Manufacturers' Monthly August 2015

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

AUGUST 2015

EXCLUSIVE:

Tasmanian industry

making its mark INSIDE >> 12

IT@MM SMEs & the connected supply chain

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Motors & Drives Reducing energy costs

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Industrial Doors Not an open & shut case

>>

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AUGUST 2015

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martin.sinclair@cirrusmedia.com.au Managing Editor: Branko Miletic Ph: (02) 8484 0976 Fax: (02) 8484 0722 branko.miletic@cirrusmedia.com.au 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 Editor-at-Large: Alan Johnson Ph: (02) 8484 0725 alan.johnson@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

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

AUGUST 2015

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Motors & Drives Reducing energy costs

Industrial Doors Not an open & shut case

>>

THIS edition features manufacturing in Tasmania, which has received a lot of doom-andgloom coverage following Caterpillar Underground Mining’s decision to move its assembly to Thailand.

What hasn’t received constant media attention is the many companies quietly going about their business and achieving export success. And it’s not just with fast ferries and mining trucks.

This month we present a tiny sample of some of the state’s industry, following a twoday tour of several factories in Hobart and the north-west region. Read on for the stories of four of the state’s innovators in composites, marine evactuation systems, agricultural machinery and energy solutions.

Manufacturers’ Monthly AUGUST 2015 5

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Comment

BRANKO MILETIC – Managing Editor

The winter of our discontent?

I

N the 1961 John Steinbeck novel, The Winter of Our Discontent, moral decay in a booming post-war American economy and the trials and tribulations of one entrepreneur constantly trying to do the right thing are vividly played out against a rich tapestry of changing socio-economic conditions.

This should ring a lot of bells with Australian manufacturers: a changing economic and social landscape coupled with an economy that is booming in some areas NEXTISSUENEXTISSUE while stalling or even shrinking in • Automation, Robotics & Production Control others.

• Made in Australia When you add the need to always ‘be on the ball’ as they • Energy and Power Management say, there are many in the Austra• Metalworking & Machine Tools lian manufacturing sector that • IT@MM – CAD/CAM/CAE could easily identify with the • Materials Handling – Forklifts & Attachments main M A 0 7 1 5 _ 0 0 0 _ S C A 1 2 0 1 5 - protagonist 0 7 - 1 4 Tin 1 John 4 : 5Stein5 : 5 5 + • Insider Series – Skills, Training & Recruitment beck’s last, and some would

say, seminal critique of modern society.

However, while a number of Australian manufacturers do have a reason to gripe, this Australian winter should at the same time hardly be one of discontent for many others.

With the Aussie dollar at record lows, demand for Aussie exports up and a federal government Canberra that in theory at least, is more business-friendly, the sun should always be shining on our smaller and somewhat streamlined manufacturing sector.

This is certainly true for those Australian companies that are using the latest technologies to promote their skills and ideas across the globe.

1 0 On : 0a 0recent trip to Tasmania for example, Manufacturers’

• Free calls between office sites • Calls from your computer • Entire staff directory on the phone • Wireless handsets and headsets • Compatible with iPhone and Android

Monthly journalist Brent Balinski found a buzzing hive of cuttingedge activity tucked away in one of the remotest parts of the state that at the same time is wining exports to some of the world’s biggest organisations.

As with John Steinbeck’s moral tale, the question is how can this be translated into a meaningful result to everyday economic life?

The answers are varied and diverse, however the underlying truth remains the same: do your very best, do it often and make sure everyone knows about it.

Because, as we all know, after winter, comes spring – a time to renew, rebuild and reform – a lesson that many Australian manufacturers should have learned over the years. branko.miletic@cirrusmedia.com.au

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Answers for industry.

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News&ANALYSIS Keeping control systems safe and secure Process safety and cyber security are distinctly different disciplines but, as Eric C. Cosman writes, there is growing realisation that they are related.

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cess safety) and ISA/IEC-62443 (cyber security) standards have aligned working groups addressing the overlap between security and safety. In the International Electrotechnical Commission (IEC), an ad-hoc group is currently investigating options for addressing this subject. These and other efforts have identified specific areas where safety and security are related.

ODAY’S industrial organisations face the common imperative of determining the appropriate response for each combination of desired security and safety for various parts of their industrial control systems.

International standards committees such as ISA84 and ISA99 are collaborating to develop information in this area that will appear in their respective standards (ISA84 and ISA-62443). In the meantime, preliminary guidance is available, as well as opportunities for stakeholders to help shape this discussion.

Risk assessment and response

Current situation Safe and reliable operation is an imperative for industrial processes. Operations personnel often refer to safety as “priority one, two and three.” As a result, process safety has become an established discipline in industry. Standards and practices available as the ISA84 and IEC 61511 series’ provide requirements for specifying, designing, installing, operating, and maintaining a safety instrumented system (SIS). These provide a high degree of confidence that the SIS can maintain or place a process in a safe state. Certification is also available for safety-related systems.

Clearly, cyber security is also essential for safe industrial operations. Most industrial facilities employ a variety of IT-based products within systems designed to control and protect dangerous processes and equipment. It is essential to protect these systems from cyber security-related threats that could potentially impact the operations and information security of an industrial facility.

The ISA/IEC 62443 series of standards and practices defines requirements and procedures for implementing electronically secure manufacturing and control systems and security practices and assessing electronic security performance. Several cyber security-related compliance specifications are also available.

Inadequate security As these standards are applied, there is a growing acceptance of the fact that a cyber security-related compromise in the operation of industrial control systems can undermine the basic assumptions used in the design of safety systems and procedures for operation and maintenance. This distinguishes industrial cyber security deliberations from those used for IT cyber security programs, which focus on confidentiality and privacy.

Complementary but distinct perspectives 8 AUGUST 2015 Manufacturers’ Monthly

Eric Cosman, a senior consultant at ARC Advisory Group.

The process safety and cyber security disciplines each have specific perspectives on the challenges associated with the design of industrial control and safety systems.

Industrial control systems are designed for safe operation. Designers perform extensive hazard analyses and safety systems are deployed to limit the impact of operator errors, device failures, and control malfunctions.

The cyber security perspective includes consideration and analysis of new, non-deterministic challenges associated with the information and communications technologies that are at the heart of modern control systems. Protecting IT-based control and safety equipment generally requires special products and compensatory controls. Training automation personnel to use and maintain this new technology is another hurdle that must be overcome.

While distinct, these perspectives are complementary. They both focus on achieving safe and reliable operations. This “shared vision” forms the basis for collaboration between these disciplines.

Whether addressing safety or security, it is first necessary to identify the specific risks as well as the approaches for their mitigation. Process safety experts have extensive experience using methods such as process hazard analysis (PHA) and layers of protection analysis (LOPA) when designing safety-related systems. Designing secure systems also requires an analysis of hazard, followed by the application of defence-in-depth and system segmentation, similar in concept to LOPA. Each of the above processes is applied within the context of a relevant life cycle for the system under consideration. Recent work by the ISA84 and ISA99 committees has resulted in the development of a common version of this life cycle that can be used for both safety- and security-related analysis. A technical report on this topic is currently available from the ISA84 committee, which will form part of the description of life cycle as a fundamental concept at the foundation of the ISA/ IEC-62443 standards.

Safety integrity and security levels

A coordinated response

Another area of similarity between the safety- and cyber security-related disciplines is the use of levels to identify the degree of response required in a specific situation. The safety integrity level (SIL) concept is well established and described in the ISA84 and IEC 61511 standards.

The concept of security levels is fundamental to applying the ISA/IEC 62443 standards for cyber security. However, because of the lack of determinism in cyber security-related threats, these levels are more qualitative than those used for describing safety.

The recognition and understanding of this shared vision has led to increased collaboration and coordination between these disciplines.

This collaboration takes several forms. Several companies that were previously focused on process safety related services have expanded their offerings to include parallel cyber security services.

The committees responsible for the ISA84 (pro-

[Eric Cosman, a senior consultant at ARC Advisory Group, has over 35 years of experience in developing, delivering, managing, and supporting operations-related information technology solutions in the process industries] ARC Advisory Group www.arcweb.com manmonthly.com.au

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BlueScope looks to learn from customers BLUESCOPE has used its people’s experience of the manufacturing industry and processes to develop what it calls its ‘Steel Efficiency Review’, a strategic model of selling a service through knowledge and expertise.

The company said that its knowledge of the lean manufacturing process was “identified as a tangible point of difference that BlueScope had within its business. It was the platform to develop a promise and model of offering a service through insight, knowledge and expertise.”

According to the steel maker, customers apply to join the Steel Efficiency Review (SER) – under which a team of the company’s consultants visit their premises to understand the ‘big issues’ – what’s worrying them about day-to-day operations, and what needs to be done to keep the business running smoothly and cost effectively.

MA 0 3 1 5 _ 0 0 0 _ B A C “Special attention is given to the

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the industry, and they may be supply seven most common areas of waste: chain managers, operations managover-production, time in waiting, ers, safety professionals, or senior transport, processing, inventory, moexecutives. “ tion and re-work,” said a company “They visit customers to discuss spokesperson.

1 “Our 2 0 1SER 5 - consultants 0 2 - 1 0 Thave 1 1 an : 1 9 : 0 the 3 +issues 1 1 : and 0 0 see first-hand the operations in action, and then generate average of more than nine years in

a report with recommendations for improving efficiency and productivity. This may be something as simple as changing supplier delivery times to remove bottlenecks in the warehouse, adjusting machinery layout, or developing an inbound goods tracking system.”

The SER is designed to provide the tools to uncover customers’ real business challenges, but without discussing ‘product for price’.

The company then uses a framework to offer best-practice recommendations that highlight opportunities for business improvements and profitable results for its customers.

“Moving from product sell to service utility has opened up an untapped point of difference in a highly commoditised market,” the spokesperson noted.

Bluescope 1800 800 789 www.bluescopesteel.com.au

Manufacturers’ Monthly AUGUST 2015 9

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News&ANALYSIS In brief...

BAE Systems cuts 125 jobs Defence supplier BAE Systems has sacked 125 workers from its Williamstown naval shipyard in Melbourne, as the shipbuilding ‘valley of death’ takes effect. The cuts followed the Federal Government’s announcement $40 billion worth of investment in shipbuilding. That investment will mainly benefit South Australian shipbuilding.

Geelong advanced manufacturing Tony Abbott has announced Geelong as the base for the new Advanced Manufacturing Growth Centre, $500,000 for the trial of a “P-TECH” college, and programmes to boost local employment. He noted the recent difficulties suffered by traditional manufacturers in Geelong, and the potential that lay with a higher-skilled workforce.

David Thodey named CSIRO chair Former Telstra CEO David Thodey has been named chair of the CSIRO, effective from November. Thodey, who left Telstra in April after six years as Chief Executive, has been appointed to the CSIRO position on a five year term.

