Manufacturers' Monthly September 2015

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

SEPTEMBER 2015

The grass isn’t always greener…

INSIDE >> 18

Skills, Training & Recruitment Addressing engineering shortages

24

Automation & Robotics The rise of robot collaborators

39

Tech Review Tough tablet pushes the boundaries

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SAFETY WITH STYLE!

Scott Safety’s new First Base 3 Bump Cap is stylish and practical. It protects heads from knocks, bumps and lacerations, offers sun protection and features a lightweight ‘breathable’ safety shell, for workers who want to look and feel cool. With its flexible internal padded shell covered in a washable and stylish fabric cap, the First Base 3 Bump Cap provides the wearer with comfortable lightweight head protection. So while it doesn’t replace a safety helmet for higher risk areas, it can protect you from those painful annoying injuries we’d all rather avoid.

TO FIND OUT MORE, VISIT WWW.SCOTTSAFETY.COM OR CALL US ON 131 772. © 2015 Scott Safety. SCOTT, the SCOTT SAFETY Logo, SCOTT SAFETY and FIRST BASE, are registered and/or unregistered marks of Scott Technologies, Inc. or its affiliates.

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Inside

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6 Editorial 8 News & Analysis 14 IT@MM 16 Skills, Training & Recruitment 20 Metalworking & Machine Tools 24 Automation & Robotics 26 Made in Australia

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

30 Auto Components 32 Warehousing 34 Materials Handling 36 Manufacturing Apps 39 Tech Review 40 What’s New 42 The Last Word

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Behind the cover

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

SEPTEMBER 2015

The grass isn’t always greener…

Average Net Distribution Period ending March ’15 18,904

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THE largest ride-on mower manufacturer in Australia, Cox Industries was established by engineer and inventor Owen Cox in the 1950s.

Today, the company produces its durable products at its factory in the Brisbane suburb of Acacia Ridge.

While times are hard for most in the Australian manufacturing sector, Cox Managing Director Ken McColl remains optimistic about the company’s future.

You can put this down to the recent drop in the Australian dollar and you can also put it down to the fact that, unlike imported products, Cox mowers are ideally suited to local Australian conditions.

2 0 1 5 - 0 8 - 2 6 T1 5 : 0 8 : 2 9 + 1 0 : 0 0 So, the grass isn’t always greener on the other side…

INSIDE >>

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Skills, Training & Recruitment Addressing engineering shortages

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Automation & Robotics The rise of robot collaborators

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Tech Review Tough tablet pushes the boundaries

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Manufacturers’ Monthly SEPTEMBER 2015 5

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Comment

BRANKO MILETIC – Managing Editor

Factories of the Future are already here

A

NEXTISSUENEXTISSUE • Cooling & Fans • Compressors & Pneumatics • Fasteners & Adhesives • Management – Finance & Leasing • IT@MM – Supply Chain Management M A 0 9Handling 1 5 _ –0Labelling 0 0 _ & MPackaging AB • Materials

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T the recent ‘Factories of the Future’ (FoF) industry event hosted by Manufacturers’ Monthly, and attended by some of the best and brightest manufacturers in the country, the overriding sentiment was one of optimism tinged with a bit of apprehension.

I say this because all the invited speakers were totally and unequivocally upbeat about the future of Australian manufacturing. None more so than Keech Australia CEO Dr Herbert Hermens, who noted to a packed out auditorium that we do some great things in Australia however too few people, especially at the highest levels of government, are actually aware of it.

“I really blame ourselves; we’re letting people take this conversation away from us,” said Hermens.

And speaking of government, a number of attendees during the Q&A session voiced their disapproval at the current levels of corporate taxation that manufacturers have to deal with.

As Cox Industries Managing Director, Ken page 2 0 1 5 - 0 8 - McColl 1 9 T 1(who 0 : 3is4featured : 1 4 +on 1 0 : 0 28) 0 said, “I don’t think our governments have woken up to

what the demise of manufacturing is going to do to this country.”

“I don’t see them in the short term doing anything that’s going to help manufacturing,” he lamented, adding that, “Governments talk about jobs, jobs, and jobs every night of the week, but as soon as you start employing people, they charge you payroll tax.”

