes regulators, manifolds and gas welding, cutting and heating equipment. Tesuco will display the Oxyturbo Set 200 which is recommended for applications such as, plumbing, refrigeration and air conditioning. The company will launch new products including its “Heat Sink” CO2 welding gas regulator, which allows for high flow without the need for power and allows for two flowmeters (25 or 40 Lpm)to be fitted at the same time.

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A new one piece cutting torch will also be on display. It is available in a number of different configurations and lengths for maximum versatility. Tesuco will also present a range of high pressure disposable gas cylinders and regulators. Portable and convenient, these 2.2 litre cylinders have a much larger capacity and last up to four times longer than previous disposable cylinders. They are available in argon, argon mixtures, CO2, nitrogen and helium.

Xtralis - Stand 2822

Xtralis plans to introduce VESDA-E, a smoke detection solution for automated manufacturing plants at NMW. Described by the company as being part of the next generation of air-sampling smoke detection systems, it can discriminate between different smoke and particle types. This is a major benefit for manufacturing operations characterised by background levels of manufacturing smoke, welding fumes, dust and soot that can trigger nuisance alarms, resulting in business disruption, and costly visits by emergency services. The system’s intelligent flair detection technology and VESDA Analytics mean targeted detection of threats is possible without nuisance alarms. VESDA WireTrace allows specific targeting of burning wire events at level close to the ambient environmental smoke level.

Product

Hardness/HBW

Thickness

Hardox HiTuf

310 - 370

40 -130mm

Hardox 450

425 - 475

3 - 80mm

Hardox 500

470 - 540

4 - 80mm

Hardox 550

525 - 575

10 - 50mm

Hardox 600

560 - 640

8 - 50mm

Hardox Extreme

625 - 700

8 - 25mm

Domex 700

750 - 950 MPa

2 - 10mm

Wurth Australia Pty Ltd - Stand 1614

Wurth Australia provides operators across a diverse range of industries fast access to 12,000 active articles stocked in three warehouses strategically located across the country. Customers in automotive, construction, transport or the metal trades can access anything from single bolts to a pallet of silicone quickly and conveniently. Every Wurth product has been rigorously tested to exacting quality standards. Wurth is offering everything from fasteners and consumables to master tools and safety equipment. www.nationalmanufacturingweek.com.au

Equipment and wear parts made with HARDOX wear plate is your guarantee of outstanding resistance to impact and extreme abrasion. That translates to maximum service life, less risk of breakdowns and enhanced productivity. Because you ask a lot of your equipment, get the wear plate preferred around the world - HARDOX, the number one choice in abrasion resistant steels. Its hardness, strength and toughness make it unlike any other steel on earth. It’s the highest industry standard for applications such as excavators, tipper bodies, conveyors, crushers, mixers, barges and more.

SSAB Swedish Steel Pty Ltd Office & Stocks Perth Brisbane Melbourne & Adelaide

:+61 8 9353 2146 :+61 7 3891 3533 :+61 3 9529 5759

E-mail: australia@ssab.com www.ssab.com www.hardox.com

9 SSAB is a global leader in value added, high strength steel. SSAB offers products developed in close cooperation with its customers to create a stronger, lighter and more sustainable world. SSAB has employees in over 45 countries and operates production facilities in Sweden and the US. SSAB is listed on the NASDAQ OMX Nordic Exchange, Stockholm.

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Metalworking& MACHINE TOOLS Understand laser welding Laser welding continues to become more widely used and in a growing range of applications, however it is important to know which type is right for you? Neil Penman reports.

Uring the last decade a number of laser manufacturers in Europe and the US have been producing laser welders designed for a specific industry and application. This has made the technology more affordable and user friendly, and therefore contributed to a wider up take of the technology in Australia.

Nd:YAG lasers nd:YAg refers to the type of crystal used in the laser, which produces a wavelength of 1064nm which is just outside the visible range of our eyes. However a laser with a wavelength of 1064nm is effectively absorbed by conductive metals, making it ideal for welding. The output powers available for nd:YAg lasers range typically from 30W to 800W and are currently the most popular for laser welding applications, which require small spot or seam welds with a few millimetres penetration depth. The nd:YAg lasers can be categorised into three groups: 1. Manual Laser Welding systems are usually complete systems with a small welding chamber where the operator holds the piece in their bare hands, or uses basic jigging. The operator positions the piece whilst looking through a microscope and fires the laser via a foot peddle. They are ideal lasers for small volume production, and lower budgets. 2. Semi-Automatic and Fully Automatic Laser Welding systems, with built in xYz motion and optional rotation axis, are used for controlled seam welds, higher volume production and/ or higher precision and repeatability. The piece is moved either by remote joystick or automation software. 3. Mobile Laser Welding systems are fairly new to the market, and are used where the item to be welded is 42 APRIL 2014 Manufacturersâ&#x20AC;&#x2122; Monthly

not easily moved i.e. for large tool and mould repairs. These systems are on wheels or caterpillar tracks and the laser head is positioned on the end of a free moving or motorised arm, so users can take the laser to the work area. inclined welding is possible on certain models. Due to the higher power requirements of the intended applications, these systems often require 3 phase power. An example of this new type of precision mobile welding is the german made ALFlak, which is used where it is necessary to produce deep welds in poorly accessible spots. The ALFlak has a wide operating radius and can weld seams of 500mm in one go, without interruption.