Contract for Newcastle train builder UGL Unipart Rail, a joint venture between Newcastle train builder UGL and British company Unipart Rail, has won a contract to upgrade Sydney’s Tangara passenger rail fleet. The $131m contract will involve the upgrade of 446 rail cars, which were designed and built at UGL’s Broadmeadow site and are currently maintained

by UGL Unipart Rail.

CSL shares top the $100 mark Shares in Melbourne-based biotech manufacturer CSL have passed the symbolic $100 mark. CSL is the first Australian company to pass the milestone since the global financial crisis. CSL’s market value is now just under $47 billion.

Grants for SA manufacturers Grants worth $28.78 million have been announced, with the aim of assisting South Australia’s manufacturing industry adjust to the end of passenger car assembly in 2017. The SA round of the Next Generation Manufacturing Programme saw co-investment grants awarded to 15 companies, ranging between $550,551 and $4,950,306.

10 AUGUST 2015 Manufacturers’ Monthly

71% say coal is on the way out – climate poll 71 per cent of Australians agree that it is inevitable that Australia’s current coal fired generation will need to be replaced because of the threat of climate change, according to a poll.

The research, Climate of the Nation 2015 by the Climate Institute came as the Federal announced that Australia will aim to cut carbon emissions by 26 per cent on 2005 levels by 2030.

This could be raised to 28 per cent depending on the economic impact.

Other findings of the research include: • 72 per cent of Australians agree that governments need a plan to ensure the orderly closure of old coal plants and their replacement with clean energy. Only 7 per cent disagree.

• Two in three (65 per cent) Australians say that reducing the investment in wind farms and householder solar power is the opposite of what is needed.

Overall 39 per cent strongly agree with this statement. Only 11 per cent disagree.

• 69 per cent agree that ignoring climate change is simply not an answer, as it increases the risk of

the situation getting worse, up 5 points from last year.

• A large majority (70 per cent, same as last year but up from 64 per cent in 2012) think that climate change is occurring with 89 per cent (up 5 points) of those accepting humans are at least partly the cause.

What members of our manufacturing community think about the climate change…

‘Dan’ Climate change is a con. Aussies believe anything the media tells them. It’s all about trading carbon credits and speculation. Can you imagine closing down all coal fired power plants and replacing them with wind? Big cities would have blackouts.

We should go nuclear like Iran.

Don’t become a backwater.

‘Anthony’ (in response to Dan) Dan, I think the con is from the coal mining companies. They are an influential bunch that has the ear of Government.

We need to move away from coal and to renewables. I’m not sure of wind power, but solar is certainly an option that is used in other countries (like Japan) as is nuclear. There is also gas and thermal to consider.

Nuclear is an option (albeit not a particular good one for politicians), however there is an issue with waste which is of great

concern. Climate change is happening and whether it’s man-made or natural the point is we need to get away from coal and start the transition now.

‘Graeme Pocknee’ To me, if we unlock 400 million years’ worth of energy stored in carbon over a 300 year period then there will be detrimental effects. However, it’s not only about how electricity is generated, but also how it is used and moved. If you localise the power source to the consumer then you reduce losses.

Also, I see examples in Germany where data banks are housed in the bottom of apartment buildings. The heat generated by the data bank warms the building.

Now we are not cooling a data bank and separately heating an apartment building – power consumption reduction and emission reduction. Smart thinking.

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.

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Comment

MARK GOODSELL – NSW Director, Australian Industry Group

Tales from the frontline Australian manufacturers are showing they are not afraid of change. As Mark Goodsell writes, companies around the country are looking for new business and finding new ways to operate in a changing world.

I

N recent months I have met with manufacturers in western and southern Sydney, Albury, Wollongong, Newcastle, Geelong and Brisbane. At every meeting, I am asked what I am seeing and hearing in the industry.

Ai Group’s Australian Performance of Manufacturing Index (Australian PMI) for July reflected the definite uptick I have felt growing in the spirit of local manufacturing over the past six months. The July result records the first increase in manufacturing sales for over a year, a continuing recovery in exports, and suggests a slight easing in margin pressure.

At 50.4 points, the index shows the sector is stable, and the three-month moving average figure records gentle improvement since the start of the year.

Given the headline pressures from mining and auto, there must be some good things going on out there to produce this result. That’s a general observation and not everyone will share the sentiment – I’d love to know what you are seeing and hearing. It coincides with the fall in the dollar, with a feeling of better competitiveness against imports, and a renewed interest in exports, including to the US. There are marked differences between and within regions. Regions that were hit by the coal price fall two years ago are finding it tougher, although that depends on your exposure to mining. Companies who diversified, including out of region, seem to have it easier.

Mining is spending money, but it’s moved from their capital to their operating budget as the equipment installed in the huge wave of investment starts to wear. Miners are also hungry for cost saving ideas for their operations.

The housing, food and health supply chains are the strongest. Commermanmonthly.com.au

cial building and infrastructure are patchy across the states, as is government spending more generally.

It’s hardly surprising that in the face of shifting markets, one of the most profound changes I hear about is in the way companies find new business. Almost every manufacturer I have met in the last two years has changed their sales or business development function in some way. How?

“

Most sectors have their differences in how you get in the door and understanding them is as important to success as the quality of your offering. Companies have even been burnt by differences in business culture and practice between regions within Australia, particularly if they have built their business only within one region.

In some sectors you have to travel

In recent times, a lot of SMEs have engaged their first sales person ever...

Some have deepened their business development capability. By simply putting on more sales staff, or increasingly, by investing in the capability to dig out customer problems and integrate that intelligence into their design and engineering functions, rather than relying on more traditional stand-alone sales skills.

A lot of SMEs have engaged their first sales person ever. Some of them say they never needed a salesman before, because work “just sort of rolled in” – but not anymore. Often the owner did sales, to save a salary, but that model is starting to show its limitations.

I have been struck by the number of companies who say they are finding new business in strange places.

That’s probably a good sign, reflecting a capability to ask the right questions and have an open mind about where opportunities might lie.

However, different sectors are a different sell. Industrial supply chains are different to consumer sectors. Defence has its own rules, as do most other government customers.

Aerospace and health have their own quality expectations.

a long way to get business next door.

The OECD assessed in 2013 that 70% of world trade was stuff being moved from one stage of value adding to the next. You may make the world’s best piece of kit, but in many supply chains a customer is the next stage of production or a turnkey system maker, even if the final destination is the consumer, company or project down the road.

If the customer is now more often offshore, selling requires different MM0 4 1 4 _ 0 0 0 _ I N D skills, the capacity to understand

new business cultures and a passport.

Industry stalwarts are disappointed that long relationships with customers don’t seem to count any more. That’s one of the sadder truths of a hypercompetitive world. A long relationship may have got us in the door previously, but it is what we learned while inside the door that now counts.

Those that seem to have done best tell stories about learning to deeply understand where their customer is going. None of that is rocket science, but some firms seem surprised when customers change tack or drift away.

And that is particularly the case when their customer is government, who can be frustratingly opaque about their intentions.

So, returning to where we began, the Australian PMI is a powerful way to focus on the overall state of manufacturing. But behind it are thousands of stories.

[Mark Goodsell, NSW Director at the Australian Industry Group, was additionally appointed to the new position of National Director – Manufacturing in 2014. He has just launched a new forum on LinkedIn – The Australian Manufacturing Group] www.linkedin.com/groups/Australian1 2 0 1 4 - 0 3 - 1 3 T1 2 : 3 3 : 1 4 + 1 1 : 0 0 Manufacturing-Group-6978955/about

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Manufacturers’ Monthly AUGUST 2015 11

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TechnologyIT@MM SMEs and the connected supply chain A connected supply chain, where everyone knows where products are, offers several benefits.

But, as Robert Fransden writes, until now many SMEs have been missing out on it.

W

ITH all the stories in the media about the Internet of Things making it easier to capture information at every point from the factory to the warehouse and beyond, surely everyone must be taking full advantage of the opportunities?

In reality there’s a huge divide between the practices of the largest manufacturing enterprises and their smaller peers.

Many of the tools and technologies required to connect the supply chain have historically only been available in complex, tier one-style software solutions.

Fortunately the situation is changing. Connecting to partners along the supply chain has become a practical possibility for any sized organisation, thanks to the automation afforded by combining modern warehousing and EDI systems along with scanning solutions capable of working with mobile devices.

The idea that EDI could be a game changer often surprises people because it has been around for so many years. But in that time, it has become a mainstay of the industry.

The breadth and duration of its uptake across small and large organisations has encouraged software vendors to build new tools and to give customers more control over their EDI experience.

As a result these days, with the help of visual mapping functionality, it is possible for users to develop their own EDI schemas.

Smooth ordering The benefits of using these technologies to connect supply chain partners can be seen in the automation of processes, the corresponding reduction in administrative work, minimised opportunities for manual errors and the improved flow of information across multiple organisations.

Take the example of a distributor who places an order with a manu12 AUGUST 2015 Manufacturers’ Monthly

Connecting to partners along the supply chain has become a practical possibility for any sized organisation. facturer via an EDI system. The EDI software automatically acknowledges receipt of the order and confirms the stock is there without any need for human intervention.

Next, as staff pick, scan and pass the stock through despatch, more notifications are sent to advise the distributor – and perhaps their end customer – that the goods are now in transit.

In this fully automated process, acknowledgements connect all parties, from order to pick, from job generated to despatch to final delivery.

The only manual process or human intervention required is the physical movement of stock.

Importantly, advanced functionality within the warehousing system enables the manufacturer to build reports on critical topics such as stock levels on hand. They can also provide forecasting information by incorporating data regarding minimum and

maximum required stock levels.

All of these reports can be scheduled to run at stipulated intervals and automatically emailed to keep the manufacturer, distributor and customer up to date at all times.

What is clear in this process is that the warehouse, the EDI system and scanning are key to both the beneficial automation and to connecting all parties. Almost all the activities that need to be documented and all the work flow processes originate or pass through the warehouse management system at some point in time.

This includes stock being received into the warehouse, receipt of orders, picking, despatch and manifesting onto the truck.

The only significant part of the flow that occurs outside the warehouse system is when the goods finally arrive at the distributor’s premises and the recipient signs on glass to acknowledge receipt of goods.

The connectivity described in the above example is not unusual today.

Among the organisations I regularly deal with are companies of just 50 employees who are using a connected supply chain to successfully compete with organisations that have 2000 staff.

The smaller company’s advantage comes from the agility of size, good warehousing practices, smart use of scanning and automation, proactive reporting and integration with a reliable EDI engine.

These organisations shine because their choice of technologies supports and connects all partners, improving communication, collaboration, forecasting and planning up and down the supply chain.

[Robert Frandsen is Managing Director of InfoMotion] InfoMotion 1300 674 994 www.infomotion.com.au manmonthly.com.au

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Generative design optimised for 3D printing AUTODESK has announced the availability of Autodesk Within, a set of generative design software solutions to help engineers create and 3D print lightweight designs for the automotive, aerospace, industrial equipment and medical implant industries.

