Manufacturers' Monthly May 2015 by Prime Creative Media

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

MAY 2015

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

MAY 2015

Innovation shines at

NMW 2015 INSIDE >> 18

IT@MM Technology reshaping manufacturing

Heating & Air Conditioning Keeping the workplace warm this winter

Metal Cutting CAD/CAM nesting software

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Inside

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For daily news visit manmonthly.com.au

MAY 2015

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

6 Editorial

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

Graphic Designer: Dave Ashley david.ashley@cirrusmedia.com.au Production Co-ordinator: Mary Copland Ph: (02) 8484 0737 mary.copland@cirrusmedia.com.au NSW Sales: Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Ph: (02) 8011 3184 anthony.head@cirrusmedia.com.au

14 Comment

28 NMW preview

42 Automation & Robotics

■ Collaboration is key

■ A roundup of what you can see at this year’s show

■ Uncaged robots: all the rage

16 IT @ MM

NSW, SA/NT & WA Sales: Cirrus Media Ph: (02) 8484 0868 anthony.head@cirrusmedia.com.au

22 Finance, Leasing & Rentals

Published 11 times a year Subscriptions $140.00 per annum (inc GST) Overseas prices apply Ph: 1300 360 126

■ Don’t pay too much ■ EFIC’s new flexibility ■ SMEs to increase salaries, hirings

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■ Keeping the workplace warm this winter ■ HVLS fans for winter and summer ■ HVAC boiler flow meter ■ Which heating system is right for your operation?

36 Metal Cutting ■ CAD/CAM nesting software

26 Automotive

40 Austech ■ Onshoring trend sets the scene for Austech

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

MAY 2015

WITH more than 200 industry-leading brands now confirmed for National Manufacturing Week (NMW 2015), this year’s event will showcase many new and Innovation shines at innovative technologies. NMW 2015 Manufacturers looking for new opportunities will be able to inspect new solutions from Bosch, CGB Precision Products, Adept Turnkey, Millsom Materials Handling 2 0 1 5 - 0 4 - 0 2 T1 5 : 1 0 4 0 : 2 2 9 + 1 1 : 0 0 and dozens more. 18

IT@MM Technology reshaping manufacturing

Heating & Air Conditioning Keeping the workplace warm this winter

Metal Cutting CAD/CAM nesting software

46 Packaging ■ How to minimise your pallet wrapping costs

48 Materials Handling ■ Sanitary tubular cable conveyor ■ K-Wrapper dewatering idler ■ MLA and SANY form alliance

50 What’s new ■ Rapid identification of PD ■ Flexible package leak detector ■ High-quality, dry compressed air

54 The Last Word ■ Rodney’s factory robot revolution

Behind the cover

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manmonthly.com.au

INSIDE >>

30 Heating & Air Conditioning

■ Steering towards an international future

Average Net Distribution Period ending Sept ’14 18,688

manmonthly.com.au

Snapshot STEM skills urgently needed Aussie SME exporters optimistic Slight improvement in April PMI

■ Technology reshaping manufacturing ■ Hype, reality and potential in 3D printing ■ New 3D printing file format

QLD Sales: Sharon Amos PO Box 3136, Bracken Ridge, QLD 4017 Ph: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 sharon.amos@cirrusmedia.com.au

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8 News & Analysis ■ ■ ■ ■

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

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

■ Rug up, winter’s coming!

NMW 2015 will be collocated with Austech, the SMART Logistics conference and Australia’s first complete safety event, the Safety First Conference & Expo. This will harness shared energies from the manufacturing, transport, building & construction, government and broader industry sectors. It all takes place in Melbourne, from May 26 – 29.

Manufacturers’ Monthly MAY 2015 5

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Comment

MARTIN SINCLAIR – Publisher

Rug up, winter’s coming!

NEXTISSUENEXTISSUE • Endeavour Awards – winners issue • Motors & Drives • Waste & Pollution Management • Plant & Machinery Maintenance • IT@MM – Mobile Technology • Forklifts, Stackers & Loaders M Ato0benefit 4 1 5from _ 0Govt 0 0Policies _ SCA • How

O last month, JP Morgan’s research paper explained how manufacturing is benefiting from a weakening Aussie dollar, which is “supporting Australia’s growth transition”; with an expected 0.6% GDP lift over two years. Is it just me, or does nobody else feel the urge to run to the bottle-o for a case of Champers? This translates to a 0.8% lift in manufacturing output; barely nudging the dial on manufacturing’s share of GDP, which is currently wallowing around 6% of GDP. In the same week, I read a stirring war-cry from Mayor of London, Boris Johnson. He begins a comment on Facebook with an observation he made at Bristol docks, where he saw row upon row of British-made cars en-route to markets around the world. The success story that is UK’s manufacturing revival (10% of GDP btw) should be revered. But this isn’t about how the UK focussed on design expertise, innovation, fiscal policy, labour reform or even trade agreements. It’s all of these combined. But it took not only political will, but also no small measure of failure to get British manufacturing back to winning ways. Love her or loathe her, Thatcher’s dismantling of the trade unions was a starting point for change in UK manufacturing. 1 2 0 Blair 1 5 -continued 0 3 - 3 0the T 1trend 5 : 2and 9 :supported 4 9 + 1 1free : 0 0 markets. Thatcher had the license to do this in the first

place because of the Winter of Discontent, during which time the UK struggled through arguably the worst manufacturing period since the start of the industrial revolution. A new leadership rose from the ashes of UK industrial failure. In Australia, overly complex labour laws and clueless fiscal policy are a hindrance to industry. But thanks to the mining boom, there’s been no Winter of Discontent. Australia’s economy doesn’t know failure and the system endures. So politicians jump on the back of 0.8% growth; even though growth comes from terms of trade impetus. The problem is, this makes lazy politicking; as does blaming the Upper House for stymying change. Currently Government lacks the numbers and leadership for proper, necessary reform. Gerard Minack, strategist at Morgan Stanley, called time on Australia’s “luck” back in December. Perhaps winter’s not far off; perhaps it’ll be more like a long drawnout autumn. But maybe a proper winter is the catalyst needed to usher in fundamental reform; the kind of reform that encourages innovation and collaboration that would see Australia as a world-beating, high-tech manufacturer. What are your thoughts? Emails are always welcome. martin.sinclair@cirrusmedia.com.au

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SnapSHOT Australian Performance of Manufacturing Index (PMI)

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8 MAY 2015 Manufacturersâ&#x20AC;&#x2122; Monthly

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Source: Australian Industry Group

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AUSTRALIA’S LEADING SUPPLY CHAIN CONFERENCE & EXPO 26 & 27 May 2015 Melbourne Convention & Exhibition Centre

COMPETENCIES FOR COMPETITIVE ADVANTAGE This year Australasia’s foremost event for Supply Chain and Logistics professionals is taking place at the Melbourne Convention Centre on 26th & 27th May, with its best ever program.

There are a host of international Global Thought Leaders including;

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Here is your best all in one chance to engage with the largest gathering of your peers in the region. Attendees will have extensive opportunities to engage, connect and network via site visits, Smart Expo 2015, Supply Chain Industry Dinner and Smart Awards.

John Phillips PepsiCo (USA)

Kim Baudry Dematic (USA)

Siegfried Zwing Knapp (Austria)

Caleb Nicholson Kathmandu (NZ)

Erich Gampenrieder KPMG (USA)

Kobus Van Der Wath The Beijing Axis (Beijing)

EMPOWER

Featuring thought-leader plenary keynotes, best practice case studies, extended focus sessions, interactive panel discussions, 70+ speakers and a choice of 8 streams – the program for Smart 2015 has been designed to empower supply chain, logistics and procurement professionals with the knowledge, skills and capabilities needed to deliver competitive advantage in their respective organisations. We would encourage you to register to attend the Smart Conference.

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Learn how to create a culture of excellence that will deliver real competitive advantage. Find out how to transform your company’s supply chain, procurement and logistics capabilities from a cost of business to a fundamental driver of business success.

Key companies presenting include: Samsung Electronics, Australian Antarctic Division, Coles Supermarkets, Diageo, DuPont China, Evok3ed, Fuji Zerox, George Weston Foods, Glaxosmithkline, KPMG, Louis Vuitton, Onesteel, PepsiCo USA, Ports Australia, Suntory, Telstra, UN Global Compact and Woolworths.

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News&ANALYSIS STEM skills urgently needed THE Business Council of Australia’s president has warned that Australia needed to adjust its education system and workplaces or be overwhelmed within a decade by technological change. In her speech to the National Press Club, the business lobby group’s head, Catherine Livingstone, said digital disruption was something the country was not prepared for. It was essential to reform education, with primary school-level exposure to STEM (science, technology, engineering and maths) needed. Training and work also needed to be integrated and continue throughout a worker’s career. “Teaching four-year-olds how to code, introducing them to computational thinking, problem-solving: they’re absolutely capable of it,” Livingstone M A 0 5said. 1 5 _ 0 0 0 _ P GE “And that’s when they should be

Slight improvement in April PMI

learning those skills. So I’d like to see that coming into the curriculum immediately. The pace of technology adoption in workplaces was another reason education reform was urgent, said Livingstone. She cited Oxford University research figures suggesting that in the US, 47 per cent of jobs were at risk of being automated out of existence. “We need to move urgently from a discussion about protecting the jobs of today, to creating the jobs of the future,” she said. “Precision welders and robotics mechanics will be more useful in the growing advanced manufacturing sector than yet more law graduates for whom there are no jobs.” The consequences of not acting would be dire, said Livingstone. “If we do not [act], we face certain loss 1 of 2 standard 0 1 5 - 0of4 living - 2 3 and T 1 social 1 : 4 0 : 3 cohesion,” she said.

AUSTRALIA’S manufacturing sector experienced its fifth straight month of contraction in April, according to the Australian Industry Group PMI. The index was up slightly (1.8 points) from March’s overall result of 46.3, though remained under 50 (the line separating expansion from contraction). There were bright spots in housing construction, low interest rates and the lower dollar. However, the local market was reluctant to invest in new equipment, said Innes Willox, the Ai Group’s CEO. “While another cut in interest rates may help boost demand, budgetary measures, particularly those targeting increased investment are more likely to provide the lift the domestic economy needs,” Willox said in a statement. Other difficulties included the weak mining sector and the wind-down of the automotive industry. Every single activity sub-index within the PMI was under 50, even exports (down 4.3 points to 47.5), which had previously been in expansion for four months. By sub-sector, the results looked more encouraging. Food and beverage led the way with a result of 55.3 (down 4.1 points), with three other sub-sectors in growth.

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Aussie SME exporters optimistic SME exporters have started the year optimistically, with 39 per cent expecting their export sales to increase over the next 12 months, according to research released by the Export Finance and Insurance Corporation (Efic). Increased overseas demand (24 per cent) was the main reason provided for this increase, with this optimism around export sales growth also up by 8 per cent from this time last year. The research surveyed 871 SME exporters. It is the fifth in a regular quarterly series conducted by Efic. Since the start of 2014, the proportion of SME exporters expecting that access to finance would become more difficult has grown by 157 per cent. This looks set to continue in 2015,

with the majority (58 per cent) in this survey expecting to find it more difficult to access finance for their export or international operations in the next 12 months. The proportion of overall revenue attributed to export sales increased by 25 per cent during 2014, highlighting just how important exports have become to those SMEs surveyed. Exports now make up 16 per cent of total revenue, with this forecast to grow by another 4 per cent in the next 12 months. Smaller exporters (with turnover of $100,000-$1m) are the most positive, with this group expecting exports, as a proportion of overall revenue, to grow by 6 per cent in the next 12 months. manmonthly.com.au

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News&ANALYSIS In brief... China’s all-robot factory Construction is underway for the new Shenzhen Evenwin Precision Technology Co. electronics factory in Dongguan, China. 1.000 robots would be deployed initially. Chairman Chen Qixing plans to run Shenzhen with 200 people (it employs about 1,800 now).

Orora wins awards Orora has won 14 gold and five highly commended awards at New Zealand’s Pride in Print Awards for 2015. The awards recognise excellence across Packaging, Publications, Business Print, Labels, Displays, Promotional, Specialty and Industrial categories. Judging considers technical excellence, materials and equipment used.

VIC budget rail announcement Victoria’s budget included a rail announcement worth a claimed $2 billion. Premier Daniel Andrews announced 100 new metro trains, 100 new trams and a “massive expansion” of regional trains in the 2015-2025 strategy, including 20 E-Class trams made at Dandenong’s Bombardier factory for 2018.

Indian GM manufacturing hub General Motors is looking to boost weak Indian sales and will establish a global manufacturing and export hub there. The US company aims to up market share to five per cent by 2025, a projected 400,000 vehicles, from 57,600 last year.

Mondelez profits after cuts Mondelez Australia’s profit for the year to December increased 43 per cent, assisted by efficiencies and a $30 million tax credit. Revenue (down 3 per cent) was $1.74 billion. It saved by cutting R&D spending by 60 per cent, removing 186 jobs, and shrinking product sizes. After-tax profit was $168.1 million.

Asaleo expansion plans Asaleo plans to expand into the nappy market. CEO Peter Diplaris told the an AGM net profit growth for the year should be at the low-to-mid single digit level. Asaleo will invest about $15m on capital spending this year, and take on Kimberly-Clark’s Huggies brand.