CO2 lasers

instead of a crystal, a CO2 laser cavity uses a sealed glass tube filled with Carbon Dioxide gas. The wavelength produced is 10,600nm, which is a long way from our eyes visible spectrum.

This wavelength is not well absorbed by metals, in fact about 80% of this laser light can be reflected off the surface of metals. The advantage of CO2 lasers is that the power is easy to scale up, making CO2 lasers capable of producing much higher output powers than nd:YAg lasers. Once the laser has passed the melting point of the surface, the high reflectivity becomes less of an issue and more of the power is absorbed for the welding process. To produce the high output power of a CO2 laser, generally requires large equipment and coolers. These lasers are generally used for larger applications.

Fibre lasers in a fibre laser the intense light is generated in an erbium doped single mode glass fibre, the wavelength produced is 1090nm. Fibre lasers are the latest technology currently available, and offer another level of control and higher weld repeatability.

Fibre lasers have recently become more popular in laser marking, but there are a few manufacturers who have also used this technology in laser welding. Due to the small spot size (0.02mm) and shot repeatability, fibre laser welders are most commonly used by medical device companies that are looking for very small controlled laser welds.

Laser safety All lasers brought into Australia must be classified and have the correct classification label clearly placed on its outer housing. The classification classes are mainly (but not wholly) dependent on the lasers wavelength and power. Following is a simplified list of the classifications, which should not be used in place of the official Australian Standards. Class 1 - any laser product which during operation does not permit human access to accessible laser radiation in excess of the accessible emission limits of Class 1 for manmonthly.com.au

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applicable wavelengths and emission durations. Class 1M - any laser product in the wavelength range from 302.5nm to 4000nm which during operation does not permit human access to accessible laser radiation in excess of the accessible emission limits of Class 1 for applicable wavelengths and emission durations Class 1 and 1M - are lasers which are incapable of damaging the eyes or skin because of either housed in an appropriate laser safety enclosure or have inherently low power output. Class 2 - any laser product in the wavelength range from 400nm to 700nm which during operation does not permit human access to accessible laser radiation in excess of the accessible emission limits of Class 2 for applicable wavelengths and emission durations. Class 2 - are lasers which have sufficient power output to cause M A to 1 1the 1 3eyes _ 0if3 viewed 7 _ BI N damage continuously. However, their outputs

FASTFACTSFASTFACTS

Laser welding • There are three types of laser welders available - Nd:YAG lasers, CO2 lasers, and fibre lasers. • Laser safety depends upon a working understanding of the classification classes. • Keep in mind that laser welders are not particularly mobile. • Beware of the expense. In terms of capital expense, laser welding is not cheap. • The technology is impressive. Laser welding can achieve things that nothing else can.

higher output or operation outside visible wavelengths. Class 4 - any laser which permits human access to laser radiation in excess of the accessible emission limits of Class 3B.

Advantages

There are three main advantages when looking to invest in laser technology: As an enabler, laser technology can do processes that no other technology can achieve, such as welding complex are low enough to allow the natural alloys, or dissimilar alloys, precise aversion responses, such as blinking, welding of small parts, welding in to prevent damage. close proximity to heat sensitive Class 2M - are lasers which can components, clean hermetic seals and be hazardous if the beam is viewed solder and contact free welding. directly with optical instruments. Regarding product improvements Class 3R - are lasers which have laser welding can produce stronger, the potential to cause damage to the more visually appealing welds, eyes from intra-beam viewing and with with no flux used in smaller precautions are required to prevent heat-affected-zone, resulting in either direct viewing or viewing less distortion and less strain on with optical instruments. neighbouring components. 1 Class 2 0 3B 1 3- -are 1 0 - 2 3which T 1 1are : 0 3 : 0 0 For + 1 process 1 : 0 0improvements, laser lasers more hazardous because of either welding can reduce preparation

time prior to welding, with no heat treatment, faster welding process than alternative technology and reduced post welding process with no cleaning of the weld or grinding.