Autodesk Within is built around a powerful optimisation engine that takes input parameters – such as desired weight requirements, maximum stress and displacement – then generates designs with variable-density lattice structures and surface skins to meet exact specifications. The resulting components are higher performing and can be considerably lighter weight than traditional designs.

They are as stiff or as flexible as needed, and are refined to enable faultless additive manufacturing.

Complementing the software, Autodesk Within Consulting provides consulting services to help companies across diverse industries quickly adopt and realise value from M Within can A 0 technology.

8 1 5 _ 0 Autodesk 0 0 _ TR O consult on specific projects and on how

best to use Within features to reach design goals.

“In industries such as automotive and aerospace, it’s critically important to continue innovating in how parts are designed and manufactured. Generative design, advances in material science, and new fabrication techniques are allowing engineers to deliver components that were never before possible,” said Mark Davis, Autodesk’s senior director of design research.

“Autodesk Within enables designers to create high-performing parts while enforcing design rules and adhering to additive manufacturing constraints.”

Autodesk Within case study demonstrating a lightweight load-bearing engine block.

Generative design is central to the design features will be incorporated into for manufacturing, when changes are future of making things. It is a process by more of the Autodesk product design exponentially more expensive. Generative which the infinite computing power of the software portfolio. cloud determines design alternatives based design can increase design quality, effiAutodesk Within is based on technolciency and performance across the board. on parameters such as weight or strength ogy from the 2014 acquisition of LondonIn addition to the Within software, set by a designer. This approach leads to based Within Labs.

Autodesk is pursuing other generaoptimisation of cost, materials and fabricaincluding Project techniques Autodesk 1tion 2 0 1 5 - early 0 7 -on2in0the T process 1 1 : 1 5 : 1 tive 6 +design 1 0 : initiatives 0 0 Dreamcatcher. Over time, generative – not after a design has been handed off www.autodesk.com.au

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Manufacturers’ Monthly AUGUST 2015 13

MA0815_014

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Business INSURANCE Is your company really covered?

Many manufacturers have insurance policies. But, as Alan Johnson reports, some find out too late that their policies don’t cover all their losses.

V

ERY few people enjoy having to pay their annual insurance premiums; that is up until something goes pear shape. And for many, it’s only then that they start reading the small print and discover their off-the-shelf insurance policy doesn’t cover that particular problem.

Stuart McKellar, General Manager, Corporate Risks Qld, with Jardine Lloyd Thompson (JLT), a leading global provider of insurance broking, reinsurance and employee benefits related advice, says this is one of the most common problems he comes across; manufacturers thinking they are covered, when in fact they are not.

“We see it all the time, manufacturers not understanding their insurance policies,” he said.

While every client is different, he says a common mistake manufacturers make is they buy off-the-shelf insurance products.

“Instead we recommend all our clients, but particularly manufacturers, to drill down into their actual risks, undertake risk profiling workshops, have valuation programs in place and review their business interruption values regularly.”

McKellar says there are major benefits for companies to do this.

“It ensures that they are not over insured and paying too high a premium, or under insured, which has flow on effects in the event of a claim.”

When it comes to insurance, McKellar describes manufacturing as a very complex industry, with many areas that can affect revenue including product recalls, and loss of production due to a 3rd party supplier.

“For example, we are seeing a lot of recalls in the press at the moment, from Samsung washing machines to air bags in a large number of vehicles globally.”

“A couple of years ago we also saw some of our local clients affected by the Thailand floods, which impacted their revenue.

“Given the lower cost of production

14 AUGUST 2015 Manufacturers’ Monthly

Accidents do happen – make sure your company is fully covered. there, a lot of parts are manufactured in the region and when the floods impacted their production, it had a flow on impact on our clients here,” McKellar told Manufacturers’ Monthly.

To understand the risks involved for manufacturers, McKellar says JLT looks at a client’s risk register and how it manages and treats the insurable and uninsurable risks, and importantly align the insurance program to that risk profile.

“Unfortunately when companies buy off-the-shelf products, they are invariably getting just the insurer’s standard terms and conditions.

“Instead we work with our clients so that we can tailor the policy coverage so that it’s fit for purpose. ensuring that if a company has a claim, the policy is going to respond.”

McKellar says a basic example of that is around the business description, making sure it is continually updated to reflect the changes in the business.

“With manufacturers, it might be new products, could be new markets, a geographical expansion, or there

might a merger and acquisition happening during the policy period.

“Companies must ensure their policy coverage is consistently evolving in line with your business,” he said.

Insurance costs McKellar explains that the cost of a tailored insurance policy should not necessarily be higher than an off-theshelf policy.

“At the moment, the balance between cost and cover is the lowest it has ever been.”

He says the current insurance market is extremely soft, with rates at historical lows.

“And with competitive pricing, insurers are looking to differentiate themselves from other insurers by providing broader cover than normal.

“Plus the insurers are taking on more risk by offering a wider range of insurance products such as contaminated products cover and product recall, which in the past was only available from a select number of insurers.”

To keep premiums low, McKellar

recommends manufacturers keep up to date with their declared values, making sure they are not over or under insured.

“They can do that by having a valuation program in place, which includes looking at the company’s assets and having a constant review of the company’s business interruption values. They can also look at how they structure their insurance programs.”

He says companies can also look at increasing their excess or deductibles to reduce premiums.

“But that should be based on an annual review of a particular client’s appetite for carrying risk,” McKellar said.

During the annual renewal cycle, McKellar also recommends that clients have in place a rolling insurance strategy, which is consistent and runs parallel with the company’s business strategy.

And not just for large manufacturing companies, he recommends this kind of strategy is in place for all manufacturers. manmonthly.com.au

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Insurance advice According to McKellar there are some bare essentials that every manufacturer’s insurance policy should cover.

To start with, he says manufacturers should cover all their assets, and any plant, stock, machinery, equipment and contents.

“Plus we recommend companies have insurance to cover business interruptions so in the event of any loss, such as a fire or flood that impacts production, they are covered to protect the business and ensure its sustainability.”

McKellar says companies should also cover their liabilities, both public and product including product recalls and associated expenses.

He says it is also important for companies to cover their staff and review their workers compensation coverage.

“Those are the traditional musthaves covering a company’s assets, liabilities there M A 0 and 8 1 people.

5 _ 0 0Then 0 _ S I E is 2 a myriad of insurances, some which

manmonthly.com.au

we recommend are emerging risks around cyber for example, then of course there is cover for Directors and Officers and the business itself.”

Another important area that manufacturers should be aware of is the agreement to onerous contract conditions, whereby some insurance policy holders may not fully understand the implications of such an agreement.

“We have seen some examples recently where companies have given blanket indemnities to their customers.

“I understand why, given the competitive world we live in today with everyone trying to grow their business and retain and grow clients, but giving away these blanket indemnities could potentially prejudice the clients rights to indemnity under the insurance policy,” McKellar warns.

Another problem he encountered recently was a new client who had been overstating the company’s declared 2 2values.

0 1 5 - 0 7 - 2 8 T1 3 : 5 3 : “By overstating the value of their

property, plant, stock and contents, the company ended up paying high premiums, when they didn’t need to.

“We were able to put in place a valuation program and ultimately save that client quite a bit of money,” McKellar said.

Regarding product recalls, he says it is clear that it is not fully understood by many manufacturers, with the risk of product recall able to be transferred to the insurance market.

“An important trigger in that policy is there needs to be actual, or the threat of, bodily injury,” he said.

McKellar said another example of what the insurance industry can achieve revolves around statutory liability.

“With the changes in OHS legislation in past couple of years, we have been recommending clients to take out statutory liability insurance to cover for any fines and penalties that are a result of a breach of legislation, which could include OH&S legislation legislation.

1 4 and/or + 1 0 :environmental 0 0 “With this sort of cover, manufac-

turers are covered for the fines, as well as the costs of defending the imposition of that fine,” McKellar said.

With manufacturers facing wider and wider economic and regulatory risks, he says it’s important companies get the correct insurance coverage.

McKellar pointed out that today, risk can arise from wide range of areas including the complexities of modern day supply chains, demanding legal and regulatory requirements, engaging in safety critical activities or through the use of sophisticated technology and manufacturing processes.

[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] Jardine Lloyd Thompson (JLT) 02 9290 8000 www.jlta.com.au

Manufacturers’ Monthly AUGUST 2015 15

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Health& SAFETY Fit for the job Occupational Health and Safety has come a long way in recent years. However, there are still a couple of significant OHS problems that need to be addressed. Matt McDonald writes.

R

ESPONSIBLE manufacturers regard OHS as a priority. They supply workers with protective gear, ensure machinery is well maintained, and allow employees appropriate amounts of sick leave.

However, in 2015 making sure that all the above has been seen to is not enough. According to Safe Work Australia, (for all sectors) compensation payouts have increased by over 70 per cent in the last decade.

And the two major causes of the increase are factors that many businesses may not have considered – the ageing workforce and the impact of mental illness and stress.

The ageing workforce As Jeremy Keane, Managing Director of Injury Treatment told Manufacturers’ Monthly, the baby boomers are getting old.

“We’re seeing an older level of participation in the workforce which is quite obviously leading to an increase in workplace injury, especially in the blue collar or more physically oriented roles,” Keane explained.

“Their musculoskeletal systems are not what they used to be.”

Thankfully, said Keane, there are practical ways to deal with this fact. And they don’t involve the mass retrenchment of older workers.

“The first place to start is to get a good understanding of the physical requirements of all of your roles,” he said.

“Once you’ve done that you can start to work on an individual basis to determine people’s capacity to complete the role they’re employed for. And that’s really profiling your workforce to make sure you’ve got people who are physically able to complete the requirements of their roles.”

In cases where individuals are deemed not capable of carrying out their current tasks there are several avenues management can follow.

Depending on the business, they may introduce automation to reduce physical labour. Or they may look to redeploy those employees internally or change workplace flexibility arrangements with things like job sharing.

“And in the very extreme obviously you may need to move employees based on their ability to complete a role safely,” Keane added.

“That would be the last option for most employers. They obviously want to provide for their workforce, especially in Australia where we see low unemployment and a high skill level in your more aged employees.”

16 AUGUST 2015 Manufacturers’ Monthly

Older workers have much to offer in terms of knowledge and experience, but employers must not push them beyond their physical capabilities.

Determining the physical fitness of potential employees before they get the job can help to reduce the incidence of musculoskeletal injury before it even occurs.

“You can do some musculoskeletal testing to determine that when you bring people in to your business they can complete the role,” said Keane.

Times have changed and people no longer spend their whole lives at one workplace so the careful selection of employees could potentially phase out the problem.

Psychological injury Figures from Safe Work Australia reveal that psychological workplace injuries are on the rise for workers of all ages.

According to Keane, this is partly because there is more awareness of mental health issues in general.

“We have seen a big increase in the press coverage of psychological injury in the workplace.

There’s a higher level of reporting of injury just because people’s awareness is increasing,” he explained.

He also pointed to a change in the work-life balance. Longer working hours hours have contributed to the problem.