12 MAY 2015 Manufacturers’ Monthly

Caution advised on CO2 reduction goals INDUSTRY lobby group Manufacturing Australia cautioned against Australia setting ambitious long-term greenhouse gas emission reduction targets. The Australian Financial Review reported that the group’s chairman Mark Chellew also backed the federal government’s Direct Action plan over the dumped carbon tax, claiming the latter was sending jobs overseas. “To go for such large targets if we aren’t seeing similar moves offshore would be unwise,” Chellew told The AFR. “Most Australians agree we have a problem with climate change but that doesn’t mean we should be exporting jobs offshore.” Brickworks was also critical of a carbon tax as a way to deal with emissions. The company (a member of Manufacturing Australia), said that it is only paying half as much under Direct Action as it was under the carbon tax. Under DA, it pays about about $13.95 per tonne of carbon dioxide output. Climate Institute deputy chief executive Erwin Jackson claimed DA was expensive and ineffective. “Under the previous carbon laws, major emitters would not only be responsible for their emissions, they would be paying around $10 a tonne, whereas the government is paying nearly $14,” he said.

Last month the Climate Change Authority recommended Australia aim to reduce its greenhouse emissions by 30 per cent by 2025. “To maintain that posture in the light of increasing international actions to reduce emissions – by developed and developing, big and small countries – makes it even less credible,” CCA chair Bernie Fraser said. “The fact is that Australia stands to be massively affected by global warming whatever its share of global emissions.” The country’s emissions are less than 1.5 per cent of the global total. The Australian Industry Group, like Manufacturing Australia, has highlighted what it believes will be the economic cost of emissions reductions. It told a taskforce that matching the US’s goal of reducing emissions by 26 per cent compared to 2005 levels would cost $25 billion, The Australian reports. “Purchasing abatement post-2020 in volumes consistent with any of the indicative targets considered above would require, at a minimum, very substantial new budget commitments, which would likely grow strongly,” the Ai Group’s submission to a taskforce on Australia’s emissions reduction target reads.

What members of our manufacturing community thought about carbon reduction goals They will love Bjorn Lomborg “To go for such large targets if we aren’t seeing similar moves offshore would be unwise,” Chellew told The AFR. Either Mr Chellew has been living under a rock or this is another short-sighted, ill-informed, self-serving piece of advice. Virtually all experts agree that Direct Action is a less efficient form of policy than using a proper market mechanism. But I guess if you can choose between paying for the pollution you cause or letting the taxpayer foot the bill, then the latter looks a lot better when you are Manufacturing Australia. And if Brickworks is paying $13.95 per tonne of carbon, does that mean there is still a price on carbon? I thought a price on carbon was axed? Perhaps this story should come with a disclaimer that shows Brickworks is a large donator to the liberal party, and its statements regarding carbon pricing should

perhaps be taken with a pinch of salt. If these guys are really so worried about jobs going overseas, they should be lobbying for border pricing adjustments (like the GST). Now they just look like apologists who don’t want to do their fair share. Andrew Clarke Remove demand charges from tariffs and solar PV becomes a good investment for most industries.

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.

Anthony In Japan the Government is going solar in a big way in terms of incentivising industry to embrace as an energy source, even with the powerful energy companies (TEPCO) having influence. Nuclear is on the outer with nearly all reactors offline and the Government needs to reduce energy import costs so renewable it is.

manmonthly.com.au

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Comment

INNES WILLOX – CEO Australian Industry Group

Collaboration is key In today’s ultra-competitive and rapidly changing business environment, innovation is the best path to success. And innovation requires collaboration between business and the research sectors. Innes Willox writes.

I Group is particularly aware of the need to boost the innovation performance of Australian manufacturers. With this in mind, we appreciated the opportunity to work closely with the Australian Technology Network (ATN) of Universities in sponsoring a report launched last month: Collaborate, Innovate and Prosper: How to Support Australia’s Competitiveness and Prosperity through Targeted Policy Solutions. Much research points to the benefits of innovation. Relative to their less innovative counterparts, innovative manufacturers tend to be more productive and more competitive. This equates to greater export success, M Ahappier 0 5 1 5staff, _ 0 0faster 0 _ Nannual PA rates of growth and more profit. Con-

14 MAY 2015 Manufacturers’ Monthly

versely, the market position of a business that is not innovating is more likely to be being steadily eroded. There is ample scope for Australia to improve its innovation perfor-

“

of us to work together…our research institutions and the business sector must collaborate. We must translate our ideas and research into real goods and services, technologies and

Successful countries have more university researchers employed in industry... mance. It will require action on many fronts and the combined efforts of many people in business, government and academia. As the Minister for Industry and Science, Ian Macfarlane, has 1 commented: 2 0 1 5 - 0 “Australia’s 4 - 1 7 T 1 future 5 : 2 0 : depends on the commitment of all

life improvements. And we must do it on a scale not attempted before.” Ai Group supports the view that Australia’s innovation performance can be enhanced by boosting coltoday’s ultra-compet1laboration. 2 + 1 0 : In 0 0 itive and rapidly changing business environment, innovativeness, and ultimately business competitiveness, is based on the ability to tap into global knowledge and experience. A company’s competitiveness is hugely dependent on the depth and quality of its networks and interactions. However, there is no doubt about it: collaborative innovation and particularly research-industry collaboration is not Australia’s strong suit. The need to boost collaboration is acknowledged by the Government. The Industry Growth Centres initiative is seeking to harness the power of collaborative innovation; additional funding has been allocated to building ‘Research Connections’ through the Entrepreneurs Infrastructure Program and the Government has sought advice to build stronger ties between researchers and businesses. The report puts forward five recommendations to establish stronger connections between the business and research sectors. Building on the foundations of the Government’s Industry Innovation and Competitiveness Agenda, these include: • Rebalancing the national research agenda to underpin Australia’s economy and future prosperity.

There are two levels of imbalance in the current system of research and research funding – Australia’s industry profile is not reflected in our research, with an imbalance between our industry strengths and our research focus; and there is a misalignment in the research agendas of industry and the university sector, with industry R&D outlay heavy on engineering and ICT and universities skewed towards medical, health and biological sciences. • Creating incentives for universityindustry collaboration. The need for Government funding of basic research is acknowledged – but strategic realignment of Research Block Grants is needed to increase incentives for university researchers to undertake research directly with industry. Similarly, incentives for business to undertake innovation – particularly in collaboration with universities – should be strengthened under the R&D Tax incentive. • Training researchers for diverse careers. Higher performing OECD countries have a greater proportion of university researchers, including PhDs, employed in industry. • Enhancing career mobility between industry, academia and government. Success for academics continues to be largely measured by the quality and quantity of publications, rather than industry experience. • Providing incentives for co-investment in research infrastructure between universities, industry and government. World-class facilities promote collaboration – a large, tangible framework of infrastructure in both CBD and regional settings provides opportunities for co-location and integration of industry and researchers. These recommendations can provide a good starting point for discussion by governments, universities and businesses. www.aigroup.com.au manmonthly.com.au

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TechnologyIT@MM Hype, reality and potential RMIT’s Professor Milan Brandt discusses the adoption, limitations, and potential of metal-based additive manufacturing systems with Brent Balinski.

“T

HERE are really very early examples of – the companies are simply exploring this technology,” said RMIT’s Professor Milan Brandt. The director of RMIT’s Centre for Additive Manufacturing noted that while there had been some Additive Manufacturing (AM) success stories at this early stage, adoption within Australia’s industry had been slow overall. “In terms of research we’ve delivered a prototype, we’ve delivered reports, but they have to do their own business case,” he said of some recent cases. “And that’s where things stop.” Brandt, who will give the keynote address at Manufacturers’ Monthly’s first Factories of The Future event, told us that his facility had never had more enquiries regarding metal-based AM than in the last 12 months. But the technology – which is transformative as well as much-hyped – hasn’t been something Australian manufacturers had invested in, with business cases of local companies often failing when brought to the board level. The Professor will discuss real-world topics such as when a business should and shouldn’t invest in 3D printing equipment, hype versus limitations, and other unsexy-but-nonetheless-very-important topics such as reliability issues with metal-based systems. In terms of metal 3D printing, monitoring and inspection are still issues, despite developments in various methods (which are very much stochastic processes, adds Brandt.) “You might get a vapour, a pore or lack of fusion, and you have no control because you’re not monitoring anything,” he said of one barrier to creating ideal parts for critical applications. “The other one is the properties of the structures, the internal stresses in the parts. So you have to then look at strategies to mitigate the stress, from the design perspective or from the path – the laser or electron beam path – because depending on the way you’re building, the stresses will be different.” A novel and incredibly promising use of the technology using titanium alloy has been developed by an RMIT research team led by Brandt. Collaborating with surgeon Professor Peter Choong of St Vincent’s, the team’s Just In TIme patient specific implant method replaces bone lost through operations to remove osteosarcoma. Designed using CAT or MRI data, the printed 16 MAY 2015 Manufacturers’ Monthly

Professor Milan Brandt, Technical Director of RMIT’s Advanced Manufacturing Precinct and the Director of its Centre for Additive Manufacturing. lattice-like structure emulates properties of human bone, such as the ability to bear loads and to flex, and has the potential to speed up recovery for a patient. According to Brandt’s university, a patent has been lodged and animal trials of the technique begin this year, with later trials on humans following. Medical implants are an area where metal 3D printing has a lot to offer. It has already been used to create tens of thousands of acetabular hip cups worldwide. A notable example of the possibilities last year was an effort by the CSIRO, St Vincent’s and Melbourne’s Anatomics in October to replace a heelbone lost to cancer surgery, saving the man’s lower leg. Further potential collaborative efforts, including those in the biomedical sector and elsewhere, have been frustrated recently by the uncertainty around the future of the Innovative Manufacturing Co-operative Research Centre (IMCRC). The IMCRC was the combined bid of the Advanced Manufacturing and Manufacturing Industry Innovation CRCs at the suggestion of industry minister Ian Macfarlane in February 2014. The MIICRC submitted its bid for Round 16 of the CRC program in June 2013, and was strongly

focussed on additive manufacturing, as is the IMCRC submission. With other countries investing heavily in initiatives to spread additive manufacturing throughout their industries, the lack of a result after all this time for the CRC is a disappointment for those involved. “Really I think the government needs to tell us one way or the other,” said Brandt, who said the lack of a result had been frustrating for participants in the bid. “You can’t have big companies [like medical technology business] Stryker wanting to be involved in this now for two years and for them to move money from year to year, it’s a challenge.” The CRC program received an $80 million cut over four years in the last federal budget, and the Miles review of the program, announced last September, is currently with the industry minister. There is speculation that an announcement about the future of the program will be made at the 25th anniversary annual CRC conference at the end of this month. For the research institutes and companies who have been a part of the stuck-in-limbo bid – such as RMIT, Stryker and a host of others – they just want clarity. “Certainly from the industry’s perspective and in the comments I’ve received from industry, it’s been somewhat disappointing that the government has not made a decision one way or another,” said Brandt. “From RMIT’s perspective and other universities – life goes on and we have to talk to companies that are part of that IMCRC, and we are looking at alternative ways of funding those projects.” [Brent Balinski has been a journalist at Manufacturers’ Monthly since 2012. He is particularly interested in 3D printing and innovation. Find him on Google Plus at https://plus.google. com/+BrentBalinskiCirrusMedia]. For more on the May 28 Factories of The Future event, go to www.manmonthly.com.au/events. The venue is Palladium at the Crown, The Crown Casino Melbourne. Tickets are $30 plus GST. RMIT Advanced Manufacturing Precinct 03 9925 4197 www.rmit.edu.au manmonthly.com.au

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New 3D printing file format Seven leading technology companies have announced a partnership to develop a new 3D printing file format.

HE 3MF Consortium – comprising Dassault Systèmes S.A.; FIT AG/netfabb GmbH; Microsoft Corporation; HP; Shapeways, Inc.; SLM Solutions Group AG; and Autodesk Inc – launched the eponymous .3MF specification at the end of last month. According to their release, the format overcomes problems associated with formats such as .STL (released in 1989) and would lift productivity and effectiveness for those using 3D printers. “The 3MF specification will empower people, maximize productivity, and unlock the full capabilities of 3D printing,” said Adrian Lannin, executive director of the 3MF Consortium. “3MF will align CAD software and 3D printing hardware and software in a more information-rich file format, specifically designed to support the needs of modern 3D printing throughout the entire printing process. Alex M A Oster, 0 3 1 CEO 5 _ 0of0netfabb, 0 _ C Rsaid, O -“I would 1 2like 0 1 5 to thank my colleagues from the founding compa-

Will .3MF strengthen the pipeline between file and build plate? nies for their time and dedication to get this done.” He added that the consortium was expected to launch several additions to the standard before the year was complete. Business Insider compared the group’s project to solve current inter-operability and usability problems to Windows 95’s introduction of “plug and 0 3 play” - 0 3 to T install 1 0 : 1devices. 7 : 2 4 + 1 1 : 0 0 3DPrint.com pointed out that the .3MF file

format has actually existed for years, but has been recently overhauled by Microsoft. The consortium’s stated mission regarding the format is reproduced below: • Rich enough to fully describe a model, retaining internal information, color, and other characteristics; • Extensible so that it supports new innovations in 3D printing; • Interoperable and open; • Practical, simple to understand and easy to implement; and • Free of the issues inherent in other widely used file formats. Launched in 2015, the 3MF Consortium is a Joint Development Foundation project with the goal to define a 3D printing format that will allow design applications to send full-fidelity 3D models to a mix of other applications, platforms, services and printers. The 3MF (for 3D Manufacturing Format) specification eliminates the widespread issues with currently available file formats.