Disadvantages The main disadvantage is the capital cost, with laser welding systems start from just under $30k and range up to $100k’s. The other disadvantage is mobility. There have been recent developments in making lasers more mobile, however they are still not as mobile as MIG and TIG welders. In conclusion, while Nd:YAG lasers are still the most popular choice in areas where small precise laser welds are needed, for applications that require larger welds and more brute force, CO2 lasers are the preferred choice. [Neil Penman MSc is Managing Director of M2 Lasers.] M2 Lasers 1300 367 648 www.m2lasers.com.au

EWR. Weld more efficiently Maximise your cost savings! Optimal use of all resources is essential for an economic and efficient welding process, be it manual or robotic. However, options for shielding gas consumption are often given too little consideration. The EWR (Electronic Welding Regulator) system can save up to 60% of shielding gas and at the same time provide superior gas coverage during the welding process.

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Metalworking & MACHINE TOOLS Eye-viz protection With so many different applications for welding, it pays to choose the right helmet for the job. Laura Carrazza explains.

N Australia, welding and grinding are responsible for nearly a third of all eye injuries and result in more than 500 hospitalisations every year. Aside from the pain and inconvenience caused, that results in thousands of lost hours – as many as 26,000 by some estimates. A lot of these injuries occur when people don’t wear protection. In a survey conducted by Monash University in Victoria, as many as half of those injured through welding related activities and a third of those injured through grinding related activities didn’t report wearing any eye protection at all.

The risks When welding, the biggest risk is ‘flash’ or ‘arc eye’– a sort of sunburn to the cornea, caused by staring too long at harmful ultra violet rays (like arc light). Extremely painful and potentially debilitating. It’s critical workers wear a proper, fit-for-purpose welding helmet that not only protects their eyes but also offers full facial and neck protection - reducing the impact of arc rays that can cause burning of the skin. One of the reasons welders get injured is because they remove their protection too early. If they’re welding for

hours at a time, it’s crucial that they are not itching to rip their helmet off the moment they finish a weld.

New helmet Cigweld’s new ProLite welding and grinding helmet features four highly sensitive sensors that can take readings and make adjustments to the variable lens in less than 1/20,000th of a second. Even at very low amperages, the helmet knows exactly how much light to let in, which makes it suitable for low current AC and DC TIG work as well as more powerful stick and MIG jobs. The helmet, which is fully compliant with Australian Standards, uses regular, replaceable CR2450 lithium batteries, plus it features a solar panel which draws energy from the arc rays. [Laura Carrazza is Marketing Manager at Cigweld.]

Laser cutting machine HEADLAND has released the enhanced Trumpf TruLaser 5030 fiber laser cutting machine which is now equipped with BrightLine fiber function for a quality cut in any sheet thickness. Now offering greater flexibility, the company describes the TruLaser 5030 as an all-purpose machine for complete 2D laser processing. Equipped with a 5kW solid-state laser, the machine can cut stainless steel up to 25mm thick. According to the company, small holes and contours can now be seamlessly cut in thick stainless steel, while increasing quality and productivity in mild steel processing between 15mm to 25mm sheet thickness. With the new BrightLine fiber function, users will be able to cut mild steel, aluminium and stainless steel up to 25mm thick, plus

44 APRIL 2014 Manufacturers’ Monthly

Equipped with a 5kW solid-state laser, the machine can cut stainless steel up to 25mm thick in “outstanding” quality. execute even finer contours and prevent slag from forming when the laser beam pierces the sheet. The machine is designed to save time with easier parts removal and extraction from the scrap skeleton. Headland 1300 592 061 www.headland.com.au

Cigweld 1300 057 804 www.cigweld.com.au

The helmet features a clever solar panel which draws energy from the arc rays it’s exposed to and uses that to power up the auto-darkening lens.

Auto-darkening welding helmet LINCOLN Electric has launched an easy-to-use, digital-interface helmet into its Viking welding helmet product group - the 2450D Digital Series. Equipped with pivot-style headgear, improved optical clarity with enhanced colour recognition and a three-year warranty, the company says the 2450D is a best-in-class digital helmet. The auto-darkening helmet offers three modes—welding, cutting and grinding. The user interacts with an easily understood, LCD-screen interface, with the protected buttons said to be easy to use with gloved hands. The helmet also produces full-spectrum shade 4-13, with variable sensitivity and delay. Lincoln Electric 1300 728 720 www.lincolnelectric.com.au

The new autodarkening helmet offers three modes - welding, cutting and grinding.

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ProductionSAFETY Industrial safety systems SICK, a specialist sensor manufacturer, develops products for safeguarding hazardous zones and for access protection. These include the below. Highly efficient Safexpert Software: Be guided through the conformity assessment; Safely and effectively attain CE certification; Simplify the work and save time. Self-monitoring Opto Electronic Protective Devices: Intelligent, opto electronic safety devices like industrial sensors, laser scanners, light grids and light curtains; Can be used for safeguarding dangerous points, hazardous areas and access control, both vertically and horizontally; These non contact devices can be tested and they correspond with worldwide safety standards. Stop and start machines safely with Safety Command Devices: Safety command devices are of major importance as man machine interface in industrial applications; Dangerous movements can be stopped safely and machine functions can be started safely whilst the protective device is open.