All this is going on when, according to Autodesk’s local Sales Director Rob Malkin, there are those in the US who are “looking at what’s happening in Australia for new ideas about innovation and smart manufacturing.”

So it seems there are those on the other side of the world who have more faith in Australian manufacturing than some of our leaders in Canberra.

At the same time, organisations such as Keech, ANCA, Anatomics and the CSIRO are regularly punching well above their weight in terms of smart manufacturing technologies.

The Factories of the Future are already here – it’s just too bad our democratically elected leaders are ignorant of this fact. branko.miletic@cirrusmedia.com.au

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Answers for industry.

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News&ANALYSIS Macfarlane flags assistance for BlueScope

A

Minister for Industry and Science Ian Macfarlane ruled out handouts to Bluescope.

MEETING of politicians, unions and business representatives in early September heard that tariffs and subsidies would not be part of any plan to save BlueScope’s Port Kembla blast furnace.

The crisis meeting at University of Wollongong’s Innovation campus lasted for 90 minutes, and saw Minister for Industry and Science Ian Macfarlane suggest a “very big proposal” would be announced and rolled out. He did not elaborate.

“There is a very big proposal that’s being discussed between [NSW] Senator Concetta Fierravanti-Wells and myself and the NSW government which we’d prefer not to talk about just yet, but it would make a massive difference to this region and so the solution isn’t just one thing and it isn’t just one package,” The Australian Financial Review reported Macfarlane as saying.

Bluescope has said it needs to save $200 million in its Australian operations, with at least 500 jobs to be cut at Port Kembla. An option raised has been to shut the steelworks – under intense competition from cheap imported product – which would put around 5,000 people out of work. There are already 10,000 unemployed in the Illawarra.

There were no announcements regarding assistance made, but Macfarlane said tariffs, handouts and “quick fixes” were not being considered.

Tariffs on imported steel and local procurement on government projects have been requested by unions.

Federal Labor’s Stephen Jones agreed with the federal government that tariffs or subsidies were not options, and it was Bluescope’s responsibility to do most of the work.

Senators Nick Xenophon and John Madigan responded to Bluescope’s plight by drafting legislation which would require government procurement of steel and other goods unless there’s good reason not to.

Xenophon said such spending should consider flow on effects such as local employment and tax revenues. Legislation would be based on the presumption that procurement – worth $40 billion annually – should be local unless there was a good reason for it not to be.

“We should structure an annual reporting framework and monitoring of procurement policies. There should be a buy Australian approach where you maximise local industry participation,” he said.

Solar energy batteries made in Adelaide?

“If the demand is required holds to store up to 10 kilowatt hours we’re actually going to start of power (about half of the average manufacturing here in Adedaily household usage). laide, we already have an office Some of the components for the here and fulltime staff so the system are made overseas and the employment opportunities are units are currently assembled in starting to roll in,” AllGrid CEO Brisbane. However, the company may Ray Pratt said. expand its manufacturing operations 1 2 0 1 4 - 0 3 - 1 3 T1 2 : 3 3 : 1 4 + 1 1 : 0 0 Adelaide would be an attracinto South Australia. tive option for AllGrid because Adelaide City Council is offering a rebate of up to $5,000 for homes and businesses in the CBD which install the WattGrid units.

(They currently retail for around $12,500).

We ooffer We ffee cost effective solutions for your automation ff South Australian Aboriginal technology tech te chno noll needs Australia wide.

Affairs Minister Kyam Maher welcomed the launch of the battery At IIS&E S&EE we specialise in systems integration and S& systems. auto au toma ma automation projects, big and small.

“The company has already estabFor mor more information phone us on 07 3856 2232. lished a sales office in the city, has engaged 10 contractors for installaINDUSTRIAL SOFTWARE & ELECTRONICS tion work and will build the cabinets Tel: (07) 3856 2232 Fax: (07) 3355 1012 E-mail: info@industrialsoftware.com.au required to store the battery system Web: www.industrialsoftware.com.au in South Australia,” he said.

INDIGENOUS-OWNED energy company AllGrid recently launched a solar energy battery storage system in Adelaide and raised the possibility that it may open a manufacturing plant in the city.

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The WattGrid energy storage system is used to store energy produced by rooftop solar panels.