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Technology IT@MM

Technology reshaping manufacturing As Australian manufacturers prepare for the year ahead, a range of economic and business forces are making the task particularly challenging. Peter Dickinson writes.

Real time access to systems is being used to streamline processes and improve efficiency.

HILE the falling dollar has boosted prospects for exporters, uncertain domestic conditions are constraining local markets. Add increasing competition from overseas and the picture becomes even more complex. As a result, the hunt is on for ways to improve efficiencies while at the same time keeping operating costs under control. Across the manufacturing sector, information technology is being embraced as a way to improve performance. Through careful selection and implementation of IT, companies can radically reshape their operations and attain a significant competitive advantage. Yet, because of the pace of change in IT, making this selection can often be challenging. It sometimes seems that products have been updated or superseded almost as soon as they’ve been purchased.

18 MAY 2015 Manufacturers’ Monthly

However, while individual components change regularly, there are some wider key trends with longer-term impacts that have particular relevance to manufacturers. By understanding these trends and putting them to work within your organisation, significant benefits can be realised.

The emergence of choice The last two decades have seen dramatic advances in information technology such as the introduction of smartphones, mobile apps, and cloudbased software with browser access. Core enterprise applications such as financials, human resources and ERP systems are now not only available as traditional on-premise solutions, they can equally be hosted by an external data centre, located in the cloud, or delivered via the Internet using a Software as a Service (SaaS) model. A cloud platform means extra

computing capacity can be ‘dialled up’ when required. For example, if a large design job requires extra computing and storage resources for a limited time, that extra capacity can be used and then discarded once the job is complete. Computing becomes an operational expense in the same way as electricity or water. Under the SaaS model, access to software is obtained by subscription. Rather than outright purchasing, a business subscribes based on the number of users. This number can be increased for an incremental cost as the business grows, or if necessary, it can be decreased during a business downturn. This degree of flexibility can be particularly important for start-up and young businesses, where growth is difficult to accurately predict. SaaS also shifts the responsibility for data backups, system security, upgrades and patches to the cloud

provider. While the outcome is hopefully reliable, on-demand access to an organisation’s most important applications the onus is firmly on the vendor to provide an ongoing, fit-forpurpose service. The applications themselves have also changed. The emphasis is on access to information and to facilitate this modern software embraces designs that improve ease of use, offer remote and mobile access, real time data, excellent search functionality and smart use of templates and forms for easy capture and presentation of data. There’s acknowledgement that different people work in different ways, and users should have the flexibility to personalise their screens or workspaces accordingly. In short, all these changes in technology have brought choice. Manufacturers have the opportunity to choose the software and the delivery model – manmonthly.com.au

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Technology IT@MM or combination of models – that best suit their business needs, their budget and technology capability.

Countertuitive Having said that, history tells us that owning key plant is central to a manufacturers’ business philosophy and a mission critical business system has been viewed as any other major asset. The preference has always been to own it rather than rent it even if that requires a degree of debt funding. It is a philosophy which can be counter-intuitive when it comes to cloud computing – which is essentially a rental model. The considerable benefits to be derived from cloud hosting are well documented and according to research firm Frost & Sullivan, 69% of Australian organisations already use some form of cloud computing services. But for those who view their critical systems as plant it is still essentially a rental model. The ideal is to combine the best of both worlds; to be able to embrace the benefits of the flexibility that the cloudMoffers A 0 5 while 1 5 _ still 0 0 being 0 _ T able R O totreat your core business systems as

an asset with the additional certainty that brings. Whether you host onpremise or in the cloud it should be a considered choice based on your business requirements not a decision that is driven by the system’s developer.

inventory levels. Warehouse staff can query centralised systems while on the floor, logging stock movements and shipping details.

The Internet of Things

Another mega trend that has significant potential for manufacturers is the emerging Internet of Things While mobility has been gradually (IoT). While we have already seen making inroads for a couple of decsignificant growth in communication ades, it’s only recently that the indusbetween machines and other devices try has seen a tremendous increase over the internet this is set to shift in the number of organisations using from being piecemeal to pervasive mobile devices and in the way these IoT will allow an even greater devices are used. level of automation. Already mining This is in large part thanks to the companies are examining the potenrising capability of mobile devices tial for driver-less trucks and trains and improvements in networks. while delivery companies are investiSmartphones and tablets today have gating the use of pilot-less drone airput the sort of power once only found craft and sensors log inventory in and in desktop computers in the hands of out of a warehouse making manual almost every employee. stocktake obsolete Such changes will By encouraging widespread use of gradually become ubiquitous. mobile devices at work, employees As the number of devices connected are able to connect directly to the to the internet increases, the potential business engine from any location. for information sharing and business Real time access to systems is bebenefit increases exponentially. Add ing used to streamline processes and the growing capabilities of both fixed improve efficiency. For example, onnetworks and the trend 1the-road 2 0 1staff 5 - can 0 4 use - 1 mobile 5 T 1 3devices : 3 9 : 4 and 3 + mobile 1 0 : 0 0 becomes even more powerful. to place customer orders or check

Mobility

Matching technologies

While such overarching technology trends offer much to the manufacturing sector, it’s vital for organisations to ensure they put them to work in the most effective way. The IT industry is very good at drumming up attention for the “next big thing”, but it’s important not to get caught up in the hype. A new cloud platform, mobile application or handheld device might seem a fantastic option, but if it doesn’t meet the specific needs of the business, any investment will be wasted. Each new technology should be viewed in the context of real-world business requirements. Only when it can be proven that an investment will reduce costs or improve efficiencies should that investment be made. Companies which do this will find themselves well placed to take advantage of future opportunities. [Peter Dickinson is CEO of Greentree.] Greentree 1800 000 737 www.greentree.com

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FinanceLEASING & RENTALS Don’t pay too much Interest rates might be at an all-time low, but making a poor decision on commercial finance can still be a very costly mistake. Alan Johnson reports.

Looking to expand? Make sure you have the optimal finance structures.

OMMERCIAL finance can be a daunting task for many manufacturers. However, there are some basic areas that when considered will make the task a lot easier on the cash flow of the business and give peace of mind to the business owner. Ken Richards, director of Interlease, one of Australia’s largest business finance broking companies, says there are five key areas manufacturers should consider before entering into a commercial finance agreement.

Preserve working capital Richards says for almost every business, the most important component is access to sufficient working capital. “Some of the most profitable businesses from a EBITDA perspective have been brought undone by having 22 MAY 2015 Manufacturers’ Monthly

limitations on their working capital; during growth phases, acquiring new businesses or when the market changes,” he said. While in some cases it can be tempting to purchase capital equipment from surplus funds or by using overdraft facilities, Richards warns that this is not always the best option. “It may be better to use those funds to pay creditors, secure discounts or to fund the expansion of the business.” Plus he advises manufacturers to consistently focus on ensuring their clients pay promptly, and in full. “This is a very important area for a company’s ongoing success, and is an area many overlook and effectively means you are providing finance to your customer” Richards told Manufacturers’ Monthly.

Optimal finance structures When looking to finance capital equipment, there are a number of issues to look at when choosing the optimal structure and term. Regarding cash flow, Richards says manufacturers should choose the option that will best match equipment finance cost with the income from the asset. “In some cases the income may be seasonal or may vary across the life of the asset. Therefore manufacturers should make sure that the finance can be structured, as best as possible, to match the expense to the income expected to be generated.” Richards points out that companies should also take into account that some assets will become obsolete much quicker than others. “For example, computer hardware will most likely achieve technical

obsolescence far quicker than a machining centre. So the decision as to what term to choose to finance equipment needs to take into account each individual asset type. “Plus different assets are deemed to have different depreciation rates and a poor selection of finance structures can reduce the tax effectiveness of capital equipment purchases, for example a machining centre running one shift for five days is not being worn out as quickly as one running three shifts over six days,” Richards said.

Minimise security offered For the financing of commercial equipment many manufacturers turn to their bank, which in many cases has funded other purchases for them, such as property. However Richards says companies manmonthly.com.au

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Equipment Finance Options Operating Lease or Rental Agreement If upgrading equipment and vehicles on a regular basis, an operating lease or rental agreement can be a cost effective and flexible solution. Companies can put the latest piece of equipment to work without the risk of holding it past its prime or outlaying large cash sums up front.

Finance Lease A finance lease is a rental agreement between a company and its financier. The financier acquires the asset on the company’s behalf and rents it from them, making monthly repayments as if renting it from the manufacturer. A finance lease differs from an operating lease or rental in that the lease assumes the risk on the future value of the asset, and has the option to acquire the asset at the end of the lease.

Hire Purchase A hire purchase arrangement allows companies to have immediate use of equipment or premises, even though the bank or financier owns it. Companies have the option of buying it at any point during the agreement and ownership is automatically transferred when the last payment is made.

Chattel Mortgage A chattel mortgage differs from Lease and Hire Purchase Agreements in that it gives companies immediate ownership of an asset upon entering the agreement. It is a fixed interest loan with mortgage as security

Novated Lease A novated lease is a vehicle lease where the company makes all rental payments to a financier on behalf of the employee, while the employee has full use of the vehicle right away.

need to remember that the bank’s overlying objective is to provide the best outcome for its shareholders. “As such, a bank will seek to obtain the maximum amount of security it can for each dollar it lends. If a manufacturer thinks like a bank, he or she will quickly understand why the banks try to get as much security as possible, and never want to hand it back,” he explained. Most manufacturers when starting out offered real estate security to obtain bank facilities. While this may have been necessary initially, Richards says manufacturers should look to have their surplus security released once the business achieves a greater financial position. “For this reason, we recommend that a business be valued annually by a financial expert such as the company’s accountant,” he said. As a general rule of thumb, Richards says manufacturers should use manmonthly.com.au

anyone except their bank to finance capital equipment. “It is vital companies only use available funds and collateral security for working capital, and not to purchase equipment or other selffunding assets and they should not over expose themselves to any one financier as this may limit the funds available. “As a company’s exposure increases with any one financier, they will increasingly want to dictate terms and how and when the debt is repaid.” Richards warns that banks offer customers the products they like with little regard to what the individual customer’s needs are or what the equipment is, how it will be used and how long it will be retained. “Additionally, the bank almost always has property security and most businesses in Australia are required to provide an All PAPS, the equiva-

lent to the old fixed and floating charge and each of these documents and subsequent finance documents cross link everything to improve the bank’s position. “Many business owners don’t truly understand what this means and what control this gives the bank over their businesses and historically this charge remains well past the repayment of debt,” he said.

Choose the optimal financier Richards says it is important companies have access to a range of finance providers so they can choose the best option for each equipment type and for the company’s needs. “For example, when a manufacturer wants to purchase more than one machine, it is important to have the flexibility to be able to use multiple financiers. “This will give the company greater access to funds, but also the ability to choose the structure it wants for each machine.” When importing equipment, Richards says it is important the financier can pay deposits and progress payments to the overseas supplier without the requirement for security or the need to use the company’s overdraft. “Plus always ensure the finance providers can finance the full range of assets including; computer software, tooling and dies, office and factory fit-outs,” he said.

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nesses have great people on their team and have access to a range of external experts who are working to help achieve goals. It is not different with commercial finance. Richards says it is vital manufacturers use a truly independent finance broker who is an expert in business and equipment finance, with an understanding of the industry and equipment. “Too often businesses are relying on their bank, a mortgage broker or someone who has limited understanding of the optimal way to finance business equipment and machinery.” He points out that the finance market is competitive and companies should only use someone who understands all of the options. “Companies should always work with their accountants throughout the year to make sure they are making informed business decisions and to help them to decide which financial solutions will best suit their needs.” In summary, Richards says manufacturers should choose their clients, suppliers and business partners wisely and resist the urge to put all their eggs in one basket. [Alan Johnson is Manufacturers’ Monthly’s former editor. He has researched and written about all aspects of the Australian manufacturing sector for over 25 years.] Interlease 1300 859 429 1 2 0 1 4 - 0 3 - 1 3 T1 2 : 3 3 : 1 4 + 1 1 : 0 0 www.interlease.com.au

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2 0 1 4 5 - 0 4 - 0 2 8 4 T0 1 8 5 : 1 4 7 2 : 5 1 1 9 + 1 0 : 0 0

Finance LEASING & RENTALS

t See us a Austech 96 Stand 5 Unison Joints was the first SME exporter to benefit from the Government’s amendments.