Suitable for up to 240 PSI working pressure at 30°C.

Safer air and water use in road and rail Ensures that hazardous zones are safeguarded. SICK 1300 405 807 www.sick.com/au

Wall mounted ventilation solution FANQUIP’s ‘wall plate exhaust fans’ are an economical and efficient means to extract heat, fumes, smoke and stale air from a factory, workshop or processing plant. Running on electricity, it runs cleanly and a system can be installed without danger of contaminating sensitive stock or food items. Fanquip wall plate exhaust fans are as easily retrofitted onto any existing premises as they are factored into the construction phase of a new building. They are manufactured as a strong and durable self-contained metal unit. MA 0 4 1 4 _ 0 0 0 _ P R I Outlet diameters are made in a

Galvanised gravity-closing louvres prevent backdraft when unit is off.

rpm – are in selected combinations with motor powers of 0.15kW, 1.8kW, 0.25kW, 0.37kW, 0.55kW, 0.55kW, 1.10kW, 1.5kW, 2.20kW, 2.70kW, 3.00kW, and 4.5kW. Free air volume ranges from as compact as 600litres per second for smaller premises through to a huge 30,000 litres per second for massive factories and energy installations, food processing locations and workshops. Voltage available is in either 1 Ph 240V or 3 Ph 415V.

variety of sizes ranging from as small as 310mm right through to a large 1830mm. Fanquip Four motor speeds – 480rpm, 1800 224 308 1 2 0 1 4 - 0 3 - 0 5 T1 6 : 1 8 : 0 2 + 1 1 : 0 0 570rpm, 720rpm, 960rpm, and 1440 www.fanquip.com.au

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RECOILA’s Gen III Air/Water series (AW Series) reels can be configured for trailer-mounting and truck-mounting to allow teams working on road construction and rail construction to safely and more efficiently handle water and pressurised air. By keeping water and air hoses on long lasting reels, hoses are always organised and off the ground, thus reducing potential trip hazards on site. These units are manufactured from impact- and corrosion-resistant polypropylene; the ReCoila AW Series is tough, reliable and made from the highest quality components to withstand tough industry demands and heavy duty cycles. ReCoila’s Gen III AW Series is available in a range of hose lengths up to 20 metres, and hose ID from 8mm to 12mm. Other advantages of installing a ReCoila reel include increased safety as the hose is coiled neatly ready for use, not lying on the floor creating a trip hazard. The AW Series reel is also suitable for compressed air, and models are available with special purpose EPDM rubber hose for applications where welding spatter adversely affects standard hoses. ReCoila Reels 1300 833 677 www.recoila.com

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EnergyMANAGEMENT Putting the sun to work on cool desserts Faced with rapidly rising energy costs which were impacting profitability, dessert manufacturer Exquisine turned to a solar PV system.

xquisinE is a family owned and operated multi-award winning dessert manufacturing company in Thornbury, Victoria. Exquisine desserts have won over 50 medals at Australia’s most prestigious dairy shows and it supplies its desserts to food service and retail companies. it contract manufactures over 90 percent of its desserts to recipes designed specifically to each customers’ unique requirements. These desserts are produced at the manufacturing facility’s custom designed commercial kitchen. Like many manufacturing facilities in Australia, rapidly rising energy costs have severely impacted on their profitability. Exquisine faced significant cost pressures, similar to many manufacturers in Australia having to deal with rising labour, materials costs and electricity prices.

nection approval within Exquisine’s required timeframe. EnviroGroup’s power engineers completed a detailed design and grid application and worked with Powercore’s application team to achieve a timely connection approval ensuring that the project was delivered to meet Exquisine’s deadlines.

Implementation EnviroGroup worked closely with Exquisine to ensure that business operations were not affected during the installation process, which took place over a two-week period with much of the work happening outside normal working hours to avoid disruption. EnviroGroup also liaised with Exquisine to keep their staff updated on the installation schedule so there would be minimal disruption. They constructed new mounting walls for equipment to

Exquisine contract manufactures over 90 percent of its desserts to recipes designed specifically designed to each customers’ unique requirements

Challenges Exquisine’s Managing Director, David Rose said the company had considered solar PV as part of its energy mix as electricity prices were increasing in 2012. Rose said, “Our facility has a large CO2 refrigeration plant that we use for our holding freezer, blast freezer and chiller as well as heating and cooling for the factory and offices and hot water for cleaning and production. Exquisine engaged EnviroGroup, a leading commercial installer of solar energy systems and Yingli solar’s partner, to design and implement its solar power solution. “it was important that we worked with Exquisine to seamlessly integrate the solar power system into their operations to maximise technical and commercial performance,” said Cameron Munro, EnviroGroup CEO. One of the key challenges EnviroGroup faced was getting grid con46 APRIL 2014 Manufacturers’ Monthly

Yingli Solar’s YGE 60 Cell 40mm Series 250W polycrystalline panels were installed at Exquisine.