“AllGrid is confident it will create more than 30 jobs as the solar battery system is introduced throughout the state.” manmonthly.com.au

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News&ANALYSIS In brief...

Help for car component makers The Australian Automotive Aftermarket Association has formed a body to promote the local automotive components manufacturing sector by focusing on innovation and export expansion. It will be named the Automotive Products Manufacturers and Exporters Council (APMEC).

3D printed AFL merchandise The AFL and 3D printing company 333D have agreed to create 3D printed merchandise for the sporting code. The deal is the first of its kind in Australian sports.

333D will work with the AFL in the offseason to develop the merchandise.

CSIRO & NICTA join for research One of the largest digital innovation teams in the world will be created when CSIRO’s Digital Productivity flagship and NICTA merge. Researchers from the two organisations will come together to form a new CSIRO entity called Data61, led by the successful and influential Australian technology entrepreneur Adrian Turner.

High tax kept CSL plant away

Import duties hold back high-tech companies HIGH-TECH manufacturers are being hamstrung by Australia’s high import costs, according to research by global accountancy network UHY. UHY found Australia’s import duties compared to GDP to be 0.46 per cent. This compared poorly to the EU’s main economies (0.13 per cent), the US (0.19 per cent) and Canada (0.21 per cent).

The managing partner of UHY Haines Norton, Michael Coughtrey, said that it was a handbrake on

What members of our manufacturing community think about import duties...

PWR considering ASX listing

David M On the contrary, Australian manufacturers are on the decline because of the ever increasing number of Free Trade Agreements Australia has signed up for or is about to sign up for. Apart from excise equivalent goods, the general rate of duty is 5 per cent!

The multifarious tariff concessions available to an importer further reduce the rate of duty.

It is because of low tariffs that Australian industry is suffering.

How the opposite applies and where the numbers come from is mysterious. Our once prolific local manufacturers are endangered to the point of extinction because of free world trade our government so heavily subscribes to.

PWR, the Queensland-based designer and manufacturer of automotive cooling systems used by car racing teams, is considering an ASX listing later this year to fund its growth plans in Australia and overseas. The company recently hosted institutional investors for an educational visit to its headquarters at Ormeau.

Anthony David, I would suggest you read some of the articles on manmonthly.com.au about some highly successful Tasmanian manufacturers. Sure many manufacturers are facing tough times, however with a

Australian biotech company CSL chose Switzerland over Australia for its new manufacturing plant because of this country’s higher company tax rate, according to the company’s director, Christine O’Reilly. The other shortlisted locations, including Ireland and Singapore were more financially attractive.

Chinese manufacturing shrinks China’s manufacturing sector slipped into contraction in August, with the official PMI recording its worst result in three years. A PMI result of 49.7 was recorded for August, down from 50 the month before. More broadly, world manufacturing is in a period of weaker growth.

10 SEPTEMBER 2015 Manufacturers’ Monthly

an area that could be generating significant wealth in the Australian economy as revenues from mining decrease.

Technologically sophisticated manufacturing businesses import a great deal of their components, as Australia lacked a critical mass to supply such companies, Coughtrey told The AFR. “We just don’t have the capacity to make the highlevel inputs,” he said.

bit of vision, planning, hard work and a little luck there are many doing great things, regardless of FTAs and TPPs, etc.

Dan Agree with David. We have a 1 Trillion foreign debt! It’s all the unions fault. We don’t have critical mass because of imports.

Stephen I’m with David and Dan. Some manufacturing sectors need protection from overseas giants.

Sure, we can’t make everything efficiently here, but in those areas we’re trying to, a little support goes a long way. Not so sure about the foreign debt, but if we gave a boost to our own, instead of pandering to others, we’d be better off in the long run.

of the Australian manufacturing industry. The decline is due to the high labour costs and low productivity...and for that you can thank the succession of Labor governments and their trade union mates.

Editor’s note: Comments are as received. Corrections are 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.

Mike K I think you have the wrong end of the stick David. The low tariffs and free trade have absolutely nothing to do with the decline

manmonthly.com.au

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Comment

INNES WILLOX – CEO Australian Industry Group

Investing in workplace literacy pays off Literacy and numeracy programs are obviously of great benefit to individuals and the community. As Innes Willox writes, they can also deliver good returns to employers.