EFIC’s new flexibility RECENT Government amendments to the EFIC (Export Finance & Insurance Corporation) Act means the organisation can now lend directly for the export of all goods, not just ‘capital goods’, allowing it to better support small and medium-sized Australian exporters. Previously EFIC’s support for exporters of consumable goods requiring working capital was to provide a guarantee to the exporter’s bank. This new lending flexibility is consistent with the Government’s focus on having EFIC help more Australian SMEs, through reducing red tape and the costs associated with accessing the organisation’s services. EFIC’s greater ability to lend directly to SMEs will help to lower the fees and charges SMEs pay when accessing finance from EFIC, due to the current duplication of credit and legal costs associated with having two parties (EFIC as guarantor and the SME’s bank as beneficiary) involved in each transaction. These changes will also help to make EFIC’S application and approval process more efficient, as well as increasing the number of SMEs, particularly smaller businesses, which can now access EFIC’S products and services more cost-effectively. EFIC will, however, continue to operate in the ‘market gap’, providing financial solutions to SMEs only where 24 MAY 2015 Manufacturers’ Monthly MTIQualos_Mitutoyo HalfVert.indd 1

the private market is unable or unwilling to help. The Government will also apply competitive neutrality principles to EFIC’s operations, as a way of ensuring these changes do not bring EFIC into direct competition with private sector financiers. In response to these changes, EFIC has created a product called the Export Contract Loan. Unison Joints, a Queensland-based manufacturer of expansion joint products, was the first SME exporter to benefit from the Government’s amendments. “EFIC’s ability to lend directly has resulted in big savings to our business, both in dollars and time, and its quick approval allowed us to move very quickly to secure an important export contract,” said Paul Fulloon, Director, Unison Joints. “We found the whole process very easy, with its streamlined application process helping to remove a whole layer of unnecessary due diligence,” Fulloon said. Andrew Hunter, EFIC’s Managing Director said it’s already clear that the new lending flexibility will allow the organisation to help even more SME exporters in all industry sectors reduce costs and receive the finance needed to succeed in international markets. EFIC 1800 093 724 www.efic.gov.au manmonthly.com.au

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SMEs to increase salaries and hire more people By ALAN JOHNSON ACCORDING to the latest MYOB Business Monitor, almost a quarter of Australian SMEs intend to hire more staff or give employees a pay rise in 2015, despite concerns on how they will attract more customers. Now in its sixth year, the bi-annual national survey of more than 1000 small to medium business owners found that 23% of business owners expect to pay their staff more, despite the backdrop of political uncertainty and a softening of consumer and business confidence. That uncertainty is not impacting everyone, with 12% of Australian SMEs looking to expand their fulltime staff base and a further 17% intending to hire more part-time or casual employees in the coming year. Businesses in NSW are most likely to increase salaries, with a quarter of those surveyed planning to pay more, whileMthe A 0state 5 1 5also _ 0had 0 0the _ Thighest SU expectations (21%) of expanding

SMEs in NSW in a positive mood. the intention to grow staff numbers their part-time or casual workforce. demonstrates the resilience of the MYOB CEO, Tim Reed, said the nation’s SMEs,” he said. latest Business Monitor results are Their optimism to work through encouraging considering the chaluncertainty and plans for future lenging circumstances Australian and reflects 1businesses 2 0 1 5 have - 0 4been - 1 facing 4 T 1 recently. 5 : 3 7 : 1 growth 4 + 1 0is:encouraging 0 0 the spirit and determination of small “The planned salary increases and

and medium businesses in Australia. “Also of note is the optimism of younger business owners, who anticipate the economy to improve within a year. “This is in contrast to the overall results where more than half of the businesses surveyed expect an economic upswing to take more than twelve months to kick in.” When it comes to attracting new customers, 32% said that is quite likely or extremely likely to put pressure on their businesses over the next 12 months, while a further 35% reported that it is likely to cause some pressure. When questioned about the future of the Australian economy, 60% of SMEs expect it will take more than a year for things to improve, while 41% of Generation Y business owners anticipate a positive change within the next 12 months. MYOB 1300 793 130 myob.com.au

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Automotive Steering towards an international future The first power steering Valve Balance Machine for use on automotive production lines was designed in a Sydney suburb, writes Hartley Henderson.

ITH the approaching demise of car making in Australia, opportunities are emerging to develop technology aimed at assisting manufacturers in other countries. The first power steering Valve Balance Machine (VBM) for use on automotive production lines was designed and manufactured in the Sydney suburb of Milperra by Kirby Engineering in the mid 80s. At that time steering systems were all based on hydraulic power steering. The basic objective of the machine was to provide a fast, flexible, easy to maintain, accurate system for balancing and testing of power steering components. The primary functions of the VBM were to precisely locate and dimensionally set axial positions as well as accurately find the hydraulic centre by precisely rotating the valve while measuring oil flow, pressure and temperature, and constantly monitoring applied torque. Once the hydraulic centre was found, with the valve being held under strict alignment conditions, the machine drilled and reamed a hole through the input shaft and torsion bar, then pressed a pin into the hole while monitoring insertion force and pin The V-Series machine featured the development of new principles of valve processing. position, locking the valve in its hydraulic centre. The machine was then required to apply a preand IP of Kirby Engineering. By then the market set force in the opposite direction to pin insertion was moving away from hydraulic power steering, to test the pin for final position and security. due largely to environmental considerations. An One or more optional torque tests could then be electric power steering system had been developed performed by the machine to accurately analyse which did not require hydraulic fluid and did not the pinned component’s results and analyse data take horsepower from the engine. for conformity to part print. Detailed information about all aspects of the machine cycle was then provided for each cycled component, both visually Emerging market on a VDU and electronically for traceability. Electrical Engineering Manager at Broens, Darren A 0 3Broens 1 5 _ Industries 0 0 0 _ M acquired O S - the 1 assets 2 0 1 5 - Woods, 0 2 - 2says 6 Tthis 1 5 meant : 3 0 that : 4 1a new + 1 1machine : 0 0 was InM2003,

26 MAY 2015 Manufacturers’ Monthly

needed to accommodate the emerging electronic power steering market. “Broens proceeded to develop the T-Series machine which was made available in electronic or hydraulic configuration to cater for both markets,” Woods told Manufacturers’ Monthly. “The T-Series machine was a totally new design that incorporated a rotary turret housing a drill spindle, ream spindle, and pin press tooling, and the machine had a greatly reduced footprint. “Around 20 of these machines were sold throughout the world, and by 2008 the industry was demanding a low cost balance machine for use only in the production of electronic power steering systems. “Broens took up the challenge and developed the V-Series machine, which was born from a blank sheet of paper and featured the development of new principles of valve processing. The result was an even smaller footprint and a greatly reduced cycle time.” Machines in the Broens range relating to the production of hydraulic power steering (HPS) systems include the Sleeve Slot Machine (SSM), Input Shaft Slot Machine (ISSM), Audit Test Stand (ATS), and the Final Assembly Test Machine (FATM). “The SSM is a 4-axis CNC controlled high speed internal sleeve slotting machine and will typically cut six or eight 4mm wide internal 36mm radius curved slots in a 22mm ID steel valve sleeve in 25 to 30 seconds, with automatic load and unload of the sleeve. “The ISSM is a 3-axis CNC controlled high speed external shaft slotting machine designed to cut slots to match the valve sleeve,” explained Woods.

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“Our VBM is a highly specialised and sophisticated computer controlled production testing machine that performs tasks that include establishing the hydraulic middle point, locking the valve at this point, testing the oil flow and pressure at the valve rotation end points, and recording the rotational angle at the mechanical end points. The machine also tests the torque required to achieve power steering assist from zero to maximum in both rotational directions, and records all data. “The ATS machine has a similar function to the VBM but without the valve locking function. Its main use is in the customer’s quality control laboratory. “Once the power steering valve has been installed in the power steering rack assembly that Darren Woods – Electrical Engineering Manager at Broens. goes into a vehicle, the amount of assistance generated (output) for the amount of torque (input) is confirmed by the computer controlled FATM which EPS benefits records all test data for traceability purposes.” According to Woods, HPS systems are graduIn relation to electronic power steering (EPS) ally phasing out in favour of EPS due mainly to and use of the Electronic Valve Balance Machine environmental and efficiency considerations. “EPS (V-Series), Woods points out that the assist is systems offer fuel savings of up to 0.33L/100km, generated by a brushless motor rather than by with a corresponding reduction in CO2 emissions a hydraulic pump as in hydraulic power steerof approximately 8g/km,” he said. ing systems. However, the same tests need to be “EPS also provides productivity benefits as performed M A 0 3and 1 5the _ 0resulting 0 0 _ Bdata A C recorded, 1 less 2 0 the 1 5 - there 0 2 - are 1 0not T 1as1many : 1 9processes : 0 3 + 1that 1 :the 0 0EPS valve hydraulic test function. has to go through and by removing hydraulic fluid

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an entire component of a steering system becomes obsolete. In addition, with EPS it is easier to offset the steering to get a perfect result compared with HPS. “Currently, approximately 70 percent of Broens HPS equipment is used in passenger vehicles with the remaining 30 percent used in light to medium commercial vehicles. For our EPS equipment, 100 percent is currently used in passenger vehicles. This is initially in the small car market, but belt drive systems can now cater for rack loads of up to 15KN, so we see significant future growth in EPS across a wide range of vehicle types. “Our volume of exports is rising significantly and now accounts for around 40 percent of the company’s revenue.” [Hartley Henderson has been a regular contributing writer to Manufacturers’ Monthly for the past eight years, covering industry developments in Victoria and South Australia. Prior to that, he held senior positions in government, semi-government and business enterprises and was National Program Director with the Productivity Promotion Council of Australia]. Broens 02 9829 1111 www.broens.com.au

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NMW Preview 26-29 MAY 2015

Manufacturing’s future on show in Melbourne National Manufacturing Week (NMW) showcases the latest products and constantly evolving technologies in the expanding manufacturing market. NMW 2015 takes place in Melbourne from 26-29 May. Here is a selection of what visitors can expect to see this year. 1

BAC Systems – Stand 5510

Bosch Group – Stand 5100

BAC will be showcasing its Bosch Group’s broad expertise “BAC 77” storage system. The and portfolio provides turnkey pallet rack system can also solutions to manufacturing combine long span, high density customers, all from the one drawers and shelves into the brand. same bay. This innovative It will be demonstrating a system makes best-use of the range of technologies, from space available – especially in business units including drive smaller stores. and control services and All of a user’s inventory can thermotechnology. be stored in a single system Included among these is with slow-moving bulk being Bosch Australia Manufacturing stored on pallets above the fast Solutions, partners to the moving parts in high-density drawers or on shelves. manufacturing industry offering solutions in automation and lean manufacturing from a Additionally, Storage M A 0 5 1BAC 5 _will 0 be 0 0showcasing _ P R Y its- range 1 of2High 0 1Density 5 - 0 Drawer 4 - 2 8 T 0 9 : 5 1 : 4 global 2 + 1supplier, 0 : 0 0and Bosch Engineering and Technical Service, providing state of the art Modules, long the benchmark in stores and warehouses of small components. product engineering and technical services.

VisitUSUs NMW 2015, 2015, Stand JOIN ATatNMW STAND4705! 4705

» » »

AEROSPACE OIL & GAS AUTOMOTIVE

MARKING AND TRACEABILITY SOLUTIONS FOR DATA DRIVEN MANUFACTURING

28 MAY 2015 Manufacturers’ Monthly

COMPONENT IDENTIFICATION AND TRACEABILITY SECURITY, INSPECTION AND CERTIFICATION MARKING PART AND BATCH NUMBERING SERIAL NUMBERING LOGO AND DECORATIVE MARKING LABEL AND TAG MARKING

 MARKING TECHNOLOGY

Phone: (02) 9783 6000 Fax: (02) 9783 6001 Web: www.whiteint.com.au manmonthly.com.au

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26-29 MAY 2015

Obara Australia – Stand 4515

Obara Australia represents the Coral Group, Italian makers of anti-Pollution equipment which incorporates 32 affiliated companies. Whilst specialising in Industrial manufacturing and heavy industry, they also provide to the woodworking, medical and hospitality sector. Coral’s base product range includes the following: fixed and portable fume and dust extraction systems, Grinding benches, water-air treatment systems, filtration systems, ventilation systems, spray booths, industrial air flow fans, Industrial vacuums.

Innovative Welding – Stand 4725

Innovative Welding is the Australian distributor for K-Tig keyhole welding systems as well as other welding automation equipment and integration. K-Tig uses CSIRO developed technology to produce singlepass welds in many metals up to 16mm thick. Materials include titanium, stainless steels, duplex, inconel, hastelloys, super alloys, nickel alloys and more. K-TIG uses self-induced effects to generate a plasma jet...There is no orifice, making the process extremely simple to manage and optimise. Case studies of K-Tig are available with customerdocumented savings of in excess of 90%. Contact 2 0 1 5 - 0 4 - 3 0 T 0 8 : 0 7 : 1 Innovative 8 + 1 0 :Welding 0 0 for further information.

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Heating& AIR CONDITIONING Keeping the workplace warm this winter Understanding thermal stratification could help manufacturers reduce their heating costs and and still keep workers warm. Alan Johnson reports.

ALKING to many manufacturers, it is clear not everyone understands how thermal stratification works in buildings, especially large cavernous buildings with high ceilings. There is also a lack of understanding on how eliminating the effect can reduce a company’s heating bills in the colder months. Stratification takes place in large buildings such as a warehouses and manufacturing facilities where warm air rises towards the ceiling, creating layers of different temperatures. We all know that heat rises, but the term de-stratification is not commonly used by many of us. It is typically used in environmental definitions to describe the vertical mixing in a lake or reservoir that totally or partially eliminates separate layers of temperature, plant or animal life. But de-stratification also is being used as companies find ways to become more energy efficient with their buildings. Stratification occurs because air from a heater, which is approximately 5-7% lighter than cool air, tends to rise to the ceiling. By incorporating thermal de-stratification technology into buildings, energy requirements are reduced as heating systems are no longer over-delivering in order to constantly replace the heat that rises away from the floor area. De-stratification systems redistribute the already heated air from the unoccupied ceiling space back down to floor level, until temperature equalisation is achieved. With regards to cooling, de-stratification systems ensure the cooled air supplied is circulated fully and distributed evenly throughout internal environments, eliminating hot and cold spots and satisfying thermostats for longer periods of time. As a result, de-stratification technology has great potential for carbon emission reductions due to the reduced energy requirement, and is in turn capable of cutting costs for businesses, sometimes by up to 50%.