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Sweet returns for dessert company. When the thought of turning on the lights started to leave a bad taste in the mouth, multi-award winning dessert maker, Exquisine Pty Ltd, decided it was time to act. Like many companies the rapidly rising and fluctuating energy costs were severely affecting their bottom line. But as it turned out the solution to their needs was to be found in an overhead, literally. Their Thornbury based factory has a large north facing roof space that was ideal for solar panels. So in 2013 Exquisine Pty Ltd commissioned EnviroGroup, a leading commercial installer, to install a 80kW Yingli Solar PV system. They chose Yingli Solar high efficiency polycrystalline panels because of their proven ability to produce ongoing high energy yields under the harsh Australian climate, making them an excellent return on investment. In fact, this large solar PV system will not only offset a significant portion of the company’s electricity usage, approximately 300 kilowatt-hours per day, but will also help reduce carbon emissions by 139.7 tonnes a year. Exquisine can now invest this energy cost saving back into the company to allow an expansion of production in the future. Sweet! For more information please visit yinglisolar.com/au or call 1300 309 489.

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energymanagemenT ensure the workforce had safe access to its solar installation equipment To meet Exquisine’s exact requirements for a reliable supply of solar energy, Yingli Solar’s YGE 60 Cell 40mm Series 250W polycrystalline panels were used as they had a proven track record to produce high energy yields under the harsh Australian climate making it an excellent return on investment. 320 Yingli Solar PV panels were used for Exquisine’s solar installation. The YGE 60 Cell series panels are high efficiency, multicrystalline silicon solar cells that offer efficiency of up to 15.9 percent. These panels are designed to minimize installation costs and to maximise the kWh output. Daman Cole, Managing Director of Yingli Solar, Australia, New Zealand and Pacific said, “Exquisine chose Yingli Solar panels based on EnviroGroup’s recommendations because of their high efficiency yields and their confidence in the quality of our panels. Yingli Solar panels are manufactured to extremely high standards and independently tested by TUV Rheinland for energy yield and longevity. Third party testing has ranked Yingli Solar as one of the top three panel manufacturers in the world for performance and quality.” Yingli Solar operates a fully verticallyMintegrated A 0 4 1 4 factory _ 0 0 0that _ Pensures EA that all the components of a panel

Thinking abouT uSing SolaR eneRgY foR YouR manufacTuRing planT?

By putting a solar PV system in place manufacturers can protect themselves against energy price shocks in the coming years. The cost of a solar PV installation now - which has a productive life-span of over 25 years – allows manufacturers to effectively lock in a portion of their energy cost at a fixed-price. The ROI for a solar PV system is generally between 20 and 25 percent for a project lifetime of over 25 years. While these installations are typically structured so that they are paid off over five years, they are designed to generate energy at least another twenty years on top of that. This can be used as a benchmark to determine how a solar PV system investment can be structured to make it cash-flow neutral. Manufacturers who are thinking about implementing solar should choose to work with an experienced commercial solar power installation company with in-house engineering expertise to complete detailed electrical design and grid connection. The installation company should be able to calculate the potential energy savings, provide a free evaluation on the suitability of a site and recommend a solution that meets a manufacturer’s requirements including grid connection and augmentation. While installers play a critical role in managing an installation project, business owners should also conduct their research independently on solar panels recommended by installers to ensure they meet performance standards, are independently tested and benchmarked. Given their lifespan it’s particularly important to choose solar panels wisely and not compromise on panel quality in order to reduce costs. Buyers should look for high quality leading Tier 1 manufacturers who invest in R&D. They should also review the track record of solar PV manufacturers and the installers’ credentials based on the work they have done on other customer sites. As product warranties for solar panels cover a 25 year period, they should look for a stable well-backed solar PV manufacturer with an Australian office who offers technical support within the country. Ultimately, with the right installation company and equipment suppliers, any manufacturing business will benefit from investigating the energy cost savings and certainty that solar provides. 2 0 1 4 - 0 2 - 2 6 T1 1 : 0 2 : 4 6 + 1 1 : 0 0

are produced and assembled on site. To back up the quality of these panels, Yingli Solar includes a 25 year warranty on the panel’s power output and a 10 year product warranty. All Yingli Solar panels are marathon tested and are continuously monitored for hotspots and cracks throughout the manufacturing process. To provide customers peace of mind for their investment, Yingli Solar offers technical support and after sales service in Australia.