A

T the Australian Industry Group, we’ve been concerned for some time about the level of foundation skills in the workforce. Our latest survey of employers indicates that 93 per cent report low levels of literacy and numeracy are having an impact on their business.

Clearly, it’s important for employers to engage with workplace literacy and numeracy programs to address this problem – so we wanted to establish a business case for employers to invest in this type of training.

The result was our development of the ‘Building Employer Commitment to Workplace Literacy and Numeracy Programs’ project.

The particular focus of this project was to establish MA 0 9 1 5 the _ 0return 0 0 _ on N PinvestA ment for employers who participate

12 SEPTEMBER 2015 Manufacturers’ Monthly

in programs. The calculation of return on investment is a difficult process, especially for such broad literacy and numeracy programs – it is always difficult to isolate the specific contribution of training from other factors.

As such, we engaged the Australian Council for Educational Research, an organisation that has expertise in this methodology, to assist us in the research.

The results are very impressive.

All of those enterprises that agreed to participate and were able to provide the necessary data produced a positive return on investment in the range of 102 to 163 per cent. These results were achieved across a number of different States and industries, manufacturing. cast iron prod1including 2 0 1 5 - 0 8 - 2 4 T 0 8 : 5 1 : 1 which 2 + 1 manufactures 0 : 0 0 For example, Intercast & Forge – ucts for railway, automotive, mining and earth moving, and construction industries – is a workplace which requires extensive Workplace Health and Safety protocols and exact compliance with procedures. As a result of their program, including customised Language, Literacy and Numeracy (LLN) training for Culturally and Linguistically Diverse (CALD) employees, they have seen a return on investment of 163 per cent. The implementation of the LLN program reduced the frequency of workplace errors, leading to considerable savings in lost time for supervisors and workers.

Results such as these are extremely encouraging and while impressive they no doubt underestimate the big benefits that accrue to companies.

While the cost of training is a pointin-time expense, the benefits of the training are ongoing. Some of the benefits related to productivity may not be immediately apparent at the completion of the training and take longer to emerge.

The message for employers from this new research is unambiguous: making an effort at the workplace to lift language, literacy and numeracy skills pays off on the bottom

line. In addition to other reasons for implementing workplace reform in this area – not least the valuable contribution to individuals and the community – it now also makes good economic sense. We hope that all employers will heed these results and engage in foundation skills training for their workforce.

A further dimension of this project was to assist employer understanding of the Australian Core Skills Framework (ACSF). This is a major means of identifying improvement and progress for individual employers who undertake the training. It is also the key means of measurement for the National Foundation Skills Strategy for Adults. Ai Group finalised an employers’ guide to the ACSF, called Unlocking Workforce Potential, in the course of the project and it has been well received.

This report makes a significant contribution to the advancement of workplace literacy and numeracy in Australia and I urge all employers to engage in this important policy area to enable a strengthening of our workforce capacity.

The final report, Investing in Workforce Literacy Pays, is available on the Ai Group website. www.aigroup.com.au manmonthly.com.au

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TechnologyIT@MM The need to keep up to speed CAD software companies work tirelessly to make the process of designing as fast and efficient as possible, however, many users are not keeping up to date on enhancements. Alan Johnson reports.

M

UCH is written about the time-saving benefits of 3D CAD; but savings can only be achieved if designers know about available enhancements.

Allowing designers to attend training courses on new versions may reduce output for a half day or so, but the time lost will be recovered many times over in the long run.

A recent worldwide survey on CAD trends, conducted by Business Advantage, a UK-based B2B research consulting practice, found that just over half of the manufacturers surveyed had upgraded, changed or added to their CAD software in the last 12 months. These companies were then asked a series of questions around productivity during transition.

The results show that on average, CAD upgrades break even (in productivity terms) in just over two months and thereafter continue to produce productivity gains.

Mark Duggan, Manager of Technical Support at Intercad, one of Australia’s premium suppliers of the SolidWorks suite of solid modelling software, said to obtain these productivity gains it is important designers have training on the CAD upgrades.

“For example, like most 3D CAD companies, SolidWorks has a major release every year, plus five service packs on average.

“So if there are problems with the software, they are uncovered and corrected very quickly in the service packs, which include enhancements and new functionality as well.