Interestingly for manufacturers, white collar environments where there are a lot of interpersonal relationships and a hierarchical structure see the highest rates of psychological injury. In such workplaces

bullying and harassment are more likely to emerge.

Even so, manufacturing businesses are not immune to the problem and Keane offered some advice as to how businesses can handle the issue.

“You really need to see it as analogous to trying to prevent physical injury in that you want to get to understand the functional requirements of people’s roles and you want to ensure that you’re connecting people to the right jobs. That’s a very simple way to look at it,” he said.

He said that up-skilling management can help.

They can be trained to be able to have difficult conversations regarding, say, performance with an employee without causing undue conflict or even being accused of bullying.

“That’s a little bit of an art. It’s a skill you can teach a manager,” Keane said.

On top of that he nominated employee training on appropriate interpersonal relations in the workplace and engendering resilience as worthwhile.

Asked if Australian workplaces were on the right track in terms of promoting mental health, Keane answered optimistically.

“Anecdotally I’m starting to see employers start to invest a lot more in psychological injury prevention just as they have been for years in physical injury prevention,” he concluded.

Injury Treatment 1300 622 734 hwww.injurytreatment.com.au manmonthly.com.au

MA0815_000_SCO

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1

2015-07-28T13:54:35+10:00

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MA0815_018

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2015-08-14T14:32:05+10:00

Motors & DRIVES Reducing energy costs Industrial motors and drives represent a major opportunity for energy savings as companies adapt to escalating power prices. Harry Singh writes.

I

NDUSTRIAL motor and drives technology has improved greatly in the last decade and, now with a greener footprint, businesses can save a lot of money by re-assessing how they use energy in the day-to-day running of their business.

Even straightforward initiatives, such as the adoption of variable speed drives (VSD) instead of fixed speed drives, can produce significant energy savings.

VSDs can typically reduce the speed required for particular operations by 20%, cutting power bills by more than 30% in common instances and achieving payback in less than a year.

The biggest problem is that the technology is growing so quickly that it can be hard to keep up with all the changes and understand which is the correct option, especially if companies haven’t looked at their options for a few years.

Perhaps government has a role here in sponsoring holistic audits of company energy use which would undoubtedly produce major savings through the use of advanced drives technologies.

Savings potential Some of the biggest savings can be made by converting the drive of fans or pumps to a VSD, especially where the flow of the fan or pump is being controlled by a valve or flow regulator.

Installation of a VSD on these applications has one of the biggest potential to save money and supply a quick payback time by reducing motor speed and thus reducing motor current.

This is because VSDs are around 94% to 98% efficient, with the current on startup limited to 150-200% of total motor current. (Direct online motors can draw between 5-7 times full motor current on startup).

As well, the advanced static and dynamic energy saving functions, adaptability and robustness of a VSD reduces impact on the environment.

In many pumping applications, it can be very cost-effective to replace the direct online start with a VSD, which can see installation payback in some cases below 12 months.

And where supply authorities penalise companies based upon spikes in demand current, this can be greatly reduced by installing a VSD. In general, electric motors are reasonably efficient when running continuously and, with the MEPS standard for motor efficiencies, this has been improved in recent years.

Where the use of motors becomes costly is when the motor is started and stopped regularly via a 18 AUGUST 2015 Manufacturers’ Monthly

As well as a greener footprint, latest motors and drives offer manufacturers significant energy savings. direct online start, which can draw five to seven times the full load current of the motor.

This high current load fatigues motor windings, generates high heat in the motor and in some cases can cause supply grid voltage dips which supply authorities do not appreciate (and may lead to penalties).

VSDs, on the other hand, limit the starting current to between 150% and 200% of full motor current and also smoothly ramp the motor to the required speed.

“

Big savings can be made by converting the drive of fans or pumps to a VSD… Advances in drive design and control means users can generate full motor torque down to virtually zero speed, which reduces high starting currents, greatly reduce motor winding fatigue and also allow users to set the correct motor speed for the application.

By putting a VSD onto a common centrifugal pump and reducing the speed by around 20%, users can see power savings of around 30-50%.

VSD can also avoid the need for larger size motors. Cost rises may not be highly significant as

specifiers go up a size or two to meet their power needs, but this approach will draw excess energy just to keep the heavier rotor turning.

Old practices The old practice of running motors direct on-line and using other means to control flow or temperature are still widely used and are wasting companies a significant amount of money.

Many manufacturers and material processors install VSDs to simply allow the machine to have a variable speed, but modern VSDs can also have a variety of industrial sensors incorporated to allow the drive to control the process better, with more control- and save the cost of a PLC or separate controller.

Today, drive manufacturers are looking at ways to make their VSDs more beneficial to the customer and are starting to design the drives with low loss drive filters, sleep modes to reduce energy consumption when motors are not running, and load monitoring, which will optimise motor current, to applications to reduce energy supplied to the motor.

Getting companies to run their equipment more efficiently will reduce their running cost over the short and long term, plus reduce their carbon footprint.

[Harry Singh is an Applications Engineer with Bonfiglioli Transmission Australia] Bonfiglioli Transmission Australia 02 8811 8000 www.bonfiglioli.com.au manmonthly.com.au

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Frequency inverters with integrated PLC FEATURING an integrated PLC, frequency inverters from Nord Drivesystems combined with geared motors can now become a full-fledged intelligent system.

All distributed SK 180E and SK 200E controllers and the cabinet inverters SK 520E and above now offer an integrated PLC. The PLC enables straightforward free programming of drive-related functions according to IEC 61131-3 in “Structured Text” and “Instruction List” using the freeof-charge Nord Con programming and parameteristion tool.

The intelligent inverters can thereby manage sophisticated tasks such as autonomous process monitoring or dynamic operation without an external controller.

As well as keeping costs down, the inverters can control a wider range of motors, witd support for IE4 synchronous motors currently being tested in the field.

In addition to their functional versatility including M A position 0 6 1 5control, _ 0 0 the 0 _distributed T RU SK 200E units also provide excellent

The PLC enables straightforward free programming of drive-related functions according to IEC 61131-3 in “Structured Text” and “Instruction List”. overload tolerance and are available for a wide power range – up to 22kW. The compact control cabinet inverters from the SK 500E line will be available up to size 11, with 160kW rating, later this year.

Nord Drivesystems 1 2 0 1 5 - 0 5 - 2 7 T 03 0 99394 : 50500 0 : www.nord.com

Motors and drives safety package AVOIDING industrial accidents while maintaining trouble-free and economical system operation can be implemented flexibly and individually using integrated and modular safety technology from SEW-Eurodrive.

The company’s portfolio of Movisafe components, gearmotors and frequency inverters offer a drive engineering solution for applications across many industries, incorpoA complete drive package with incorporated rating monitoring for safe motion, functional safety. safe positioning and safe brake gearmotors with built-in safety rated brakes management. and safety rated encoders, frequency In compliance with EN ISO 13849-1, inverters and decentralised drive systems which is intended to minimise the risk with integrated safe torque off (STO) funcposed to employees by technical equiptionality up to PLe in accordance with EN ment, the Movesafe safety controller is ISO 13849-1, matching safety controllers flexible and easy to program with its intefor safe input monitoring, safe limited speed grated safety function for all crucial safe and safe positioning, and accessories like motion requirements. prefabricated encoder cables that will miniSEW-Eurodrive offers its customers a mise errors and reduce wiring efforts. single source for a complete drive package solution with incorporated functional SEW-Eurodrive 1300 739 287 0 safety.

7 + 1 0 : 0 0 The safety package comprises www.sew-eurodrive.com.au

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Manufacturers’ Monthly AUGUST 2015 19

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2015-08-13T15:39:21+10:00

Motors & DRIVES Keeping components aligned Hydraulic bolting systems offer industry optimum outcomes for motor and gearbox alignment.

Alan Johnson reports.

E

LECTRIC motors and gearboxes can operate together for significant periods of time with few reliability issues, however, if they are poorly mounted or misaligned, serious and often costly problems can occur very quickly.

Having the motors and gearboxes poorly mounted or misaligned can cause problems such as bearing and seal breakdown, coupling failure and possible consequential damage to other components.

The problem often occurs when components are assembled or replaced in working environments where there is urgency to recommission the machinery, especially when drive motors and gearboxes are swapped out with replacements which may have some differences in mounting M A 0 hardware, 8 1 5 _ 0 or 0 originate 0 _ A R Mfrom different manufacturers.

Clamp Broke?

Revamp Your Clamp

lation times as the mounting bolts/ John Bucknell, CEO and Founder nuts do not have to be screwed down of Australian hydraulic fastening and fully tightened repeatedly with company Technofast Industries, torque wrenches or other means. explains that the correct alignment When used in conjunction with of electric motors and gearboxes is the correct alignment tooling, the always required when changing one hydraulic nuts and bolts allow the or the other. operator to bring all corners of the “Large machines are often aligned electric motor or gearbox down using laser equipment to ensure simultaneously for measurement of best outcomes, with the procedure alignment. normally requiring linear adjustment Necessary linear adjustments or and shim packing for correct height shim packing can be done by quickly alignment.” releasing the hydraulic pressure, After each alignment adjustment, the mounting bolts must be tightened making changes, then reapplying it to achieve the optimum result. and the alignment measured to as“When all is to spec, the EziTite’s sess the outcome. This may require a lock ring is simply nipped up tight, number of passes to get the required the pressure released and pressurresult and often takes many hours of izing equipment removed from the labour and downtime. finished job.

Bucknell says the use of his The 1company’s 2 0 1 5EziTite - 0 8 -hydraulic 1 2 T 1 bolts/ 0 : 1 0 : 0 4 + 1 0whole : 0 0process takes just minutes, not hours.” nuts can dramatically reduce instal-

Hydraulic nuts/bolts Bucknell says hydraulic nuts and bolts are also ideal for simultaneously tensioning bolting arrays such as fasteners on a flange, joint or cover, often loading 100 per cent of the fasteners at once.

“This gives an extremely accurate even load onto the bolted joint, ensuring a leak-free start-up.”

He says the use of the hydraulic nuts and bolts offer the user additional benefits including improved safety, by removing flogging spanners and larger wrenches, along with greater accuracy and much reduced downtime on vital equipment.

“Plus of course there is minimal physical effort required to operate hydraulic bolting systems. Even in tight spaces, as long as you can connect the pressure hose you can tighten the bolt,” Bucknell added.

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www.armstrongindustries.com.au 20 AUGUST 2015 Manufacturers’ Monthly

manmonthly.com.au

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1

2 0 1 5 - 0 7 - 2 0 T1 1 : 1 8 : 4 4 + 1 0 : 0 0

NOT ALL BODIES ARE CREATED EQUAL

Accurate alignment critical to reliability of electric motors and gearboxes.

He explained that the hydraulic nuts and bolts can be specified and manufactured using high strength alloy or stainless steels to suit application requirements, with protective covers or optional surface treatments available.