Result It took two weeks for the solar PV system to be commissioned and nstalled and a further two weeks for grid connection. The system was connected to the grid in August 2013. The solar PV installation contributed approximately 300 kilowatthours per day of electricity, reducing Exquisine’s carbon emissions by close to 140 tonnes a year. The return on investment for the lifetime of this solar PV installation is expected to be over 25 per cent which is typical for a medium sized manufacturing business. Exquisine can now invest this energy cost saving back into the company to allow an expansion of production in the future. Yingli Solar 1300 309 489 www.yinglisolar.com/au

How we helped hotel guests sleep easier. Peace can go to any lengths to quell unwanted noise and boost your business prospects. One recent project was for a major international hotel group. By containing air conditioning noise it not only beneetted hotel guests, but helped the local community rest easier. Don’t just sleep on it, call Peace now or view our capabilities online.

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Materials HANDLING Efficient, safe, high-density storage DEXION’s high-density Satellite storage solution offers productivity and storage advantages compared to typical ‘block stack’ and ‘drive-in’ storage applications. Satellite solutions are most suited to businesses requiring high-density storage of multiple pallets. The satellite solution optimises storage against available volume by leveraging available depth space.

The stack height is limited only by the warehouse’s dimensional reach. Stack depth is typically 5-15 deep – more than other configurations – but can be deeper if the product profile permits. Unlike other configurations, satellites are also uni-directional – they can be loaded from one end and unloaded from the other, producing greater storage capacity. Automatic battery recharging

options also perfectly suit businesses operating multiple satellite units, with an operator not having to exit the forklift to replace it, saving time. The storage system can be tailored to any application, as it’s scalable to both warehouse capacity and task activity. Dexion 1300 491 990 www.dexion.com.au

Multi axis robot energy chains

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TREOTHAM’s Chainflex CF Robot family transfers energy and data in dynamic applications for Profibus, CAN-bus, Industrial Ethernet. The braided shield has an optical coverage of 85 per cent. The pressure-extruded outer jacket is abrasion-proof, oil-resistant and is made of a flameresistant, halogen-free PUR mixture. The twistable PUR motor cables can be supplied 2 0 1 4 - 0 2 - 2in 5 T 1 0 and : 3 non-shielded 7 : 3 2 + 1versions. 1 : 0 0Importance shielded was attached to the damping elements protecting the

elements as they twist. High-grade PTFE gliding layers continues to give a sturdy basis for special torsion-resistant insulation. On a test structure 1m long in a technical centre, the FOC cable presented in Hanover has carried out over 4 million strokes. At a torsion angle of +/- 180°, there was no change in great data transfer behaviour. Treotham Automation 1300 615 110 www.treotham.com.au

A world of cable carrier options TSUBAKI KABELSCHLEPP cable carriers: • Full range of options to suit your requirements – plastic, steel and combined hybrid materials • Available in 1 mm width increments • Over 100,000 variants in steel and plastic material • Standard widths from 6 mm to 2,500 mm • From single chain link to harnessed assemblies ready for installation • Comprehensive range of cables carried in stock

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Whatâ&#x20AC;&#x2122;sNew

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See more new products at manmonthly.com.au

Energy-efficient pump drive solutions

Structural steel fabrication cutting system

nORd drivesystems supplies complete pre-assembled distributed drive units for a wide performance range to 22 kW. In addition to energy savings of up to 60%, users benefit from reduced noise emissions, low wear, and increased plant service life as well as the ecological advantages. The SK 200e series comprises reliable and economical frequency inverters especially tailored to pump applications that precisely adjust power output as required. They are compatible with mains voltages worldwide. nORd configures complete drive systems for various application areas (IP55/IP66, ATeX zone 22/3d). AdvAnced Robotic Technology (ART) has Integrated process and PI controller functions enable the fully automated control of created the Metaltek XB series 10-axis structural process variables and compensation of distursteel fabrication system. bances - in stand-alone and mobile applications According to the company, it is intended to The system offers full 4-sided as well as in complex setups with several answer the need for fully automated structural plasma processing for the steel drives. With two analog inputs, the steel processing in one machine. fabrication industry. inverters can directly process sensor In order to eliminate as much manual labour as data such as pressure or flow rate. possible the designers have included full mateOptional signal and power plug rial handling and all functions are automated and connectors facilitate handling simple to operate. The machine is designed to reduce labour and double handling while and ensure compatibility. increasing productivity and profits. Operation is straightWith a footprint of 3750 mm x 3600 mm, the system offers full 4-sided plasma forward and flexible via processing for the steel fabrication industry. It also features advanced cnc robotics, control terminals, bus, or via high-definition plasma cutting, in-house developed software and a control interface. an optional potentiometer that Moreover, 3-axis material handling conveyor systems and cross-transfer conveyors enables adjustments directly for load and unloading eliminates a large percentage of lifting, flipping and moving of at the inverter. steel members between machines. The pump drives can store up to four NORD Drivesystems Advanced Robotic Technology operation modes MA 0 4 1 that 4 _ can 0 0be0displayed _ S P I and 1 2 0 1 4 - 0 3 - 1 7 T 1300 1 9 :050 3 347 0 : 0 6 + 1 1 : 0 0 1300 565 528 changed directly at the control unit. www.nord.com www.advancedrobotic.com