“They are not just bug fixes. For example, there might be an inspection function, but the service pack might include extra options,” he told Manufacturers’ Monthly.

While changing versions is pretty straightforward these days, Duggan warns users not to change mid-project, especially if it’s a large project.

“Designers are far better to finish a major project in the same version as they started in. You wouldn’t want 14 SEPTEMBER 2015 Manufacturers’ Monthly

Software training for designers is essential to achieving productivity gains. to be on Service Pack 4 or 5 of 2014 software then upgrade to 2015 half way through a major project, because once saved in that later version, you can’t go backwards.

With everyone modelling slightly differently, Duggan said it’s a good idea to test some typical drawings and assemblies in the latest release as copies and see how they perform.

“For example, they could set up a little test environment and do some rebuilds there to make sure everything is working OK with the way they are modelling and go from there.

It’s common sense really, however you would be surprised how many people don’t do it. Ideally you shouldn’t have to, but you are advised to, same as making back-ups – just in case.”

“With new versions, we encourage everyone to attend our innovation days where we show them what’s new in a product. It’s not possible to show all that’s new in two 45-minute sessions, but we are able to show the key points.

“We also have hands-on test drives where we invite people in to our local offices where they can try out the latest versions of the software.”

Duggan said these sessions can be very valuable to designers.

“Just recently we had a designer come in with 20 sheets in a drawing file complaining the system was taking too long.

“He had all these sheets in there, with a lot of configurations, and didn’t realise he could simply split them up by clicking on the drawing tabs, like an Excel spreadsheet.”

Duggan explained that users can simply click on these tabs and select ‘copy’ and open up another drawing file and ‘paste’.

“All the modelling will be brought across into that new file then delete that tab. This option of copy and paste had been available since 2014, but was new to this designer.”

The point is designers must keep up to date with software changes.

“We come across similar cases quite often; where designers are missing out on many of the short cuts, all designed to make their job easier and quicker.”

Configurations According to Duggan, another area many designers are not aware of is configurations, where users can have the same model but with different dimensions, or maybe the length of an extrusion might be longer in one than the other.

“We have seen designers model separate parts, when they don’t have to. Rather, we encourage designers to use the design tables, which put all the dimensions into an Excel type spreadsheet and do what they would

normally do in Excel; copy and paste, and pull the ‘fill’ arrow down and have many more different configurations for the same thing.

“In a matter of seconds designers can have numerous extra versions of that file, with different length extrusions, for example.”

Duggan said there are many designers out there who are experts in certain areas, but know very little about others, which can drastically affect design time .

“For example, designers might be experts in sheet metal, but when they are given some other job, they really struggle as they don’t know what’s available to make it easier and quicker for them.

“We came across one young chap just recently who was doing welded structures, which was not his normal area. He was drawing the frame and extruding shapes along it.

“He didn’t realise there is a whole library of shapes called ‘weldments’ available to designers.

“Instead he had been doing it all from scratch, and taking much much longer than needed.”

While Duggan said it’s important to keep up to date with the latest versions, he understands it can be difficult.

“Unless designers set aside some time for training, it rarely gets done.

He warns that just giving a designer training material is not enough. The designer will always find something more important to do. It is far better to set aside a day or half day to go and have a look at the latest version they are using,” Duggan said.

[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] Intercad 1300 223 226 www.intercad.com.au manmonthly.com.au

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Plant operation software SCHNEIDER Electric has released a new version of its StruxureWare Plant Operation Ampla Manufacturing Execution Systems (MES) software. New features include inventory management, conformance to plan, user experience enhancements, and improved performance and scalability.

Designed primarily for mining, minerals and metals industries, the software is designed to improve operational performance by delivering real-time visibility of plant and business information so users can improve competitiveness in global markets. By driving the optimisation of production, processes and performance, the software is designed to increase operational efficiencies and reduce energy consumption.

Ampla 2014 introduces the concept of Material Classes and Test Specifications to its Material Model. Materials can now be categorised based on the amount of processing they have undergone – for example, from un-prepped ore to blended ore. Material Classes can be used together with structured material naming to allow material origins to be readily identified when data from multiple sites are combined. The result is fewer configuration points while delivering greater visibility into the entire value chain.