30 MAY 2015 Manufacturers’ Monthly

Installation of the fans along with R19 insulation and fluorescent lighting has resulted in a significant decrease in utility costs. Plus by creating and maintaining consistent temperatures from ceiling to floor and wall to door, condensation is reduced, as are its companions, corrosion and mould.

Ceiling fans What many companies don’t realise is that a simple ceiling fan can be used to break down air stratification in the winter, as well as cooling in the warmer months of the year. Brian Smith, managing director of Big Ass Fans Australia, says many people associate fans with cooling in hot weather, when in fact fans are also very useful during the colder months, with many customers seeing

their biggest energy savings during this time. “Thermal stratification is a big problem in large manufacturing facilities with high ceilings. Heating systems have to run constantly, stacking hot air from top to bottom until warm air reaches the thermostat set point and finally triggers the system to shut off. “Our fans are slowed, not reversed, and recirculate the warmer air trapped at the ceiling back down quickly, creating uniform temperatures and taking the load off heating systems,” Smith told Manufacturers’ Monthly. He explained that all the company’s fans are equipped with variable

speed, allowing customers to have a precise control of the speed of the fan, and therefore precise control of air velocity. This means the fans can run slowly enough so they don’t generate a draft in winter. “Customers typically report savings of up to 30% on winter heating costs after installing our fans,” Smith said. US manufacturer Custom Vinyl Products recently moved into a new 12,192m2 facility to help streamline the company’s window manufacturing process. The company needed an efficient way to circulate conditioned air throughout the building without installing expensive ductwork. Instead Custom Vinyl installed three 15.4m diameter Powerfoil X fans from Big Ass Fans, which work in tandem with the facility’s rooftop units, providing air circulation to all employees. Donald Peinado, General Manager at Custom Vinyl Products, said the use of the fans along with R19 insulation and fluorescent lighting has resulted in a significant decrease in utility costs, providing year round comfort and savings to his growing manufacturing company. “We have twice the amount of space and rooftop units in our new building, but our gas bill is lower,” Peinado said.

De-stratification fans Another option manufacturers might consider is a dedicated de-stratification fan. Airius manufactures stand-alone fans (axial turbine) that are suspended just below ceiling height, with each unit capable of equalising between 60 and 220m2 of floor area. The company’s free hanging product range is available in several models with various motors/controls to accommodate ceiling heights from 2.5m to 38m and are easily adaptable to changing floor plans. As with any blade fan, the spinning blades create turbulence, which manmonthly.com.au

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A typical de-stratification system includes a series of units mounted just below the ceiling, evenly spaced throughout a facility. reduces airflow distance. Instead, Airius’ multi-vane stator transfers this energy to create an airflow column increasing throw distance. Each unit comes with an adaptable bail and eye bolt allowing it to be easily installed and angled up to 90° off vertical to deliver airflow to where it is needed. A typical Airius de-stratification system includes a series of units mounted just below the ceiling, evenly spaced throughout a facility. They are designed to work in conjunction with each other and heating and/or cooling systems to improve comfort, reduce heating and cooling costs and reduce carbon emissions. Peter Maloney, from Tasmania’s Axeman’s Hall of Fame, is a recent convert to de-stratification fans. “When I first saw the units in boxes on the floor, my initial impression was doubtful that these air transfer units would work. “This was due to not understanding the way they operated. Once they were installed, hooked to power, the switch was flicked and their function was explained to me, I still had doubts due to the size and appearance of the manmonthly.com.au

Airius Air Pear units. I still could not grasp how the building could benefit from just four units when this was the coldest time of year.” However when they were switched on and the building heated to a consistent temperature with the heated areas being evenly controlled, Maloney said the experience of temperature variation within the building changed completely. “Basically overnight the Australian Axeman’s Hall of Fame’s atmosphere had altered. The cost savings are overwhelming as all other heating has been largely reduced and the next bill should indicate a large reduction in power usage cost.” He said the heating benefits alone make the cost of the units feasible. “Previously we needed five units to heat the building and this was not effective but with the efficiency of the Airius Air Pears we now only require two,” Maloney said. Big Ass Fans 1300 244 277 www.bigassfans.com.au Airius 04 0184 8888 www.airius.com.au

2 0 1 5 - 0 4 - 1 4 T1 5 : 2 2 : 3 8 + 1 0 : 0 0

Air Consumption Meter & Process Display Panel for Air Conditioning Monitoring

3DSuit Motion Capture System

Pressure, Temperature Distribution Measurement Films Bestech Australia U14, 44 Garden Blvd

MEL.: 03 9540 5100

Dingley VIC 3172

SYD. : 02 9624 4233

Enquiry@bestech.com.au www.bestech.com.au Manufacturers’ Monthly MAY 2015 31

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Heating & AIR CONDITIONING HVLS fans for winter and summer PACIFIC HVAC Engineering has re-launched the MacroAir range of HVLS (High Volume Low Speed) fans in Australia and NZ. The fans are a scaled up version of the familiar ceiling fans used domestically and commercially to provide cooling and air circulation benefits. Ranging in size from 2.4m to 7.2m in diameter, the fans can move up to 10,000 cubic metres of air per minute as a gentle breeze but with a running cost of less than 20 cents per hour. According to the company, the fans have found a strong following in manufacturing and warehousing facilities as well as in aircraft hangars and maintenance workshops. Sudevan Nallathamby, General Manager for MacroAir in Australia, says the fans are also effective for keeping birds from leaving ‘calling cards’ on expensive equipment such as aircraft. In an open plan space like a factory or an indoor sports arena, one 7.2m fan is able to cover an area the size of six tennis courts while consuming three quarters of a kilowatt of electricity. To compare, the company estimates it takes 26 conventional pedestal fans consuming a total of 15kWh of electricity to achieve the same air flow with a lot more noise. As well as being exceptionally efficient, the HVLS fans are almost silent in operation. They are is designed to deliver increased comfort for people working in or visiting large volume buildings like factories, warehouses and big box retail spaces all year round. In colder months the fans can be used on low speed to bring warm ceiling level air down to floor level (de-stratification), greatly increasing comfort and virtually eliminating cold weather condensation build up, while in summer months the fans can by create a perceived temperature reduction of 4 to 6°C. The company says a notable case study for the effective use of MacroAir Big Fans has been the take up by Bunnings Hardware stores in Australia’s Eastern states. Because of the warehouse nature of the stores,

In an open plan space like a factory or warehouse, one 7.2m fan is able to cover an area the size of six tennis courts while consuming three quarters of a kilowatt of electricity. conventional ventilation systems were too expensive to install, leaving staff and customers sweltering in summer and freezing in winter. After seeing the fans in action, Bunnings senior management decided to trial the concept in its store at Fountain Gate, Victoria, three years ago. The trial outcome was very positive with increased customer retention and improved staff morale leading to stronger sales and reduced staff absenteeism on extreme weather days. Since the decision was made to progressively roll out the new program, nearly forty sites have had the fans installed. According to Nallathamby, Bunnings is not the kind of business that throws money around unless there is a payback. “They have concluded that employee productivity and increased sales delivers a fast payback”. The fans use high efficiency aerofoil profile blades made from anodised aluminium mated to high quality gear boxes and motors with sealed-for-life bearings.

The company has also introduced AirVolution D, another HVLS fan, but one that is centred around a direct drive DC motor that eliminates the need for a gearbox. The new motors feature on board control electronics that are said to be simpler, lighter, more efficient and completely free of mechanical noise. The reduced weight of the fans combined with a new locking attachment has done away with the need for guy wires as well. As well as new HVLS fans, Pacific HVAC Engineering has introduced a new fan products catalogue for smart phones and tablets. The free app lets users quickly identify products in the company’s range and get the information onto the screen in an instant. Product data can then be viewed or emailed from the app itself. Pacific HVAC Engineering 1300 733 833 www.pacifichvac.com

HVAC boiler flow meter AMS Instrumentation & Calibration Plant has released the ST98 air/gas flow meter from Fluid Components International (FCI), designed to optimise the fuel-to-air ratio for boiler control in plant HVAC systems while reducing plant fuel costs and protecting the environment. By carefully monitoring the natural gas flow of plant HVAC system boilers, fuel consumption, plant energy costs and pollutant emissions can be reduced. The natural gas flow measurement solution provided by the ST98 Flow Meter allows facility engineers to

32 MAY 2015 Manufacturers’ Monthly

monitor and control the precise amount of fuel needed to run HVAC boilers efficiently. The flow meter’s thermal mass flow sensor design provides direct mass flow measurement without the need for additional temperature or pressure sensors or density calculating devices, as well as the plant real estate and technician time needed to install these extra devices at their additional cost. Its insertion style configuration makes the ST98 meter simple to install in existing piping without cutting the pipe or welding.

The flow meter is suitable for service in plant natural gas and numerous other process gases, hydrocarbon mixed or dirty gases, biogases including methane, and plant compressed air and HVAC systems in a wide range of industries, including electronics, oil/gas, chemical, power generation, food/beverage, pharmaceutical, pulp/ paper, steel and wastewater treatment. AMS Instrumentation & Calibration 03 9017 8225 www.ams-ic.com.au

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4440_Factories

2015-04-24T12:09:55+10:00

The Australian Manufacturing Industry is going through great structural change, adopting new technologies and techniques that are shaping innovation, productivity and ultimately how factories of the future will function. The 2015 Manufacturers’ Monthly - Factories of the Future breakfast series aims to bring together forward thinking manufacturers in a knowledge sharing environment to learn from industry experts, academics, government and suppliers about the latest industry insights and best practice. This highly focussed series of events is designed for the busy executive who wants to both acquire and share knowledge and who values quality networking opportunities.

Factory of the Future series What: Breakfast Date: Thursday 28 May 2015 Time: 7am for registration – 9:30am Location: The Crown Casino Melbourne Cost: $30 per person (+GST) Queries: Please contact Alice Wearne, Event Manager, alice.wearne@cirrusmedia.com.au or 02 8484 0822 Join us during National Manufacturing Week next month – for tickets, go to

www.manmonthly.com.au/events/factories-of-the-future

Principle Sponsor

Sponsors

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MetalCUTTING CAD/CAM nesting software Sophisticated automatic nesting algorithms can quickly run through countless parts arrangement scenarios in order to achieve the tightest possible part yield, writes John Salsbury.

N MANUFACTURING terms “nesting” is the process of arranging parts on a sheet as to minimise material waste. Fabricators who cut sheet metal, plate, aluminium, composites, wood, and even fabric typically employ some sort of nesting – either manually or through automatic nesting software. It stands to reason that the tighter parts can be arranged the more parts that can be placed on a sheet. In the example pictured on this page, one can see that, with the help of nesting software, parts may even be placed inside other parts. SigmaNEST employs sophisticated automatic nesting algorithms to quickly run through countless parts arrangement scenarios in order to achieve the tightest possible part yield.

What are the key benefits fabricators can achieve with nesting software? Fabricators benefit from nesting software in many ways. Manual nesting can slow production down to a crawl. By automating the process fabricators can achieve significant and sustained productivity gains and cost savings. Material optimisation alone can reduce waste by 5 per cent or more. Faster machine cycles are created by tool path optimisation, which determines the best path by minimising or eliminating redundant, extended, or additional tool movement. Nesting software can also extend tool life by reducing pierce points or directing cut paths away from potentially dangerous situations, like collisions. Common-line nesting contributes to tool life as well; cutting edges shared by multiple parts with a single cut. Time savings can be especially significant when cutting thicker material. Other benefits include fuel savings, an ability to integrate with MRP/ERP, along with inventory and remnant management.

What type of productivity gains can 36 MAY 2015 Manufacturers’ Monthly

Sophisticated nesting software can quickly run through a number of nesting scenarios to determine optimum material yield. Cutting paths are applied allowing the machine to effectively move from one part to another increasing cutting speed and saving both time and consumables (gas, waterjet abrasives, extend cutting torch life).

a fabricator expect using nesting software? Advanced nesting software is all about increasing productivity. Fabricators can expect faster machine cycles because of reduced cutting

“

Nesting software is needed for manufacturing strategies with faster programming speed, the ability to manage various due dates and priorities, and the ability to integrate with MRP/ERP system software.

Fabricators should research and choose software that focuses on efficiency as well as motion time and a reduced number of pierce points. Engineers who are at or exceeding capacity, unable to keep up with demands, and facing overtime costs will benefit from reduced programming time.

Sometimes overlooked but nonetheless critically important is the fact that fabricators achieve productivity gains by employing a single nesting software package to drive multiple cutting machines regardless of type or manufacturer, rather than pur-

chasing, learning, and maintaining multiple software packages.

What are the top five factors fabricators should consider when deciding on the nesting software to meet their needs? • Robust features deliver tighter nesting and maximised cutting machine performance • Integration with MRP • CAD Import • Automation • Flexibility to run multiple machines regardless of type or brand Additionally fabricators should choose software on the forefront of technology and a company that continues to aggressively improve its products.

If nesting software if a part of the machine tool vendor package, what manmonthly.com.au

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A typical punching machine.

should fabricators consider to ensure it’s a quality nesting software program? Quality nesting software should support advanced machine functions, as well as a variety of machine types, different brands, and multi-process machines. Most software that comes bundled with a machine is focused mainly on machine motion; it will run, but not the most efficiently. Machine software is generally a “lite” nesting package with basic capabilities and hardly ever selected by the consumer. Quality software

should always be chosen, not accepted by default. Fabricators should research and choose software that fits their short- and longer-term needs and focuses on efficiency as well as motion.