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What’sNEW

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Automation controller Schneider electric, a global specialist in energy management, has launched the new Modicon M580, an automation controller which is the key component of PlantStruxure, the company’s integrated The automation controller is automation architecture. built for powerful performance. According to the company, the controller is the world’s first ePAc, the next generation PAc (Programmable Automation controller) which is based entirely on ethernet. it gives industrial plant teams the power to design, implement and run a process that actively employs all the benefits of open networking, such as increased visibility to key process data and events, enhanced transparency and consistency of information, and large capacity for data traffic. The company says the heart of the controller is the SPeAr (Structured Processor enhanced Architecture) microprocessor that embeds inside the controller standard unmodified deterministic ethernet and applies it to all communications, including all the way to the hardware connection on the backplane. This is said to result in high levels of transparency and performance, without any need for manual configuration of each connected device – the SPeAr technology applies ethernet communications to the field bus, control bus, and internal backplane bus, and, consequently, to all the connected equipment and modules. ethernet is also automatically applied to every device in the network, such as electrical distribution, low-voltage boards, and energy management functions – to form a complete and open system. Schneider Electric 1300 369 233 A D _ MA N MJ A C A P R _ 1 3 . p d f P a gwww.schneider-electric.com e 1 1 1 / 0 3 / 1 3 ,

Toggle Clamps Safe, Simple & Effective

Jacmor Engineering stock a range of Mild Steel and Stainless Steel Toggle Clamps. Initially designed to secure lids on screw conveyors to allow easy access. Jacmor's adjustable Toggle Clamps are now used in literally hundreds of other applications.

The washdown sensor delivers reliable operation in temperatures ranging from -25° to +70° C.

Washdown sensor TUrcK has added the Q80Wd sensor to its lineup of washdown sensors. The Q80Wd is an addition to the uprox+ family of factor one sensors that require 1 correction 0 : 5 0 factor A M to detect any metal no type. The Q80Wd features an improved design with a durable, stainless steel M12 connector and a chemical resistant PPS thermoplastic housing that is designed to deliver resistance to chemicals and caustic cleaning agents, as well as shock and impact. Additionally, the housing materials are food-safe and meet FdA regulation 21cFr 177, 1500(9) for the U.S. and FdA/eGVO 1935/2004 for the e.U. The Q80Wd features 2 side mounted Led’s for optimal viewing. MM0 4 1 4 _ 0 0 0 _ I N D The existing uprox+ washdown family

is comprised of 8, 12, 18, and 30mm diameter barrels, 42mm Qpaks with sensing ranges between 1.5 and 50mm. The uprox + technology is able to sense all types of metals at the same distance, not only eliminating the need to change the position of the sensors for different metal applications, but also reducing the number of sensor types needed for plant operations. in addition to an extended sensing distance, the Q80Wd delivers reliable operation in temperatures ranging from -25° to +70° celsius and is iP68 approved or iP69k approved with optional back plate.

Turck 1300 273 687 2 0 1 4 - 0 3 - 1 3 T1 2 : 3 3 : 1 4 + 1 1 : 0 0 www.turck.com.au

SCADA SYSTEMS PC & PLC PROGRAMMING Wee ooffer W ffee cost effective solutions for your automation ff tech te chno noll technology needs Australia wide. At IIS&E S&E S& E we specialise in systems integration and auto au toma ma automation projects, big and small. For mor more information phone us on 07 3856 2232.