Ampla 2014 also delivers enhancements to its Planning module with easy comparison of planned and actual figures, with deviations from plan highlighted, providing an initiation point for root-cause analysis.

Schneider Electric 1300 369 233 MA 0 9 1 5 _ 0 0 0 _ T R O 1 www.schneider-electric.com.au 2 0 1 5 - 0 8 - 2 0 T1 0 :

Forklift mounted computer DESIGNED for use in the toughest distribution centre environments, manufacturing facilities and freight operations, the Honeywell Thor VM3 is the industry’s most capable full-size vehicle-mounted mobile computer.

Combining laptop-like simplicity with advanced application performance, the device gives operators the right tools to improve productivity and task accuracy.

The VM3 offers the best purposebuilt device in its class due to its simple and easy system integration, Combines laptop-like simplicity with advanced application and flexibility to support multiple operperformance. ating systems.

It includes the largest display available in a Windows CE platform vehicle-mount computer, while equipping operators with the legacy Thor features, including a quick-mount Smart Dock and field-replaceable front panel, to allow greater worker productivity, minimise support costs, and maintain compliance with all IT policies.

The VM3 offers the latest security and productivity-enhancing features and functionality to maximise efficiencies in activities such as case picking, truck loading, putaway and replenishment.

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Skills,TRAINING & RECRUITMENT Technical skills are not enough While technical skills are important, they are not everything. As Alan Johnson writes, manufacturers are advised to also include vital softer skills in their training programs.

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ANUFACTURING is increasingly becoming a high-tech industry with strong technical skills vital for the operation of some very sophisticated facilities in Australia. However, other more softer skills are also required as manufacturing moves into a new era.

Bob Paton, CEO of Manufacturing Skills Australia (MSA), says that while it is important manufacturers keep their workforces’ skills up to date, it is equally important the workforce has training in softer skills around lean manufacturing, good management and leadership skills.

“These skills will develop and mature a workforce so they can face the future and the challenges that MA 0 9 1 5 _ 0 0 0 _ K E E 1 2 0 1 5 - 0 8 - 1 4 T 1 4 : 1 9 : 1 will 5 + come 1 0 : out 0 0of that,” Paton told Manufacturers’ Monthly.

Employees and employers are calling for more e-learning opportunities.

“My advice is for manufacturers to work out what their business is, where it is going, what it needs in terms of product and processes, and then what sort of skills they need to deliver on that.”

And rather than trying to recruit new skilled people, Paton said the investment in existing workers is far more effective and efficient.

“Bringing an existing workforce along into the future is certainly the key to it. And there are opportunities for manufacturers to train their workers in those areas,” he said.

“Depending on what state or territory a manufacturer is based, there are a number of training incentive and payment schemes.”

Paton pointed to the Commonwealth Government which provides a

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significant amount of funds into industry through the Industry Skills Fund. The Fund provides up to two thirds of the cost of training existing workers.

The Fund is available for upskilling existing workers; be it full qualifications, parts of qualifications or areas that are not formal qualifications, but are areas that are going to assist the enterprise in improving productivity.

There are also incentives for employers to offer existing workers additional traineeships or apprenticeships.

According to Paton, manufacturing employers presently spend a substantial amount of money training their workers, either in formal cash outlay sense or through time off to attend other programs.

“They are significant investors in training, with the money the public purse puts into industry training closely matched by industry,” he said.

Paton pointed out out that there are many exciting opportunities for Australian manufacturers, but said Australia needs to prepare if it is to successfully capitalise on them.

“It is critical that we look ahead to set a strategic direction for manufacturing and focus on developing a responsive workforce,” he said.

“If we don’t have the skills we need, when we need them, we will simply be left behind. To meet this demand, we need to make changes now, for the workforce of the future.

“The expectations are that manufacturing will rely on high level skills, strong capabilities in technology use and greater integration of design and innovation skills. We need improved outcomes across management, customer service and business development. These skills take time to develop; we need to increase the focus on up-skilling in key areas immediately.”

He also called for more elearning opportunities, where manmonthly.com.au

students can learn at their own time and pace. “Both employees and employers want this”.

Attracting high performers If it hopes to attract high performers and the best school leavers, Paton believes manufacturing will need a new image.