The hydraulic bolts are precision engineered, high performance, hydraulically operated fasteners which incorporate mechanisms for tensioning. They can be easily fitted using standard pumping equipment such as hand operated, electric hydraulic or air hydraulic pumps.

The company’s hydraulic nuts can be rapidly applied by being installed on bolt studs then hydraulically actuated, stretching the bolt to the precise tension required and then locking it in place mechanically with a locking device.

The reverse procedure permits equally rapid disassembly when it is eventually required for maintenance, for example.

The hydraulic nuts and bolts are said to be ideal where accurate and reliable loading is required on bolting, where vibrational or torsional stresses are a problem, and regular maintenance requires repeated adjustment or removal of nuts. They are also suitable for confined or difficult nut locations.

Standard range of the EziTite hydraulic bolt is 20mm to 100mm diameter and features a unique lock-ring thread technology to ensure maximum retained load and a spherical seat ensures correct alignment to the joint face.

Available in a variety of seal designs for temperature/pressure requirements, the maximum pressure of EziTite hydraulic bolts is 100MPA, though custom designs may be higher.

Technofast Industries 07 3803 6550 www.technofast.com

Overload protection device RINGFEDER Power Transmission has developed Tschan TNT, a combination of Gerwah’s GWS torque delimiters and Tschan’s elastic claw couplings of the Nor-Mex and TNB series for the requirements of heavy-duty machines and equipment such as extruders, shredders and conveyor plants.

This combination is said to provide highquality simple overload protection, which in turn guarantees maximum safety and reliability in complex and therefore expensive power trains.

For example, the combination of the zero-clearance TNT torque delimiter and the manmonthly.com.au

Tschan Nor-Mex makes it possible to change the spacer ring effortlessly, without having to axially move the input and output ends.

If combined with the Tschan TNB, it is even possible to change the buffers without removing the part. Once the retaining screws have been removed and the holding ring has been pushed back, each of the mounted buffer pins can be radially removed.

In addition, combinations with Gerwah multi-disc clutches as well as Tschan Posiflex denture clutches will be available in the future.

Ringfeder Power Transmission www.ringfeder.com

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Thickness

Hardox HiTuf

310 - 370

40 -130mm

Hardox 450

425 - 475

3 - 80mm

Hardox 500

470 - 540

4 - 80mm

Hardox 550

525 - 575

10 - 50mm

Hardox 600

560 - 640

8 - 50mm

Hardox Extreme

625 - 700

8 - 25mm

Strenx 700

750 - 950 MPa

2 - 10mm

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Manufacturers’ Monthly AUGUST 2015 21

MA0815_022

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2015-08-14T14:59:58+10:00

Tasmanian MANUFACTURING Tasmanufacturing: a visit down south

M

ANUFACTURING in the southernmost state has received a lot of attention this year. Much of it has to do with Caterpillar Underground Mining’s decision to move its manufacturing to Thailand, coming at the cost of about 280 jobs and flow-on effects for the company’s numerous suppliers.

Soon after the announcement, a taskforce was formed, chaired by deputy premier Jeremy Rockliff. Soon after this, the state budget committed $3 million to the taskforce’s recommendations on adjusting to the exit.

Though it’s a serious setback, the north-west

of Tasmania – and the state in general – has an impressive manufacturing sector. The formidable marine engineering prowess of Tasmania – where nobody lives more than 90 minutes’ drive from the water – in particular is well-known. It’s not just fast ferries and mining trucks, however.

Here is a tiny, tiny sample of some of the state’s industry. Manufacturers’ Monthly visited eight clever, successful businesses. Their output ranged from hydraulics to energy solutions to defence furinishings. Each had dealt with isolation from the rest of Australia and from international markets – all had export sales – in their various ways. And each

spoke with a frankness, authenticity and generosity that you do not always find on the mainland.

Purely for space reasons, the stories of only four have been included in this edition. For the same reasons, the stories following are abbreviated versions. For the other stories, and for extended versions of the below, visit www. manmonthly.com.au [Manufacturers’ Monthly travelled to the state as a guest of Brand Tasmania] Brand Tasmania 0419 564 745 (Robert Heazlewood) www.brandtasmania.com

Liferaft maker that’s blowing away the competition Hobart’s Liferaft Systems Australia may not be a household name but, as Brent Balinski writes, it is a supplier to navies and shipping giants all over the world.

“THIS is like building parachutes, in this company,” explained Mike Grainger, managing director of Liferaft Systems Australia (LSA).

“At this production facility it’s like building parachutes, only our parachutes have 100 people hanging off them.”

LSA specialises in marine evacuation systems (MES), a demanding niche involving a very serious, lifeor-death application: getting as many people to safety as possible.

It is one of one four firms worldwide in the MES market, which it has changed through various innovations.

These include an evacuation slide deploying passengers and crew directly into a vessel, and creating the world’s first 100-person liferaft. Its product range is limited and focused, and everything is tailor-made for clients.

These include the US, New Zealand, British, French and Dutch navies.

“We don’t make small liferafts for sailing yachts, we don’t make lifejackets or immersion suits,” said Grainger.

The firm began in 1992, formed to provide their slide-based solution to Hobart’s world-renowned shipmaker, Incat. For three years Incat was LSA’s only customer, but now the inflatable structures specialist ex22 AUGUST 2015 Manufacturers’ Monthly

LSA exports 98 per cent of what it makes, and is a supplier to several of the world’s navies. ports 98 per cent of what it makes.

“North America and Northern Europe are our biggest markets at the moment. The largest ferry operators in America are using our systems.

Defence is also a big part of our business,” Grainger told Manufacturers’ Monthly.

Current contracts include US Navy vessels and the Royal Navy in the UK for two aircraft carriers under construction.

“One has been launched, the other is about halfway through its construction phase,” Grainger added.

“That was a big feather in our cap – for those massive ships, which are as big as the biggest aircraft carriers in the world, they chose to use our systems.”

Serious applications are governed by extremely strict standards. The company receives three random visits a year from an international classification society, which conducts random checks including to see if systems are built within millimetres of technical drawing specifications.

Systems are also randomly inflated during inspections, and must do

so within a certain time. The massive structures generally inflate within 60 seconds.

“Everything we do here comes under an international convention called SOLAS, and that’s the Safety of Lives at Sea Convention, which was implemented after the Titanic disaster,” explained Grainger, who is chairman of the board of global shipping association Interferry.

Equipment must also be able to work within a range of –30 to 60 degrees C. Working to such a niche and such a demanding set of criteria presents difficulties.

R&D assistance with projects, such as a recent redesign of the company’s slides, is hard to find.

Unlike, say, engineering data for the properties of types of steel, locating information on inflatable structures is hard to come by.

“There’s no-one in this country that can tell you how much a tube of air will bend under a certain pressure or for a given volume,” was an example Grainger gave. “So we developed all that data in-house and put it to good use.

Liferaft Systems Australia (LSA) 03 6273 9281 www.lsames.com manmonthly.com.au

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Building an empire in the dirt Service, innovation and reliability have helped Dobmac prosper over more than three decades supplying the agricultural market. Brent Balinski reports.

“PHILIP is able to look at a problem and say ‘Probably if we came at it like that...’ and he’d fart around for days – months even,” explained Gary Dewhurst-Phillips, Business Manager, Dobmac Agricultural Machinery, recalling the development of the firm’s unique broccoli harvester. “[It] was developed using two bicycle frames we brought from the Ulverstone tip, a couple of boards between them, knives underneath it to see what kind of effect you’d have to get to have the broccoli cut properly compared to doing by hand.”

Dobmac founder Philip Dobson has since retired from the company, now run by his son Mark, though he remains an influential consultant in the root crop sector.

Dobmac’s specialty is “potatoes, onions, carrots – stuff that grows in the dirt,” Dewhurst-Phillips humbly added.

The top-picking, fully-mechanised harvester was the focus of $2 million spent on R&D, and was aMworld-first.

A 0 9 1 4 _It 0all0 started 0 _ P I with E potatoes, 1 2 0 1 4 though, which have thrived in the heavy soils of

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Dobmac’s unique clamp mechanism.

Tasmania’s north-west for nearly two centuries.

Dobson Senior, a former farmer, built his first machine in 1983, an automated potato planter. A boilermaker by training, Dobson lost the use of a leg in a farming accident. He tried modifying farm machinery before 0 8 - 1 2 T 1 1 :eventually 1 8 : 3 3 building + 1 0 : his 0 0own.

Dobmac designs and manufactures machinery

including the above, as well as lifters, cutters, windrowers, and other products.

Dobmac’s machinery is sold all over the world, and ANZ clients include the likes of McCain, Simplot and Harvest Moon. The famous potato planter managed to break into the tough US market last year. Back home it’s a “weapon of choice” locally and over the country.

“I reckon every Tasmanian potato farmer either owns or has a contact with the place they serve for a Dobmac planter,” said Dewhurst-Phillips.

Reliability has been there from the beginning, insisted Dewhurst-Phillips, citing the 1983 potato planter, one of which was traded back in five years ago.

“And it still functions,” Dewhurst-Phillips said proudly.

“We’ve put it aside to keep for the museum that we’ll build later [laughs].”

Dobmac Agricultural Machinery 03 6425 5533 www.dobmac.com.au

Manufacturers’ Monthly AUGUST 2015 23

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Tasmanian MANUFACTURING Apple Isle firm plants the seeds of niche manufacturing In Tasmania, there is no shortage of bad manufacturing news such as the story of Caterpillar Underground Mining shifting its manufacturing from Burnie to Thailand. Brent Balinski spoke to Southern Prospect’s Lee Whiteley about where local industrial opportunities lie in the future.

SOUTHERN Prospect got started in 2006 after wind turbine-maker Vestas ended assembly operations in Wynyard, north-west Tasmania, shedding around 60 jobs.

Vestas’ then-managing director in Australia, Lee Whiteley, formed the business to maintain and service installed turbines. It employed around 15-20 and has since looked for ways to expand, and where the skills in the north-west coast might be put to use.

“We call it Southern Prospect because when we set it up we didn’t know what we were going to do, and it was about generating new prospects for the people that have lost their jobs in the other business, and in the community,” explained Whiteley.

The need to identify and exploit new prospects has been regularly discussed in the region and in the media, following mining giant Caterpillar’s decision to end its manufacturing operations in Burnie, where underground mining vehicles have been made since 1975.

Cat announced in April it was doing away with 280 jobs and sending production to Rayong, Thailand. A Transition Taskforce, which Whiteley is a part of, was announced soon after the news.

Whiteley also has a long history with the mining manufacturer, beginning his career as an electrician at Caterpillar Elphinstone.

Caterpillar winding up its manufacturing is of course bad news for an area with already high unemployment and its fair share of difficulties in recent years transitioning from traditional manufacturing.

However, there are successful companies, a talented base of local skills and plenty of opportunities with the right approach, said Whiteley.

SP has taken on a number of long-term unemployed in the region, winning a Mission Australia national award in 2013 for training and placing 16 candidates over 12 months.