How does the software differ from others on the market? There are many varieties of software on the market today running the full gamut in terms of functionality, performance and capabilities. Some only nest, and some have better nesting varieties than others.

Some systems are designed to work solely with one particular machine. OEM-provided software often onlyMruns A 1 their 1 1 4respective _ 0 0 0 _brand, B O K butversatile software, such as Sigma-

NEST, drives virtually any cutting, punching, or bending machine. 1What 2 0kind 1 4 of - issues 1 0 - can 0 8 aTfabricator 1 2 : 5 1 : 5 4 + 1 1 : 0 0

face with nesting software and how

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An advantage of nesting software is the ability to mix jobs from different orders. This saves time and reduces scrap. A Colour Offload allows the machine operator to quickly see which parts belong to which jobs. manmonthly.com.au

BOKERS.COM/MANM Manufacturers’ Monthly MAY 2015 37

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Metal CUTTING >> can they avoid or overcome these issues?

Fabricators whose operation includes a variety of cutting machines may have a unique nesting program for each. If this is the case training will be needed in each machine’s software system. Sometimes manufacturers are forced to assign a unique programmer to dedicate himself to a specific machine’s software package. It’s the same with software upgrades. Fabricators who have multiple software licenses will need training for every license. Another issue that stems from machine variety is that certain parts can only be cut on certain types of machines, which can contribute to a limited machine throughput. Part-specific nesting software can create a bottleneck of work orders, whereas general nesting software creates an even spread of work with multiple programmers running the same software package on multiple machines. Fabricators with software that nests poorly will create an increase in the scrap rate, wasting money and material. Better performance nesting will decrease scrap and waste. Again, a robust yet flexible nesting software allows multiple and dissimilar cutting machines to be pro-

This image shows how various parts can be “nested” in order to get the most parts on a sheet. This saves both material and cutting time. grammed with a single system. This provides a number of advantages including the ability to make future machine purchases without being tied to a specific OEM for nesting. In addition a single programmer can now work with any and all machines allowing resources to be reallocated as needed.

How does the nesting software operate

in a multiple machine environment where a fabricator might have several laser cutting machines or a lights-out environment? What should fabricators keep in mind? In a lights-out environment, fabricators will be the most prepared for work orders if they have MRP integration, inventory tracking, and good organization. In addition, software must sup-

port automation control, such as load towers and unloading robotics. Fabricators with several laser cutting machines need nesting software with the ability to post to multiple machines at once.

What top three changes have occurred in nesting software and what top change or improvements can the market expect to see in nesting software? The top three changes that have occurred in nesting software are: • Ability to effectively perform common-line cutting • Automatic NC features such as auto tabbing, auto bridge cut, auto chain cut • MRP integration and Remnant tracking Changes the market can expect to see in the future include: • Router optimisation for maximum multiple sheet efficiency • Integration with press brake software • Improvements in multi-sheet partial depth routing – for multiple stacked sheets – where parts near the upper sheets are different than parts near lower sheets

Parts can be arranged for common-line cutting. This allows the machine to cut multiple parts with a single cut... again saving time, material, consumables, and extending tool life. 38 MAY 2015 Manufacturers’ Monthly

[John Salisbury (johns@sigmanest. com) is Sales Manager/Director at SigmaTEK.] SigmaTEK Australia 07 3246 5213 www.sigmanest.com manmonthly.com.au

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Success secured at 120 mph With speeds hitting up to 120 mph, roller coasters demand the highest standards of engineering. Manufacturers and maintenance professionals rely on LOCTITE threadlockers and retaining compounds as an alternative to mechanical locking devices to ensure reliability and withstand vibration. For success through every twist and turn.

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Austech

AMTIL is once again bringing its Manufacturers Pavilion to the Melbourne Exhibition Centre.

AUSTECH is co-located with NMW.

Onshoring trend sets the scene for Austech This year’s AUSTECH exhibition seems to be approaching just at the right time. Co-hosted with National Manufacturing Week, it is expected to attract a combined total of over 10,000 visitors.

“T

HE weaker Australian dollar is starting to drive manufacturers back to Australia in a sign the economy is adjusting to a post-mining boom world,” BlueScope Steel boss Paul O’Malley said recently. “After a very strong trend toward offshoring, we are starting to see some domestic onshoring for the first time in almost six years.” Indeed, while manufacturers opened the New Year with reductions in sales, production and new orders, the fall in the value of the Australian dollar could stimulate the manufacturing sector over the coming months. “Being present at AUSTECH is an absolute must for all manufacturers of production technology aiming to serve customers on the Australian market and to demonstrate their competence, efficiency and capacity to them,” said AMTIL Event Manager and Austech organiser Kim Warren. “Now that we see a first positive trend towards onshoring, AUSTECH is an event not to be missed by owners and managers of job shops, manufacturing facilities or research departments. In order to be competitive, they require efficient manufacturing technology, comprehensive engineering skills and good service.”

40 MAY 2015 Manufacturers’ Monthly

Thousands of industrial decisionmakers regularly attend AUSTECH and National Manufacturing Week (NMW) to get ideas and find ways to cut costs and get more work. “We attend Austech regularly and purchased our Amada fibre laser cutting machine after the last exhibition,” Eric Woodgate, Managing Director of Shamic Sheetmetal Pty Ltd said. Hare & Forbes customer Michael Arena from Arena Engineering is another regular visitor to the show, where he sees new technology demonstrated and chooses the best for his needs. Ultimately, it is about finding ways to cut costs and get more work; which is required to keep up with technology. From 26 to 29 May, the Melbourne Convention & Exhibition Centre will be the place to be for all of Australia’s industrial decision makers, hosting several major industry events under one roof: AUSTECH, with a focus on machine tools for metal cutting and forming, production systems, high-precision tools, CAD/CAM and accessories; NMW, showcasing the latest products covering sectors and technologies that are driving industry growth including:

• Sustainable Manufacturing and Engineering Services; • Safety First Conference & Expo; • SMART Supply Chain & Logistics Conference; • Inside 3D Printing Conference In addition, there will be the Victorian Government Manufacturing Hall of Fame Gala Awards Dinner, which recognises Victoria’s most advanced and export-oriented manufacturers who excel in business innovation and productivity and contribute to the Victorian economy. Of course, the Hall of Fame gala ceremony on Tuesday 26 May will offer fantastic opportunities to network, together with AUSTECH and NMW’s Happy Hour in the afternoon, as well as other social and networking events over the four days of the show. And AMTIL is once again bringing its Manufacturers Pavilion to the Melbourne Exhibition Centre. The unique showcase runs from 26 to 29 May as part of Australia’s premier advanced precision manufacturing and machine tool exhibition, highlighting the capabilities of Australia’s precision engineering and advanced manufacturing industry. The Pavilion provides Australian component manufacturers, preci-

sion engineering firms, toolmakers, advanced manufacturers, general engineering companies as well as OEMs the opportunity to exhibit their unique capabilities “The importance of our precision engineering and advanced manufacturers in this country having the opportunity to promote the capabilities and capacity they have to offer is critical in view of international competition,” explained AMTIL’s CEO and Exhibition Director Shane Infanti. “The Manufacturers Showcase provides the perfect forum for these companies to put themselves in front of Austech visitors, many of whom outsource and contract out their work.” As a biennial event, AUSTECH 2015 is a show not to be missed by anyone involved in advanced manufacturing in this country. Whether you are based in WA, New South Wales, Queensland or Victoria – make sure to gather for this special event in May and dominate the competition by choosing the best technology for your needs. AMTIL 03 9800 3666 www.amtil.com.au/austech manmonthly.com.au

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

www.kemppi.com

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Automation& ROBOTICS Uncaged robots: all the rage right now There’s an apparent explosion of interest in smaller, safer, easyto-program robots for manufacturers. Brent Balinski takes a look at the fast-growing collaborative robots category.

CKNOWLEDGED as the first industrial robot, the Unimate robot arm was installed at General Motors’ now-decommissioned Ewing Township, New Jersey plant in 1961. The big metal arm has long since been retired – and entered Carnegie Mellon’s Robot Hall of Fame in 2003 – and factory robots have gotten more and more popular since the first of their kind appeared. Weighing 4,000 pounds (not far off two tonnes) and costing $US 25,000 (about $US 200,000 in today’s terms) the Unimate is the antithesis of the booming class of collaborative robots. Its step-by-step movements – put to use handling hot die castings and welding tasks – were driven by a primitive magnetic drum memory. Comparatively elegant, cheap, safe to be around, and able to be programmed by line workers with no coding experience, the new cobots couldn’t be more unlike their forbears. They are most obviously “lightweight, easy-to-program and affordable,” Shermine Gotfredsen, General Manager, Asia Pacific (excluding China and India) for Universal Robots, told Manufacturers’ Monthly. “It’s becoming very affordable for manufacturing – even the SMEs, not just the MNCs,” said Gotfredsen, of some of the almost “plug-and-play” robot options out there. Perhaps the two best-known examples of collaborative robots are those made by Gotfredsen’s employer (headquartered in Denmark) and

42 MAY 2015 Manufacturers’ Monthly

the Baxter Robot, made by the USA’s Rethink Robotics. Both companies’ products have force sensing technology that mean they will not injure a person who stands in the path of a robot arm. They generally work on a fixed base (cage-free) alongside humans, handle relatively small payloads, and can be easily programmed through a user-friendly HMI and by manipulating the robotic arm through a set of movements, meaning re-tasking is simple. Last-month Swiss power and automation giant ABB chose the world’s premier industrial expo, Hannover Messe, to unveil its long-awaited, two-armed YuMi co-bot (which has its origins in the firm’s Frida concept robot). And Japan’s Fanuc has just unveiled its CR-35iA, a comparatively heavy-duty offering. “A couple of years back you would’ve seen one or two robots in the collaborative robot space; now you find a dozen or more vendors that have robots that they’re certainly calling collaborative robots,” Jim Lawton, CMO of Rethink Robotics, told Manufacturers’ Monthly following the release of his company’s new Sawyer product. In general, worldwide industrial robot sales in general are booming – up 27 per cent last year, according to preliminary figures for 2014 from the International Federation of Robotics.

However, there’s also no denying the current buzz around this reasonably new category of factory help.

Demand is huge Universal Robots launched in Australia just last year, citing strong local interest and what Universal could potentially offer smaller manufacturers. Business has grown steadily since in Australia and explosively in the rest of the region. Elsewhere in APAC, where Universal set up its regional headquarters in Singapore at the beginning of 2015, sales are going through the roof. The IFR’s figures put Asian robot sales at approximately 140,000 units last year, over 60 per cent of the world’s share. China in particular stood out, with 56,000 purchases (up 54 per cent from 2013). “This region is a fast-growing region for industrial robots. and this quarter alone for the Asia Pacific region I am operating in, we have already had a 50 per cent growth this quarter compared to last quarter,” explained Gotfredsen. “So, definitely! [laughs] Definitely it’s a very strong market.” According to the ambitious Universal, it is on track to reach its goal of doubling revenues every year for 2014 – 2017, and launched a new tabletop product, the UR3, in March at Chicago’s Automate 2015 show. In the same week UR’s main com-

Factory robots getting smaller, “friendlier”. petitor, Rethink Robotics, launched its own smaller collaborative robot. The interest in smaller, more nimble, more flexible robots from industries is huge, said Lawton. Some have said the market might be heading for saturation point, but the amount of unmet demand is enormous, suggests Lawton. He points to research from Boston Consulting Group suggesting at present there are around nine-tenths of manufacturing tasks that are not yet automated, and a chunk of these can now be tackled. “This is such a huge and significant space,” he said. “This is in the US what we call the Wild West. It’s largely uncharted territory. “And so there will be a bunch of companies – like Rethink Robotics, like Universal Robots, and probably a handful of others – that are very rapidly innovating and bringing new, interesting collaborative robots to market.” manmonthly.com.au

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Explaining the boom Though there is anecdotally a lot of interest in the category, hard, official details on sales aren’t here yet. “[No,] because this application is just starting,” Gudrun Litzenberger, General Secretary at the IFR, told Manufacturers’ Monthly. “There are a lot of testing applications in various industries.” The IFR did however agree that sales would likely increase in the future. In general, sales are being driven by China, followed by and South Korea. The automotive industry, which adopted the first factory robots, is still the most significant sector, followed by electronics. Co-bot makers argue that their machines make productivity gains available to SMEs those which were previously only available to, say, big automotive companies. Not every firm can budget and planM for and A a0 whole 5 1 5 lot _ 0of4 money 3 _ DA A time spent on integration if they

ABB released the YuMi at Hannover Messe. Then comes installation and coddecide they might want to invest in ing and getting things running reliautomation. ably. And then there’s error handling. “When a manufacturer makes “That’s often multiple hundreds of the decision that they want to go hours of programming time that goes automate a task, they may need some into just the error handling comporobotic arms, some PLCs, a conveyor, nent of it,” he said. wires, string them all together, they The link between automation and need various sensors, part positioning and 1sensors 2 0 1 5 -cameras 0 5 - 0and 1 T3D 1 sensors,” 0 : 2 7 : 1 productivity 9 + 1 0 : 0 is 0 an obvious one, and helps explain why China, with its explained Lawton.

rising wages, is investing so heavily in importing industrial robots. (It is also investing in developing a domestic robotics industry. Around 16,000 of the robots sold last year in China were locally made.) The flexibility of robots that can be relocated within a plant and quickly re-programmed for a different task is also suited to smaller companies that manufacture high-mix, low-volume goods. “New solutions such as interfaces, control units and software allow diverse tasks to be automated even by people without any experience in robotics,” explained Litzenberger. “This opens up new potential applications for medium-sized companies in diverse industries.” It has not just been the smaller businesses buying lightweight robots, however. For example, Universal has already sold ten robots to one client alone, Boeing Australia.