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Victoria Head Office 20-22 Macquarie Drive Thomastown Vic. 3074 Australia Telephone: 61 3 9463 0888 Facsimile: 61 3 9465 8788 E-mail: info@jacmor.com.au FreeCall 1800 334 005 Web Site: www.jacmor.com.au

52 APRIL 2014 Manufacturers’ Monthly

INDUSTRIAL SOFTWARE & ELECTRONICS Tel: (07) 3856 2232 Fax: (07) 3355 1012 E-mail: info@industrialsoftware.com.au Web: www.industrialsoftware.com.au

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WITH SMARTSIGN,® COMMBANK CAN. CommBank’s new online technology, SmartSign,® offers your business faster access to finance for new equipment. It allows you to accept your finance agreements online anywhere, anytime. The time between signing and having access to the funds is usually 48 hours, with SmartSign® it’s less than 4. For more information go to commbank.com.au/smartsign

Things you need to know before you Can: Finance applications are subject to the Bank’s normal credit approval. Full terms and conditions provided in the loan offer. Fees and charges are payable. The access to funds through SmartSign® capability will be available up to four business hours after electronic acceptance of loan has been completed. Commonwealth Bank of Australia ABN 48 123 123 124. AFSL and Australian credit licence 234945.

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2014-03-19T08:59:05+11:00

The lastWORD It pays to take the right measurements One of my most memorable consulting assignments involved the solution to a productivity problem at an injections moulding facility. The plant had 14 injection moulding machines producing precision nylon parts of high quality for the Australian market, writes John Blakemore.

HE CEO and the Plant Manager were planning to double production by investing approximately $20 million in 14 new machines. My contract was to improve the performance of the existing plant. After observing and measuring the machines, and collecting the current management data that the management used to monitor and measure the plant performance, I trained the operators in basic data collection and started the teams re-measuring the machine performance. The results are shown in the figure below. The defect rate was approximately 15% in weeks 1 to 5. In week 6 the defect rate climbed to 45%. This was a result of the new measurement system that was introduced to more accurately measure machine performance. The operators had, over a long period of time, improved the percentage of good parts per machine cycle by blocking off the cavity in the multi-cavity die that was causing the problem. The management were not aware of this practice. As a result, a die in the machine with 176 cavities which should have been producing 176 good parts per cycle was producing far less. Up to 80 plus cavities were blocked off in some dies. The result of this that instead of producing 176 parts per cycle the machine was producing, say, less than 100 parts per cycle. The information fed to management was that the defect rate was 99 per cent plus when in fact if the cavities were not blocked off the defect rate would have been approximately 50 per cent. The solution was to measure the blocked

manmonthly.com.au

cavity as a defect. The focus was then to fix the die and produce 176 good parts per cycle. The productivity could then be doubled. What a revelation! When this data was taken to senior management, the initial; reaction was disbelief. Management had no idea that this was happening.

The Japanese have a solution called genchi genbutsu which translates to ‘go and see for yourself’. Why didn’t the senior management know what was really going on? Did the plant need another 14 machines? Over the next 34 weeks, the teams worked to repair the dies and

improve the general maintenance of the machines. Aside from a few minor problems the defect rate continued to fall to almost zero after 40 weeks. We were heading towards a six sigma performance. At the end of this period, the company was confident enough to consider exporting to Singapore, USA and Japan. Five weeks after the first container was sent to Japan - just before Christmas - the company received a worrying message: the Japanese customer was sending back defective parts. There was panic in the company. We all anticipated that container loads would be returned. Instead the small parts arrived in an envelope. In all, 20 parts from the whole container. The customer believed that we could benefit from an analysis of the parts returned and we certainly did. It is easy to criticise management in this case. Western culture has taught us many bad habits. The Japanese have a solution, it is genchi genbutsu… “go and see for yourself”.

When studying any system it is important to go directly to the source. Simple and costly errors can be made if there is a supply chain of information involved and the data at the source is not collected and analysed, and this was the case for the client above. It is important that the communication channel remains open and there is an honest and trusting environment between operators and managers. Another client of mine had a serious measurement problem when they thought they were measuring the real demand to be placed on a system but instead they changed the real demand into an error-laden forecasting system, with input from the marketing department based on what they thought they could sell, and this resulted in massive overproduction and waste. There is a cardinal rule for manufacturing businesses….make only what you can sell with the correct quality cost and delivery. Any non-demand input into a manufacturing plan will increase the variation and produce a less desirable fit between demand and production and hence will result in excess finished goods inventory and hence more working capital. [John Blakemore set up Blakemore Consulting International, a specialist in the application of Lean Manufacturing continuous flow and innovation of process and product. For further details of measuring systems see ‘Competitive Manufacturing Management’...Velocity which can be downloaded for free from www. blakemore.com.au] Blakemore Consulting International 02 9357 2518 www.blakemore.com.au Manufacturers’ Monthly APRIL 2014 54

MA0414_000_CON

2014-02-21T15:12:20+11:00

Improve your machine safety It’s more than just a legal requirement

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2014-03-03T14:15:46+11:00

BIG ASS COMFORT. BIG ASS SAVINGS. BIG ASS FANS. “We’ve eliminated 100 ineffective box fans from our floor, saving $19,500 a year in operation costs.” Trever Carlson Environment and Technical Service Manager Federated Co-operative Ltd.

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