Identifying opportunities has been the goal since the beginning for Southern Prospect, according to its managing director. This now takes on an increased urgency.

“We [in the region] obviously have a lot of mining experience, we’ve got some energy experience.

So what might the products be that go with those kind of industries and that kind of skill set?”

Currently the company’s output is split roughly evenly between what it calls its special projects - including custom-made generators and temperature control units - and creating wire harnesses for mining applications.

“So today we supply more [wire harness] product to the Thailand factory than we do to the Burnie Cat factory,” Whiteley told Manufacturers’ Monthly.

Recent wins include a contract for enclosures on a hybrid energy project.

24 AUGUST 2015 Manufacturers’ Monthly

Lee Whiteley of Southern Prospect sees opportunities in the energy and electrical harness areas.

“And we think that will obviously increase again. So we really need to keep our eye on that and retain as much business as we can.”

Special project work received a boost earlier this month with further work for Hydro Tasmania.

SP earned a contract to supply three modular enclosures for a Diesel Uninterruptible Power system for the Flinders Island hybrid energy project.

The units are part of $4 million in contracts to provide hybrid solar/wind/diesel power to the island.

In future, renewable energy will continue to create work, Whiteley believes.

The company started out servicing wind turbines, and more maintenance opportunities could emerge as wind farm owners take back the operation of their assets from OEMs. “And when that starts to happen across the country then there’ll be opportunities to do service work for those wind farm owners,” he said.

For the region, the end of Caterpillar Underground Mining’s operation will leave a “fairly significant hole” in the economy, said Whiteley.

A positive aspect is that it’s forcing local suppliers to rethink what they do well and how they might apply their skills in other areas and with other customers.

Whatever happens, he said, it would be a mistake for suppliers to throw in the towel.

“We really can’t afford that to happen,” he said.

“Because you start to unpack that capacity that has grown here since 1975, then that’s not a good thing.

Southern Prospect 03 6442 7900 www.southernprospect.com.au manmonthly.com.au

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Penguin Composites adapts to changing climate Penguin Composites has rolled with the times over nearly four decades, and smartly tackled a variety of very different tasks. Brent Balinski spoke to the company’s CEO and founder.

“WE make power poles, pipe work, chemical tanks, igloos, dog wash trailers, pressure vessels; we’ve done some artwork, too” explained John van der Woude, founder and CEO of Penguin Composites.

The north-west coast business has dealt with changing fortunes in various markets by doing business in as many of them as possible.

To the above list can be added things like trench covers, tanks, walkways and chair-lift components – which have been exported to several international airports. It recently added a lightweight windlass cover to its repertoire.

Penguin lends its expertise with resins, fibreglasses, acrylics, vinyl esters, phenolics and other materials to many applications.

Whlie it started in 1976 as a maker of fibreglass kayaks and canoes, its RV market is now a focus, A recent task was a set of super-strong, light resin transfer after an acquisition of Islander Campers in 2009. moulded windlass covers for Muir Winches.

“We are continually improving and streamlining our processes. It’s a constant, ongoing change. Lots proud of the slide-on Innovan model, about half of new models,” van der Woude told Manufacturers’ the weight of a comparable steel camper and thus requiring much less muscle to tow.

Monthly.

The M Acompany 0 8 1 5 makes _ 0 0 0an_ off-road G L O caravan 1 model 2 0 1 5 - 0 7The - 3focus 0 T on 0 8RVs : 5 understandable.

8 : 4 4 + 1 0 : The 0 0 local caravan market grew over 4 per cent last year, in two different sizes. The CEO is particularly

according to the Caravan Industry Association of Australia.

An area where opportunities are shrinking is Caterpillar’s Underground Mining operations in Burnie.

Like many in the region, Penguin has a long history as a supplier to Caterpillar (heat shields and dashboards). Though once a large part of output, sales to Cat have shrunk to perhaps a tenth of turnover.

The company’s diversification should see them adapt, reckons the founder.

“Having a broad base, we’re able to move across; to survive, basically.”

Its adaptability is a point of difference that’s relevant fo the broader Australian manufacturing sector.

“We’re a low volume, custom company, and that’s where we can specialise in Australia,” he said.

“If it goes high volume it goes overseas. High volume becomes a commodity. We’re not in the commodity market.”

Penguin Composites 6437 2791 www.penguincomposites.com.au

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IL

SP

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00 13 Townsville

COMPANY ANNOUNCEMENT On 1 August 2015, Global Spill Control and Perth Petroleum Services merged to become Australia’s largest spill equipment manufacturer and supplier.

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manmonthly.com.au

Matthew Baldock Director Global Spill Control

Brad Lowson Director Global Spill Control

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Manufacturers’ Monthly AUGUST 2015 25

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LeanMANUFACTURING Lean design as a key to profitably Everybody has heard of Lean Manufacturing. However, according to Hartley Henderson, there is a related concept that businesses must also adopt if they hope to perform at their best.

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VER recent years the concept of Lean Manufacturing has received extensive exposure as a way to conserve resources, reduce waste, and improve profitability.

There is no doubt that many manufacturers have benefitted in varying degree from implementing Lean Manufacturing processes in their operations, but are the full benefits of a Lean approach being missed because of the lack of a strong focus on Lean Design?

In the current challenging economic conditions it is more important than ever that enterprises identify opportunities and develop innovative avenues to productivity improvement in order to achieve a competitive edge, ongoing growth and improved profitability.

The team of lean Managing Director of Lean Design Australia, Gary Stewart, has extensive experience working as a consultant on Lean Design projects with a broad range of companies, both in Australia and overseas.

“There are significant benefits in taking a Toyota style Lean Design approach over a Lean Manufacturing approach. A single properly conducted Lean Design effort will deliver far more cost reduction, far more quality improvement and far greater profitability in far less time than any 30 Lean Manufacturing efforts,” Stewart said.

“The key is to focus on setting cost, time and quality targets as hurdles that must be achieved by the design for every product you make – long before you work out how to make it.

“Even if you are only a ‘make to drawing’ manufacturer, you can benefit from Lean Design because it will identify very early on all of the cost, quality, time, and manufacturability problems inherent in that design before you start cutting 26 AUGUST 2015 Manufacturers’ Monthly

steel and trying to Lean Manufacture it.

“All cost overruns, missed deadlines, and failed product developments are symptoms, not root causes.

Unless the root causes are addressed, no amount of additional oversight, extra regulation, rearranging of organisational boxes, creation of new offices, or changes to production or processes will help make better products. In fact they usually make things worse.”

Build human capability Stewart believes that the true secret of the Toyota approach is its human-based ‘Right First Time’ thinking across the whole business,

“

Lean Design is about changing the way your people think and thus changing the way they work... rather than Lean Manufacturing.

“The primary purpose of the factory is not to build cars – it is to build human capability, and the product is inconsequential. Lean Design is about changing the way your people think and thus changing the way they work.

“A primary purpose of Lean Design is learning to see how to make things much better, and the primary purpose of manufacturing should be to build the knowledge and capability of your human being, not products.

“It’s not about Lean Design as a process – it’s about what your people can do for your customer using Lean Design.

“A key to successful Lean Design is to establish an Integrated Project Team (IPT) where the program management system is built into the design. People should be used to create the future, and IPTs are the way to the future.

“There is a need to look at the root cause of costs and this must be manmonthly.com.au

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done before CAD drawings are done because after that it’s too late. Hurdles and targets must be met before proceeding, as at the CAD stage up to 90 percent of cost, quality, manufacturability, and time are all locked in.

“If the time is spent up front to get it right fewer problems will be experienced during production.

Time lines can be very dramatically reduced if time is spent up front to take time out of the back end.

“Lean Design can enable you to take 30-60 per cent of cost out of your products and 20-40 per cent of time out of your designs and production operations, while delivering up to 30 per cent lower cost of ownership to your customers.”

Lean design cuts cost “This project involved on-board vehicle power consolidation and resulted in a 63 per cent reduction in cost, 45 per cent reduction in size, 66 per cent fewer Mparts, A 0 8 and 1 5 76 _ 0per 0 0cent _ Sfewer UM sub-assemblies. In addition, there was

“Another successful but less sophisticated Lean Design project was undertaken at Kodak where the design of a projector door assembly was subjected to a critical review. Prior to commencement of the project, the door assembly consisted of 5 parts at an assembly cost of $2.50 which was reduced to 2 parts at a cost of $1.00.

“The outcome was that the door carried out the same function but the number of parts was reduced by 60 per cent, cost was down by 60 per cent, quality improved by around 90 per cent, and production time was reduced by some 85 per cent.

“The follow-on effect on manufacturing was that the number of processing steps was reduced by 90 per cent, there was an 80 per cent reduction in operators, and the cost of parts storage was eliminated.

Gary Stewart, Managing Director of Lean “Design creates 70-90 per cent Design Australia. of your cost structure and problems, but through the application of Lean a 69 per cent reduction in assembly Design, a change of thinking can be steps, 71 per cent improvement in less 1quality 2 0 cost, 1 5 -and 0 750 - per 2 0 cent T1 5 : 1wir3 : 5 developed 6 + 1 0 : to 0 0transform a business, create a new level of human capabiling harnesses,” he said.

SUMMIT INDUSTRIAL.NET.AU 1300 CHILLERS manmonthly.com.au

ity, and a new level of product design and development.

“Without doubt, Lean Design can enable companies to produce products that are far more affordable, far more functional, far higher in quality, and far more manufacturable.”

Lean Design® is a registered trademark of Munro & Associates.

[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, semigovernment and business enterprises and was National Program Director with the Productivity Promotion Council of Australia] Lean Design Australia 0400 888 186 www.leandesign.com.au

SUMMIT INDUSTRIAL CHILLERS PROVIDE A RELIABLE AND ACCURATE SOLUTION FOR THE PROCESS COOLING ESSENTIAL TO THE PLASTIC INJECTION MOULDING INDUSTRY

Manufacturers’ Monthly AUGUST 2015 27

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Packaging Repackaging our future Climate change won’t go away. Therefore food manufacturers must start considering innovative ways to reduce food waste and become more resource efficient. Gareth Reynolds writes.

C

ONSIDER this. For every bag of groceries you buy this year, you will most likely throw one in five of them in the bin.

It sounds ludicrous, but with the average Australian household now wasting around $1,036 worth of groceries each year, it is an all too prevalent reality that is often ignored.

While many will shake their head at how much hard earned money Australian families are throwing away, the scale of food waste and the resultant environmental impact should be just as baffling.

When food is wasted the vast majority of it ends up in landfill, where it rots and releases harmful methane gases into the atmosphere.

The impact of this is greater than most think because the energy and resources used to harvest, process, warehouse and distribute this food are also wasted.

Of Australia’s total greenhouse gas emissions, 23 per cent comes from our food supply chain – second only to coal fired power stations.

Waste not, want not According to the NSW Environmental Protection Agency (EPA) report published in 2012, a whopping 74 per cent of food is wasted before it even has a chance to be sold.