Reshoring and robots “The conversation has certainly

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Manufacturers’ Monthly MAY 2015 43

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Automation & ROBOTICS changed now, and it’s still early days, but people are seeing that there’s some value there,” Rodney Brooks, CTO, chairman and founder of Rethink, told Manufacturers’ Monthly. Brooks began Heartland (later renamed as Rethink) after noticing the low amount of automation within parts of China, and simultaneously realised the seemingly endless pool of labour wouldn’t be there forever. He sees co-bots as something that will shrink supply chains and help bring much manufacturing closer to where items are consumed. The adoption of robotics has been linked by many others to a trend of re-shoring production in the US. “It will be possible to do more manufacturing in more locations of the world where you don’t need that really specialised supply chain,” Brooks said. Rethink believes that collaborative robots will be a major disruption in the manufacturing industry. In a way that intuitive, user-friendly tools (think of the iPhone) have changed the way we work, robots with a little commonsense that can be used by anybody might do the same thing. Brooks often cites the PC and the drastic (and overwhelmingly positive) changes it brought to offices, with Baxter having similarities for those in factories. In the way that a user doesn’t need to be a computer programmer to use a spreadsheet on a PC, a factory worker doesn’t need to be a programmer to use an interactive robot.

Litzenberger said that the “manmachine partnership” would be important in “advancing intelligent production visions (Industrie 4.0).” “Here, user-friendly robots are opening up opportunities for automation in differing sectors,” she explained.

Limitations With all the possibility and maybe even a little hype around the collaborative robots out there, it’s probably reasonable to remind ourselves that they can’t do everything (and aren’t intended to). Each model the vendors provide is different, to begin with, in terms of basic things like degrees of freedom, speed, repeatability and payload. Regarding payload, this is typically only a few kg. (A major point of difference for Fanuc’s offering (“the world’s strongest collaborative robot”) is its ability to lift up to 35 kg.) Different robots have different things they can do well, and things they can do poorly or not at all. Also, where mobility for a robotic solution is needed, for example, a cobot is the wrong tool for the job. “What we have been particularly interested in are robots where you have mobility and you also have manipulation capabilities – in the case of Baxter, for example, it is fixed,” explained Elfes, who works on the CSIRO’s robotic co-worker project, Guardian. “And I think different solutions have different applications.

Shermine Gotfredsen, General Manager, Asia Pacific, Universal Robots. 44 MAY 2015 Manufacturers’ Monthly

Baxter robots made their way into Australian factories this year. There are situations where a standard robotic arm will makes sense and will provide what is needed, however. Another limitation for all kinds of robots, not just collaborative types, is dexterity. Brooks, who is a former Professor of robotics at Massachusetts Institute of Technology and one of the most celebrated roboticists of all time, concedes this. “I’m hopeful that now people will start to explore dexterity more than they have in the last 40 years,” he said. “And we’ll see if progress is made. But you can’t just order up progress on these things. It may take a few years yet before we have much dexterity.” And in these early days of collaborative robots, actual applications out there in the field in Australia are limited. There have been ten Universal arms sold to Boeing, but

there has only been a total of 50 sold in Australia overall. There are even fewer Baxters out there making things locally, and the first one in Australia operating in an industrial setting was installed at Haigh’s just this year. All this may say more about our businesses’ conservatism in adapting newer technologies, though. And for all the attention given to robots and their usefulness in many applications, they remain un-intelligent. There are many places where they will simply never replace human beings in factories. “Ultimately we don’t have robots today that are as smart and as versatile or as competent as humans,” offered Elfes. “And personally I don’t think we will ever have robots that are as competent.” Auto Control Systems 9258 4555 www.autocontrols.com.au manmonthly.com.au

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Packaging How to minimise your pallet wrapping costs All industry uses packaging in some way and many, many businesses need to wrap pallets. Matt McDonald looks at a pallet wrapping system that promises to keep the costs of so doing down.

USINESSES looking to minimise the amount of money they spend on pallet wrapping need to seek out the best possible price for stretch film. It all comes down to price per roll, right? Wrong, says Tim Salisbury, Managing Director of AAA Packaging. “A lot of companies have been blinded as to what their real expenditures are. And it all comes back to one point, which is how much does it actually cost to wrap you pallet,” Salisbury told Manufacturers’ Monthly. “It’s got nothing to do with how much a roll of film costs. Or how much the machine costs or how much time it does or doesn’t take.” It comes down to the total cost it takes to wrap your pallet, he said. And the best way to keep the total cost nice and low is to use as little stretch wrap as you can. Salisbury explained that research by his company concluded that more than 75% of stretch wrapping equipment tested performs below acceptable levels. This leads to companies wasting tens of thousands of dollars on the stuff.

The system So the company has developed a pallet wrapping system that reduces unnecessary wastage. “It offers not just a little saving. It offers a very substantial saving… and heavily reduces the wastage used in film,” Salisbury said. “At the end of the day that’s what the bean counters are looking for.” Dubbed the ‘The Perfect Wrapping System’, it involves the use of the COne Stretch Wrapping Machine range and Euro Stretch Film. The C-One machines are available in semi-automatic, automatic, and fully automatic models. The semi-automatic machines are normally used in low volume applications where no more than 30 loads an hour need to be wrapped. These machines require that the load be 46 MAY 2015 Manufacturers’ Monthly

Businesses which would benefit from using them don’t have to be that large.

Who can use the system

The C-One Plana Pallet Wrapper is part of the C-One Stretch Wrapping Machine range. brought to the machine either by fork lift (high profile) or by pallet jack (low profile). An operator then has to attach film to the load before wrapping can begin. With the automatic models, it is possible to load pallets onto the wrapping machine using a forklift (without getting off the forklift). And the fully automatic machines don’t need an operator at all. Loads are transferred to the machine via a conveyor system into the wrapping area where it begins to wrap the pallet. AAA Packaging claims the system will save its customers more than 20 per cent on wrapping costs and more than 50 per cent on stretch film usage. Salisbury pointed out that, on top of that, they can expect further savings in the area of waste disposal. Asked if the company offers a money back guarantee on these as-

surances, Salisbury said this is not necessary as the work is done before it comes to that. “We put a proposal together. We go out to a new prospect with… computerised measuring gear and we’ll find out what they do…do cut and weighs, ask lots of questions, take a full report…” “We’ll do a lot of testing of the current ability of whatever film they are using to hold and retrain movement within the pallet and test that against our own [film] and then we’ll offer them a proposal which includes the documented report of what they’re currently using against what we could supply them.” According to Salisbury, C-One Stretch Wrapping Machines aren’t prohibitively expensive. Depending on what options you get with them, the price for everything you need lies somewhere between $11,000 and $17,000.

“Someone that is spending 50, 60, 70 thousand dollars a year [on packaging] is still fitted for some of our systems to be installed, purchased or loaned,” said Salisbury. “Their savings are not going to be as big as some of the bigger ones, that’s all.” He said that, provided a business intends to regularly use the system and they’re spending $4000 – $5000 every month, they stand to benefit from it. He added that the company offers several options to potential customers – purchase outright, rental, lease, or loan. Apart from cost savings, Salisbury pointed out that the C-One Stretch Wrapping Machine Range also performs well in terms of safety, reliability, environmental waste and time saving. Asked if the ‘perfect’ wrapping system can be improved upon, Salisbury said he expected to see further advances in the industry in coming years. He said suppliers which intend to continue selling their current products and systems into the future, will not be around in five years’ time. They won’t survive. In contrast, Salisbury is confident his company has a bright future. “We’re proud to be the company that’s shaking the foundations of some of these prior producers and suppliers,” he said. [Matt McDonald, a Manufacturers’ Monthly journalist, writes on a broad range of topics. His special interests include Safety and Industrial Relations. Contact him at google.com/+MattMcDonald28] AAA Packaging Supplies 1300 764 963 www.aaapackaging.com.au manmonthly.com.au

MA0415_000_ANS

2015-03-24T13:36:09+11:00

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Materials HANDLING Sanitary tubular cable conveyor

The dewatering idler is designed to extract excess water on the conveyor belt surfaces.

K-Wrapper dewatering idler IT has been estimated that the maintenance costs to keep rotating machinery such as conveyors working effectively can account for 30 – 50 per cent of total operating costs. And this figure does not include the lost production time accrued in downtime for stoppages to fix conveyors and install replacement parts. Of this maintenance function, there is a distinction between regular preventative actions and intermittent reactive maintenance. Kinder & Co’s K-Wrapper dewatering idler is a preventive maintenance tool engineered to extract excess water on the conveyor belt MA 0 2 1 4 _ 0 0 0 _ D A T surfaces. If left moist, this can lead

A new FLEXI-DISC sanitary tubular cable Conveyor, for fragile bulk foods and non-foods, allows rapid wash down of the system between production runs. The sanitary conveyor moves bulk material using high-strength, one-piece polymer discs affixed to polymer-coated 304 or 316 stainless steel cable, that slide within smooth stainless steel tubing, moving fragile products gently, quietly and dust-free. The discs evacuate the conveyor tubing of material at the conclusion of a conveying cycle, virtually eliminating wasted product. Any material clinging to the cable and disc assembly can be continually removed during operation by the stiff bristles of a brush box or by a residual return chute equipped with a disc ramp that dislodges material and returns it to the product stream. All material outlets, inlets and tubing are fabricated of 304 or 316 stainless steel with quick-disconnect covers and continuous welds ground smooth and flush with contiguous walls polished up to mirror finish. Wet or dry cleaning accessories can be quickly attached to the FLEXI-DISC cable to allow rapid, thorough sanitising of the system, minimising downtime between changeovers, while optional Clean-In-Place systems provide automated sanitising of the system. Clear inspection tubing can be located in any straight run, allowing visual monitoring of fill percentage during conveyor operation, and of cable/disc cleanliness during washdown procedures. Gentle handling and cleanability offered by the conveyor make it suitable for friable bulk food and nutraceutical products, as well as contamination-sensitive chemical products. Modular system components, including 304 or 316 stainless steel tubing, drive wheel housings, tension wheel housings, metered and non-metered inlets, and discharges with and without valves, can be combined in unlimited configurations to move materials horizontally, vertically or at any angle, through small holes in walls or ceilings. The sanitary conveyor is offered as a stand-alone system, or fully integrated with upstream and downstream equipment such as inlet hoppers, bag dump stations, bulk bag dischargers, bulk bag fillers, drum/box/container tippers, weigh batching/blending systems, screeners, filling machines and storage vessels manufactured by Flexicon and others. Flexicon 1300 353 942 www.flexicon.com.au

to belt misalignment as well as the conveyed material slipping or spilling from the belt itself. Uncontrolled loss of product can quickly lead to a major safety hazard. The product is made from long lasting and corrosion proof polyurethane and has a low tension effect on belt cleaning. It is belt friendly, is available for all belt widths and is suitable for reversing conveyors as well as high speed conveyors. Once installed and swapped into place with a current idler, it requires no reactive maintenance. Kinder & Co 03 9587 9244 1 2 0 1 4 - 0 1 - 0 7 T1 5 : 4 1 : 3 1 + 1 1 : 0 0 www.kinder.com.au

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Wet or dry cleaning accessories can be attached to the FLEXI-DISC cable rapidly for thorough sanitising of the system. manmonthly.com.au

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MLA & SANY form heavyweight alliance MLA Holdings has established a partnership with the SANY Group for the exclusive distribution of their container handlers and heavy forklift range in Australia. This alliance brings together MLA’s leading heavy equipment service team and the new SANY product range that includes Reach stackers, Laden Container Handlers, Empty Container Handlers and Forklifts between 16-46 tonne capacity. The original Chinese SANY Group was founded in 1989 and has developed to be the fifth-largest construction machinery company, and the second largest manufacturer of container handling trucks in the world. SANY is now the fastest-growing company in this segment. With market capitalisation of $US21.6 billion, it is listed in the world’s top 500 most valuable companies. Currently, the company L O G _ Lemploys E N _ 0about 0 0 40,000 1 2 people in more than 150 countries.