This is largely due to labelling issues, supply chain inefficiencies, lack of stock rotation, inadequate refrigeration, with consumers playing their part too by not understanding the difference between “use by” and “sell by” dates.

Strictly from a business stance, avoiding waste makes sense. It saves money, reduces environmental impact and can build brand recognition.

Like most things however, the devil is in the detail, and in many cases reducing waste can seem challenging.

That being said, there are a num28 AUGUST 2015 Manufacturers’ Monthly

ber of things food manufacturers can do to help reduce their waste profile.

Use your supply chain for good In recent years, supply chains have taken centre stage in the move towards a more environmental and socially responsible society. The 2013 United Nations Global Compact Corporate Sustainability Report found that companies are increasingly talking about supply chain sustainability.

It is here, deep within the supply chain, where food manufacturers can start taking a stand against waste and the resultant social and environmental impacts.

By starting with the traditional measurements of cost and performance and then looking beyond them to consider the entire value chain – including sourcing, distribution,

usage and recycling – manufacturers can address social and environmental challenges without sacrificing cost competitiveness or performance.

Through this process, food manufacturers should be able to make smarter, more informed choices that consider the entire product lifecycle and reduce overall environmental and social impacts, while also ensuring economic viability.

Embrace technology In any discussion about climate change, it is unfortunate that packaging is often considered part of the problem rather than the solution.

Technological advances mean packaging can now be in the vanguard in the fight against waste.

For example, packaging that uses vacuum and oxygen scavenging tech-

nology has been found to increase product quality and shelf life by reducing oxidation and the resultant degradation of many food products.

Ensuring a clean environment in food processing rooms should also be a first priority, as processing hygiene has a critical impact on shelf life.

From a food manufacturing perspective, another simple way to help reduce food waste is by ensuring your product labelling is clearly defined so consumers know exactly how to store their food and when to consume it by.

Find a good partner For those food manufactures not in a position to radically overhaul their supply chain, or take on the latest technologies, there are still ways in which to reduce the amount of food ending up in landfill. manmonthly.com.au

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For example, some food is discarded because it is considered unavoidable waste that cannot be sold or eaten.

Vegetable peel, egg shells and animal bones are a perfect example. Many of these by-products end up in landfill but, through the right partnerships, there are ways for reuse. As an example, animal bones could be further processed to produce liquid beef stock or processed to feed livestock and animals.

Another way we can become more food savvy is through partnerships with food recovery organisations such as FareShare, OzHarvest and FoodBank.

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These charities collect excess food from commercial outlets and deliver it free of charge to the needy across the country.

FareShare alone provided nearly 900,000 free meals last year from food that would otherwise have ended up in landfill.

For companies unsure how to reduce their food waste, turning it into something that benefits disadvantaged parts of the community.

[Gareth Reynolds is Executive Director of Marketing ANZ Food Care, Sealed Air] Sealed Air www.sealedair.com

‘Bag in Box’ solutions WALLS Machinery has been appointed an agent for Niverplast’s packaging equipment throughout Australia, New Zealand and the Pacific Islands.

Niverplast are manufacturers of ‘Bag in Box’ packaging lines, including case erecting, bag inserting, product quality check, camera counting, bag sealing, box closing and palletising. Some machines in their range include the CombiPlast, EasyPlasy and VarioSeal.

The CombiPlast combines box erecting and bag inserting technology in one compact solution. Boxes are mechanically squared and bottom taped, and then a bag is inserted, providing a bag in a box ready to be filled with product.

The EasyPlast automatic bag inserter provides the latest bag inserter technology for boxes, crates and buckets. Feeding prefabricated bags in the automatic bag

inserter, these bags are placed perfectly tight into pre-erected boxes, crates or buckets.

This delivers a product carrier with a bag ready to be filled with product.

The VarioSeal is a multifunctional machine which seals filled bags inside the product carrier. It can even apply a vacuum to the bag to protect products even more. Thanks to the complete automatic adjustments, it can handle a large range of box or crate dimensions. It can also be executed as a VarioFold machine which folds the bag in the box instead of sealing it.

Niverplast develops innovative film concepts to protect and transport a wide range of products. The operations are concentrated on the internal logistical process.

Walls Machinery 1800 500 436 www.wallsmachinery.com.au

When a box needs a bag, Niverplast can help. manmonthly.com.au

Manufacturers’ Monthly AUGUST 2015 29

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IndustrialDOORS Safe, compliant door automation When businesses consider work safety and the potentially hazardous equipment on their premises, they often forget about commercial doors. That’s a big mistake.

D

ID you know that as a builder, building designer, architect or tenant of a factory, warehouse or commercial property you are potentially running the gauntlet with your automated commercial door? These large doors can pose potential risks to employee health and safety as well as damage to property.

Did you also know that it is the responsibility of those who specify, manufacture, supply, install, own or operate commercial doors to check whether their door installations are safe and compliant?

Non-compliant automated commercial door and opener installations can pose a greater risk of injury or entrapment to persons and damage to property or vehicles. Commercial doors that shut either automatically or by a single press of a button

Large commercial doors are often the largest moving objects in the building. require entrapment protection to prevent risk of injury or property damage.

Compliant commercial door openers offer a number of innovative safety features, including safety inputs for monitored entrapment protection devices such as light curtains, bump edges and IR beams.

When an obstruction is detected, these devices signal the door to stop and auto-reverse, preventing potential injury and loss.

Grifco, Australia’s largest manufacturer of commercial door openers

has become increasingly aware of potential risks that are currently facing many commercial and industrial operations.

“As a major partner to the commercial door industry, Grifco aims to increase awareness of potential risks and key aspects of the current compliance requirements,” said Grifco Marketing Manager, Rodney Boag.

“Compliant commercial door openers provide peace-of-mind for owners and operators as the openers meets the safety requirements of Australia and New Zealand standards and of-

fers the latest in safety innovation.”

Compliant commercial door openers, such as the Grifco eDrive +2.0, also provide added convenience for operators, offering remote access solutions, which make life easier for users and can effectively improve productivity in the workplace.

The company ensures that installing a safe and compliant automated commercial door opener has never been simpler or more cost effective.

They provide a range of new openers as well as upgrade options for existing automated door systems.

Commercial door automation – who is responsible for what?

Suppliers should: • Supply a compliant opener that provides all the necessary safety inputs so the installer can ensure that every commercial door automation system can be made compliant.

Commercial door manufacturers & installers should: • Advise customers of the requirements of the standards.

• Ensure all quotes, tenders & submissions state that the quoted installation will meet the requirements of the standard.

• (If the manufacturer is the installer), ensure that the commercial door automation system functions in accordance with the standard prior to handover to the client.

30 AUGUST 2015 Manufacturers’ Monthly

• Ensure clients are provided with advice regarding the safe operation of the door.

Independent commercial door installers & service contractors should: • Ensure that the system can be configured to meet the standard prior to commencing an installation.

• Ensure that the commercial door automation system functions in accordance with the standard.

• Ensure clients are provided with advice regarding the safe operation of the door.

Building design engineers & architects should: • Ensure all specifications for commercial door automation systems insist the installation complies with the requirements of AS/NZS 60335.2.103

End users, developers & commercial property owners/ occupiers should: • Demand confirmation from the door installer/supplier that the commercial door automation system installation meets the standard.

• Understand that WHS law requires workplaces to be safe, whatever the purpose. A commercial door is a substantial moving object, so to ensure all risks are mitigated, the functional requirements of all doors should be assessed by a competent person to ensure the installation and operation complies with the standard.

Grifco 1800 474 326 www.grifco.com.au

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It combines a doorstop and handle in a single unit, and is available with or without an escape release.

It is used for the simple safeguarding of safety doors for the smallest transponder-coded safety switch CES-C04.

The bolt system complies with all the requirements in the EN ISO 14119 standard.

The bolt can be used for doors hinged on the left or right, and the wide, strong handle makes the door easy to open and close.

To prevent the door from accidently closing, the system allows padlocks to be fitted in the bolt tongue and in the handle in the open position.

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THE Euchner multifunctional gate box from Treotham Automation is a modular interlocking guard system designed for the protection of safety doors on machines and systems, which features an integrated lockout mechanism with optional escape release handle, and optional buttons and indicators.

The unit is easily mounted on frames, grilles or profiles, and the handle can be mounted level or rotated 90, 180 or 270 degrees without disassembly. Once linked to the machine controls, the access door will be prevented from opening until the machine has safely stopped.

The modular design of the system allows progressive addition of features. Start, enable, emergency stop and other functions can be added to the basic handle/lock module to turn it into a small control terminal.

This allows the unit to be used for interlocking, guard locking, escape release, and machine functions such as start/stop or emergency stop.

The intuitive operation of the optional escape release enables persons to exit the danger area quickly and easily.

When working in the restricted area, the bolt tongue can be locked with up to three padlocks in the integrated lockout bar, preventing unintentional activation of the interlocking/guard locking.

The Euchner multifunctional gate box is compliant with Safety Level ‘e’ in accordance with EN ISO 13849-1 or SIL3 in accordance with EN 62061, and EN 1088 for protection against tampering. An LED display provides continuous information on system status.

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Sophisticated safety sensors are included as standard.

High speed security doors NEW 36pp brochure now available.

Contact us to get your FREE copy.

Contact our team today to find a solution for you.

M.T.I. Qualos Pty. Ltd. 55 Northern Road West Heidelberg, Vic. 3081 Tel: 1300 135 539 Email: sales@mtiqualos.com.au Website: www.mtiqualos.com.au

IN the past, high speed roll doors have essentially been used to protect climates in warehousing and manufacturing, as well as processing and cleanroom applications.

They are constructed using a PVC door blade. However, when security is required, this type of door is not sufficient.

DMF International is an Australian manufacturer and supplier of specialised high speed roll doors and also has the licensed Australian agency with German supplier, Efaflex Gmbh. With this increased product focus, DMF can supply and install a range of high speed security roll doors and folding doors, Australia wide.

These specialised doors come with door panels stronger than a roller shutter and are designed to operate hundreds of times a day at speeds of up to 2m/sec.

32 AUGUST 2015 Manufacturers’ Monthly SeeThru_ManMonthly.indd 1

The Efaflex high speed security doors are an ideal design for warehouses, emergency services facilities and car parks in secure buildings.

The doors’ blades can be double walled extruded aluminium, acrylic glass or polycarbonate see through, or ventilation panels, or a combination of the above.

Sophisticated safety sensors are essential for doors of this nature, and these are included as standard, or can be enhanced from a selection of sensors as advised by DMF’s technical team.

Another advantage of these DMF doors is that they are custom manufactured and can be configured to accommodate openings that may not have much dimensional clearance.