SANY reach stacker. SANY Europe, the European head- quality tailored to suit all types of heavy lift functions. Heavy equipquarters of the group, was founded in ment users in Australia now have 2008 as SANY Germany GmbH. The a choice of the most modern and ultra-modern manufacturing facility innovative container handlers and in Bedburg, Germany, is producing heavy forklifts sourced from either container handlers and heavy forkGermany or China. lifts meeting the highest European 0standards. 1 4 - 1 1 - 2 8 T 1 1 : 2 5 : 0 1 + 1 1 :Matt 0 0 Saunders, MLA General Manager Sales & Operations comThe latest products have build-

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mented, “MLA is thrilled to be partnering with the SANY Group. Over the past 20 years, MLA has proudly developed an unrivalled knowledge of the needs and requirements relating to container handlers and heavy forklifts.” Michael Kidd, MLA National SANY Product Manager said that performance, safety, economy, reliability and comfort are of primary importance to users of container handlers and heavy forklifts. “These traits are integral to the new SANY range. Already we have supplied many SANY container handlers to the Australian branches of some of the world’s most respected companies. SANY in partnership with MLA has the vision and capability to offer a refreshing alternative to the Australian market,” he said. MLA 131 652 www.mlaholdings.com.au

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Manufacturers’ Monthly MAY 2015 49

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What’sNew

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High quality, dry compressed air KAESER’S CSD 105 rotary screw compressor has been installed by FGB Natural Products, the manufacturer of Bosisto’s ‘Parrot’ brand Eucalyptus Oil to ensure a reliable and efficient supply of high quality and dry compressed air. FGB Natural Products (FGB), an Australian owned and operated pharmaceutical company, specialises in manufacturing natural; over the counter pharmaceuticals, nutritional supplements, household products and more, FGB also manufactures eucalyptus oil and eucalyptus oil based products at its facility in Oakley South, Victoria. They recently called on Kaeser Compressors to replace their ageing compressed air system. Requiring reliable,

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high quality and dry compressed air, FGB chose to install a Kaeser CSD 105 rotary screw compressor along with a 1000 litre air receiver and DC108E dessicant dryer. The CSD series rotary screw compressors deliver premium quality compressed air and superior efficiency. At the heart of every CSD rotary screw compressor lies a low-speed Sigma Profile screw compressor block equipped with flow optimised rotors. Developed by Kaeser, the Sigma Profile achieves power savings of up to 15 percent compared with conventional screw compressor block rotor profiles for a highly energy efficient solution. Kaeser 1800 640 611 www.kaeser.com.au

High-performance sensors WENGLOR’s new PNBC range sets new standards in accuracy with their maximum resolution of 0.06μm with only 0.05% linearity error. This precision is supported by excellent reproducibility and thermal stability – even at output rates of up to 30kHz. This range of sensors work with a high resolution CMOS line array and determine distance to the object by means of angular measurement. Top quality optics make measured values possible which can be read out with 16-bit resolution and can thus go all the way down to 0.06μm.

Thanks to proven algorithms, stable measured values are obtained even for difficult to measure surfaces, for example sheet metal with speckle effect, and can be reliably evaluated. With a maximum range of 1000mm, PNBC products are amongst the most accurate sensors available on the market and with measuring frequencies of up to 30,000Hz, PNBC sensors are well above average relative to other, comparable distance sensors. Treotham Automation 1300 615 110 www.treotham.com.au

All rotary screw compressor blocks powered by IE3-rated drive motors

Handheld controllers gain IECEx approval

Features backlit, anti-reflection, LCD display.

50 MAY 2015 Manufacturers’ Monthly

JAY ELECTRONIQUE has now added the Beta 2 button and Beta 6 button units to their IECEx range. As with the previous models, these are also approved for use in potentially explosive gas atmospheres classified zone 0, 1, 2, or dust classified zones 20, 21, 22. The new models inherit all existing features of the SAFIR family such as a backlit, anti-reflection, LCD display able to indicate the battery charge level, the behaviour of the radio link, the name of the equipment being controlled remotely and feedback from the equipment such as weight of load, overload, limit switches, alarms or fault diagnostics. Navigation menus also allow the user to configure

the application, integrate a large number of functions or monitor a specific part of the equipment. Further customisation of logos and pictograms which appear on the screen is also available utilising the iDialog software supplied with each unit. Safety is at the heart of the SAFIR product range with the emergency stop function certified “SIL 3” per EN 61508 or “PLe” per EN 13849 and the standard function buttons, certified to SIL2 according to EN61508 or PLd according to EN13849. Control Logic www.control-logic.com.au 1300 374 073

manmonthly.com.au

MA0515_000_VEL

2015-04-17T14:05:10+10:00

Purification becomes irrigation.

See how we work with our clients and the community on the challenges of CSG at veolia.com.au/kenyaplant

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What’sNEW Real-time energy info

Rapid identification of PD

EMERSON Process Management has released unveiled Energy Advisor, a realtime energy management information system that automates the process of monitoring and managing energy consumption across mills, plants, and refineries. With real-time, meaningful information about a site’s energy performance, process manufacturers can identify inefficiencies and irregularities and take corrective action, saving on average 5 to 10 percent in Savings can have significant impact on the bottom line. energy costs annually. In energy-intensive process industries like chemical, metals and mining, commitment to improving our customers’ industrial energy efficiency and we began oil and gas, pulp and paper, and refining, focusing on how to help our customers where energy is often 30 to 50 percent of best optimise combustion processes, their operating expense. steam systems, and on-site electrical “Energy Advisor is a natural extension generation.” to Emerson’s Smart Energy Management portfolio,” said Peter Zornio, chief strategic Emerson Process Management officer, Emerson Process Management. 1300 553 051 “In 2011, we announced the company’s www.emersonprocess.com.au

BAUR’s PD-SGS Handheld PD ultrasound partial discharge and TEV (transient earth voltage on metallic surfaces of transformers, switchgear, etc.) is an ideal survey instrument to determine the state of health of electrical assets such as HV and MV switchgear, and to single out those requiring more detailed inspection and/or maintenance. The capacitance coupled TEV detector measures surface voltage in the frequency range of 20 to 200 MHz. Ultrasound measurement for internal PD has a measurement range of -6 to 70 dBµV. Measurement results are displayed on a bright, highly legible OLED with dB indicator. The instrument is supplied with a Li-ion rechargeable battery (12 hour functional time) and chargers for use in vehicles and mains power. The housing has an IP54 rating making it suitable for outdoor use. Standard delivery package includes stereo

Bright, highly legible OLED with dB indicator. headphones, chargers and transport case. Power Parameters 1800 623 350 www.parameters.com.au

Module for compressed air FESTO’s new energy efficiency module MS6-E2M energy saving in compressed air systems simpler. This service unit system monitors and regulates operating parameters in new and existing plants completely automatically. MS6-E2M actively intervenes in the air supply, particularly during stand-by operation, meaning the consumption of compressed air can be reduced. Simultaneously, the automatic monitoring of important operating parameters such as flow and pressure ensures a reliable production process. It is suitable for new, energy-efficient machines but, via the connection of the sensors to a PLC, it can also be used as an easy retrofit on older installations. The module can be adapted by the user by means of a manual input device (MMI) or Profibus to the requirements of a particular installation. The user can quickly and easily specify parameters on the basis of which the E2M detects whether the machine in question is currently in production operation or not. During downtime, the compressed air supply to the machine is shut off, thus 52 MAY 2015 Manufacturers’ Monthly

A permanently anti-static (R ≤ 109 Ohm) item.

Anti-static flexible ducting

Checks installation for leaks in shut-off mode. preventing any air escaping through leakages on the machine. This is similar to the automatic stop/start system in a modern car saving energy. Festo Australia 1300 889 696 www.festo.com

DUCTING specialist Eximo has launched FoodFlex AS, a flexible, anti-static polyether-polyurethane ducting solution with a stainless steel wire spiral. It is designed for a variety of food manufacturing applications. FoodFlex AS (AS is for anti-static) is translucent, has a temperature resistance of –40° to +100° C and is designed to be used for the suction and discharge of abrasive and granular materials. The product is resistant to chemical hydrolysis and a wide range of food-specific microbes, is lightweight, non-toxic and food safe according to

US FDA-regulation 21 CFR 177.2600. FoodFlex AS is also permanently antistatic (R ≤ 109 Ohm), and conforms to TRBS 2153 to provide excellent abrasion resistance and flexibility. Eximo founder and Managing Director Roger Marriott said AS is, “A unique food safe and highly anti-static flexible ducting product designed to provide... the safest and longest lasting environmental protection solution on the market.” Eximo 1300 138 038 www.eximo.com.au

manmonthly.com.au

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Flexible package leak detector BESTECH AUSTRALIA’s bench top model TSE6086B tests packages for leaks and goes go / no-go answers independent of the operator. It conducts leak testing after packing to ensure the quality of finished products, improve their shelf-life, and, therefore, contribute a greater guarantee of product compliance. It can detect holes (leak) as small as 10 micron in diameter allowing sensitive measurement without stressing package contents thanks to the unique chamber design. This leak testing equipment is used by clients to test biscuits, snack foods, salad, MAP packs, milk powder, medical bandages, pharmaceuticals etc. with proven results that make us the leading provider in the industry. The testing chamber is designed to fit most package Non-destructive, stainless steel sizes found in the supermarket. Finished products are food package leak tester. placed manually, and the handle is closed to initiate a fully automatic test sequence. Results are displayed with Pass or Fail lamps, along with a quantitative measure of the leakage rate. The test run as fast as 5-15 seconds for most standard packs and testing results are logged into a spreadsheet importable format to PC for trend analysis and traceability. Bestech Australia 1300 209 261 www.bestech.com.au manmonthly.com.au

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The last WORD Rodney’s factory robot revolution We’re at a tipping point when it comes to the adoption of smart factory robots, says artificial intelligence guru, inventor and entrepreneur Rodney Brooks. Brent Balinski reports. An answer to labour shortages Rodney Brooks’s robotic innovations have found their way into places as varied as the battlefields in Iraq and Afghanistan, the radioactive ruins of Fukushima, the surface of Mars, and even onto our livingroom floors. The Adelaide-born MIT Professor Emeritus is right now concerned with the world’s factories, though. He believes the need for help – in the form of factory robots – has never been greater. “Manufacturing across the world is suffering from a lack of labour,” he said. Brooks said he started to see the supply of work in China dry up in about 2005. He had been visiting regularly since 1997 in his previous board/founder role at iRobot and saw that outsourcing was looking less and less sustainable. “You talk to a Chinese manufacturer and they’ll say their biggest problem is recruitment and retention for their labour,” he said of the situation today. The country is currently scrambling to develop and buy enough robots to deal with its labour availability and price challenges. One high-profile example of the rush for robots is the iPhone contractor Foxconn. Globally speaking, Brooks believes it’s a “knee in the curve” moment for collaborative robots, such as those made by the company he co-founded and is chairman and CTO of, Rethink Robotics. “I think people are starting to see that it makes sense to put robots in to do the really dull, repetitive jobs that the robots can do,” he told Manufacturers’ Monthly, during a visit to Australia in April. “And [also] have people who are much smarter than any of the robots – and much more dexterous – to do the more dexterous tasks. And that’s a way to increase productivity in a world where they just can’t get enough labour.” The apparent explosion in demand for non-human help that is easy to 54 MAY 2015 Manufacturers’ Monthly

program, flexible, relatively cheap and safe to work around can be seen in the race by established robotics companies to add “co-bots” to their offerings. A fresh example is the introduction of ABB’s YuMi at last month’s Hannover Messe expo.

Moving IT benefits to factories The adoption of adaptable robotics is also suited to small-volume, highvariability producers – a profile that matches a large chunk of Australian manufacturing. According to Rethink, the new category of easy-to-use robot will be for factory workers what the PC was for office workers. Where the PC replaced the need to, say, create spreadsheets with ink and hands, the Baxter will replace the need to, say, pick and place widgets, allowing the worker to do something more interesting but not rendering them obsolete. As the PC didn’t replace office workers – just enabled them to do their jobs more productively – the new generation of factory robots are pitched as a technology that will assist factory workers rather than put them out of jobs. Baxter is the enemy of boring jobs in factories, rather than factory jobs fullstop, says Rethink.

The first industrial adopter in Australia is fourth-generation, premium confectioner Haigh’s Chocolates, scheduled to have a Baxter up and running at their Parkside factory this month. In the early days of its deployment in research facilities and US factories, it has been used to undesirable – for reasons of tediousness or otherwise – tasks as varied as bagging bits of plastic, opening stool samples, and in third party logistics.

Fast, cheap and everywhere Brooks began his love of computers and robotics early on. At 12 he built a machine that could play tic tac toe out of telephone switches and light bulbs. He completed his Masters at Flinders but has been US-based since the late-1970s, finishing his PhD at Stanford in 1981 and joining the faculty at MIT in 1984. In the mid-1980s, Brooks gained notoriety by his bottom-up approach to robotics. An idea inspired by mosquitoes, he noticed that despite very little brainpower they could still move about effectively and operate well enough in their environment. He decided that, rather than try to build robots loaded with a top-heavy

mental maps of the world which would become out-dated once their environment changed, robots could have a decentralised way of operating. Operated through “subsumption architecture”, these robots had different, simple sets of behaviour. Arranged in a hierarchy, higher tasks depended on lower tasks being able to be carried out. The stripped-down bug-bots reacted quickly in response to their changing environments, and despite their basic “brainpower” were able to act effectively in response to what was happening around them. One of the best known of these robots was Genghis, which spent a decade on display at the Smithsonian Air and Space Museum in Washington. The architecture used to let the ant-like Genghis walk around, bump into things, react, and keep going, was used in the Roomba vacuum, the best known robot from the MIT spinoff company iRobot, which Brooks co-founded. (He left the company in 2008 to found Heartland, which later renamed as Rethink.) The AI concept is still relevant today, and there are echoes of Genghis in Rethink’s factory helper. Baxter comes with a variation of the subsumption architecture built into its robot DNA. “And that’s what lets Baxter be aware of different things in parallel, for instance it’s picked something up, it’s put it in a box, something goes wrong, and it drops the object, sadly,” explained Brooks. “A traditional robot would just continue and sort of mime putting the thing in the box, but Baxter is aware of that, changes behaviour – that’s using the behaviour-based approach, which is a variation on subsumption. So it is part of Baxter’s intelligence.” Training Systems Australia 03 9557 7993 www.trainingsystemsaustralia.com.au manmonthly.com.au

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