DMF International 1800 281170 www.dmf.com.au manmonthly.com.au

9/07/14 5:51 PM

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2015-08-13T16:01:42+10:00

What’sNew New model infrared cameras

Brought to you by

High lift reversible drum vac

EXAIR’S high lift reversible drum vac is FLUKE Corp. introduces eight new Fluke TiS Performance recommended for the recovery of fluids Series Infrared Cameras, with improved resolution to such as coolant, hydraulic oils, sludge and help industrial, HVAC, and maintenance professionchips, waste water, tramp oil and liquid als analyse equipment health more quickly and spills. It has been engineered to recover accurately. liquids found within below grade sumps, The new TiS models deliver up to two-and-a-half wells, underground tanks, pits and drains times more pixels and a 70 per cent improvement in with up to 4.6 metres of lift. The unit’s distance-to-spot than the Fluke Ti1xx series cameras powerful vacuum can fill a 205 litre drum in for better image quality to enhance identification of just 85 seconds from 4.6 metres and, with potential equipment problems in industrial and electrithe turn of a knob, the same stainless steel cal maintenance, process industries, and in building pump can quickly empty the drum. applications.

Since it is powered by compressed air, The new models feature large 3.5 inch screens to help it has no electric motor to wear out and pinpoint issues while still in the field and offer one-touch has no impellers to clog. In fact, it has no image access, which eliminates the need to scroll through a moving parts, assuring maintenance free menu to view images. Eight models are available, five fixed focus operation. It is designed for continuous and three manual focus, with resolution up to 260 x 195 pixels. and heavy duty applications where electric The rugged infrared cameras upload images to the Fluke Connect vacuums fail, and can also be used for Cloud via a wireless connection to securely store and manage images lighter duty applications. and potentially reduce administrative time back in the office.

Available from Compressed Air Reports can be created and emailed from the jobsite via Fluke Australia, the CE compliant high lift reversConnect, eliminating the need to return to the office to process Fluke TiS40 ible drum vac attaches quickly to any reports. infrared Fluke Australia closed head 205 litre drum. camera.

Systems the two-way pump MA 0 8 1 5 _ 0 0 0 _ A N C 1 2 0 1 5 - 0 8 - 0 7 T 02 1 38850 : 33333 8 : 0 8 + 1 0 : include 0 0 www.fluke.com assembly, 3 metre flexible vacuum hose

Has no electric motor to wear out and has no impellers to clog. with 90 degree quick release elbow connection and one aluminium wand.

Deluxe Systems add a drum dolly, heavy duty aluminium tools and tool holder.

Compressed Air Australia 1300 787 688 www.caasafety.com.au

It’s here!

The tool grinder you’ve been waiting for

3 models – FX3 Linear / FX5 Linear / FX7 Linear Linear motors – Unique cylindrical design rated to IP67 AM5000 system – Latest technology with faster processing Full touchscreen monitor – Customisable with Windows 8 In-machine automation – Uses less floor space (robot or FastLoad) Remote pendant – Handheld for easy operator access & set-up

Enhanced Accuracy • Upgraded Technology

Be innovative …be part of ANCA manmonthly.com.au

Currently hiring application software engineers info at www.anca.com

Manufacturers’ Monthly AUGUST 2015 33

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What’sNEW

Brought to you by

Robotic CNC plasma beam coping machine ADVANCED Robotic Technology (ART) has introduced several incremental updates to its Metaltek XB1200 CNC beam coping machine, intended to make it more productive and versatile.

Traditionally, beam coping has been done manually by marking the dimensions for coping on the workpiece as per the drawings and then manually cutting out the cope from the steel beam using oxy-fuel gas torch. This method leaves a rough cut requiring considerable chipping & grinding to improve the finish.

The company has studied the needs of every steel fabrication shop in Australia, from small to large, in order to develop an automated, versatile machine, giving steel fabricators around the country a competitive edge; not only by creating an efficient automated machine made by ART in Brisbane, but also by offering local service and support.

With a footprint of 3750 x 3600 mm,

Metaltek XB offers full four-sided plasma processing for the steel fabrication industry.

Metaltek XB offers full four-sided plasma processing for the steel fabrication industry, advanced CNC robotics, highdefinition plasma cutting and in-house developed user-friendly software and control interface.

Moreover, three-axis material handling

conveyor systems and cross-transfer conveyors for load and unloading eliminates a large percentage of lifting, flipping and moving of steel members between machines. The operator simply prepares the next length of steel for loading while the previous one is cutting. A tick box on the

touchscreen lets the controller know that the next length is ready to load.

The drawbridge is able to extend 2.5 metres into the cutting envelope to support the material, clamp and draw for hitch feeding, and roll out the finished part.

The drawbridge feed and synchronised rollers are both servo controlled, to ensure highly-precise material feeding. The CNC controller can also automatically feed the next piece of material from the cross-feeds onto the in-feed roller conveyor for automatic cutting.

Inside the cell work area, the machine automatically senses material dimensions, and an extra-articulated robotic arm performs the desired cuts, even underneath the beam. In conjunction with the gantry system, the arm achieves unparalleled reach.

Advanced Robotic Technology 07 3393 6555 www.advancedrobotic.com

Colour label printer

Accurately detects and differentiates between successive packaging items.

DeltaPac photoelectric sensor THE DeltaPac photoelectric sensor accurately detects and differentiates between successive packaging items on the fly. This ensures faster, smarter and more economical production.

In other words: The photoelectric sensor is a patented technological world first.

What makes this possible is the patented Delta-S-Technology from SICK. Two energy scales each featuring two receivers and quadruple LED technology PinPoint 2.0 merge with SICK’s SIRIC ASIC technology and integrated distance measurement.

The functional principle of the photoelectric sensor utilises the edge contours of objects. In the gap-less transition from one object to the next, the edges change the reflectance behaviour of the package surface.

This change in direction of reflectance is used for outputting switching signals. Object 34 AUGUST 2015 Manufacturers’ Monthly

contours with radii of up to 20mm are thus detected reliably.

The high-precision evaluation characteristic of the photoelectric sensor ensures detection of even the smallest changes in angle.

In this way, one can dependably detect up to 200,000 packages an hour at speeds reaching 3m/s.

Fast commissioning without adjustment or well-directed process optimisation by means of individual parameterization – the company has translated the demands by manufacturers of packaging machines into preconfigured devices. Installing, connecting, detecting – the user does not have to deal with extensive operating instructions.

SICK 1800 334 802 www.sick.com

THE LX2000 colour label and tag printer offers print speeds of up to 152.4mm per second.

In other words, it allows you to print 60 large shipping labels (100x150mm) every minute. It also prints about 25% faster than the previous industry Large separate ink tanks mean more prints before leading LX900 colour changing ink cartridges. label printer.

The printer has several advantages compared to competitive label printers. Firstly large separate ink tanks mean more prints before changing ink cartridges.

USB and Ethernet connectivity and wireless connection options mean everyone in the office can enjoy using the printer. Print width is a super wide 203.2mm and a built in pizza wheel cutter means it is possible to cross cut after every label or after every job as required.

The printer ships with free Bartender Ultralite labelling software and Windows 7/8 and Vista and Mac driver development is underway.

A change to pigment based inks from dye based inks mean labels have much stronger UV resistance as well as chemical and water resistance.

New lower ink costs mean lower cost of ownership, this means users can print two or three times the amount of labels for the same cost as previous models.

The 4800x1200 dpi print capability ensures accuracy and legibility of barcodes and text as small as 2 points.

Label Power 1300 727 202 www.labelpower.com.au manmonthly.com.au

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The last WORD Spectralink answers Cape Grim Beef’s call Cape Grim Beef, a sixth-generation family business that processes high-quality beef for export, put out a call for better communications infrastructure. Intellect IT answered.

C

APE Grim Beef is headquartered in Port Melbourne and has two processing facilities, one in Smithton, Tasmania and the other in Tongala, Victoria.

Communication within the business is vital to ensure a rapid response to market demands and changes. It is also important due to occupational health and safety (OH&S) considerations, since the processing facilities include some high-risk workspaces.

In an emergency it would be critical to be able to contact the first aid team or emergency services as quickly as possible.

Effective communication was hindered in the past due to an out-dated, switchboard-based telephone system and a network of two-way radios.

The process was unwieldy and meant communication was inefficient. This resulted in frustration amongst staff and could result in delays in making important decisions regarding customer orders, shipping, labelling and more.

Connecting employees To overcome these challenges Cape Grim Beef installed a new IP PBX linking all three sites, as well as Spectralink IP-DECT 6500 servers and 45 x Spectralink 7620 industrial handsets at the two processing facilities.

Cape Grim Beef worked with long-time outsourced IT partner, Intellect Information Technology, with which the organisation had a longstanding relationship.

Grant Ryan, managing director, Cape Grim Beef said, “Intellect IT presented the solution and we saw a demonstration of how it would work.

We liked it immediately because we could see that it would make communication more efficient throughout the organisation.

“The biggest problem was not being able to directly contact people at our facilities, and there was no ability to do conference calls, which meant that discussing issues and making decisions was more challenging than it should have been.

“Now, when a member of the sales team wants to speak with a production facility to confirm quantities, specifications, delivery times and costs, they can directly dial the relevant person, conference someone else in if necessary, confirm all the details and get on with fulfilling the customer’s needs. It all happens a lot faster and more reliably than in the past, which has let Cape Grim Beef improve customer service.”

The Smithton site is made up of a number of manmonthly.com.au

The Spectralink 7620 phones are specifically designed to cope with the difficult conditions of the Cape Grim beef processing plants. different buildings in a regional area of Tasmania, so mobile phone coverage is sporadic and even the two-way radios did not always work reliably. This could become a problem if decisions needed to be made quickly.

Robert Cox, Smithton site manager, Cape Grim Beef said, “Recently there was an issue in the US and shipments...were being held up. Head office decided to change the production schedule and divert product to a different location.

“It was critical that the production facility could get this message as soon as possible so that we could make the necessary changes to production, as well as apply for the proper permits and paperwork to enable the change in destination for the product.

“Without the Spectralink telephones, this process would have taken a long time and there may have been the potential for errors to be made as messages were passed on. With the Spectralink system we were able to get the right information to the right people right away, and respond to the changing conditions effectively.”

Additional benefits of the new phone system include a more efficient approach to maintenance and easier compliance with OH&S requirements.

Robust handsets The Cape Grim Beef processing plants are a harsh environment with concrete and steel surfaces, some very hot areas and some very cold areas, as well as a lot of liquids. The Spectralink 7620 phones are specifically designed to cope with these conditions.

Robert Cox said, “I have seen a number of the phones dropped accidentally but so far we have had no issue with any of them; they are very tough.

“The phones work just as well in the freezer units or boning rooms as they do in between buildings...because Intellect IT placed the repeaters and base stations in strategic areas to maximise the amount of coverage.”

Importantly, the introduction of the Spectralink wireless phones has improved communication throughout the organisation.

Grant Ryan said, “Being able to contact each other so easily and quickly has really brought people together and they feel that they are working very effectively as a team. You just dial an extension and speak to the person you need.”

Intellect Information Technology 1300 799 165 www.intellectit.com.au Manufacturers’ Monthly AUGUST 2015 35

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