“With a few exceptions, manufacturing today is no longer a dirty, brown smoke stack kind of industry, and can now offer prospective employees clean and exciting work,” he said.

“The idea that only not-sosmart school leavers went into manufacturing is no longer the case. Those labour-intensive, low skilled jobs are gradually disappearing, because our economy can’t afford them.

“

Manufacturing needs a new image if it is going to attract high performers…

Paton said one of the things that is starting to change the image around manufacturing is the push around STEM (Science, Technology, Engineering and Mathematics).

“The debate and discussions around STEM have illustrated the increasing number of ‘sexy’ jobs within the industry. That itself generates a different impression and perception of what manufacturing is like today,” Patton said.

Paton also believes some of the consistency of messages provided by government, in particular, and economists around manufacturing have improved and will continue to improve that image.

“While not everyone is going to need a degree in STEM, but the STEM demands on all workers is increasing greatly with the latest technology and processes being used in the manufacturing industry.”

Advanced manufacturing Much has been written about developing the skills needed for ‘advanced manufacturing’; however Paton believes we are using the wrong term, because it means many things to many people.

“It’s not just high technology, it’s often about the way people go about their work. It could just be the application of Lean Manufacturing techniques into an enterprise that has never practiced Lean before, which can have a profound effect on the company’s productivity and bottom line,” he said.

“Without a change in technology, a company can [still] become a more advanced manufacturer.

It’s not just about the equipment on the floor, it’s about how the people go about their work, culture and attitude. I think this is a big issue in itself.

“Putting lean processes into an existing facility with its existing equipment and combining that with more advanced technology companies will end up with a very efficient, responsive type of manufacturing operation.”

Paton said the innovation around ‘advanced manufacturing’ can be introduced in several ways, but often it needs a people investment as greatly as it needs capital investment in equipment.

Regarding the move to ‘advanced’ manufacturing, he is not convinced it’s all about training capabilities. He feels it is more about the enterprise approach and how manufacturers are going to change their businesses.

“That’s really where leadership and management skills have an impact, because if a company is looking to reposition itself they clearly need critical thinking and strategic, innovative leadership around that to envisage the future and to relay that and share that goal with others in the enterprise.

Then you need managers who can then take those visionary things and implement them,” Paton said.

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Skills, TRAINING & RECRUITMENT STEM-ing our engineering shortages An Australian program, which links schools with industry in a collaborative environment, is successfully engaging students in an engineering future. Alan Johnson reports.

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REA’s goal is to equip our children with the skills and knowledge to allow them to take on the world.

completing the required maths and The problem is Australia’s workscience to enter engineering. force is ageing and the development Globally, things don’t look much of technical skills is not keeping brighter. More than 50 per cent of the pace with the retirements. We have a world’s engineering graduates come static rate of graduates, high dropout rates 1 2and 0 1 lower 4 - 1and 0 - lower 0 8 Tnumbers 1 2 : 5 1 : 5from 4 + Asia 1 1 :and 0 0while migration assists us in the short term, the massive popof secondary students interested in ulation and domestic economic development in India and China means we’ll find it harder to compete. Signs of the economic recovery in the US will just add to the pressure.

However, one not-for-profit social enterprise, Re-Engineering Australia Foundation (REA), is working hard to overcome the problem, whose objectives are to encourage students to have an interest and understanding of Science, Technology, Engineering & Mathematics (STEM) careers. Its slogan is ‘Committed to building a better Australia’.

Dr Michael Myers OAM, founder and CEO of REA and one of Australia’s most influential engineers, said REA’s goal is to equip children with the skills and knowledge to allow them to take on the world.

“It is imperative that we inspire, equip and guide the younger generations to be innovators, to embrace FAX +1-612-7298910 world-best technology, to expand their sales@bokers.com world view and to believe that they can make a difference,” Dr Myers said.

REA’s revolutionary programs link schools, industry, TAFE, universities and parents in a collaborative environment focused on changing the metaphor of the education process.

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“Our unique ‘applied learning’ technical programs, backed by extensive research, are changing the education paradigm.

“We have discovered how to excite and mentor young boys and girls so that they embrace learning and technology far beyond their years.”

Dr Myers, an engineer, businessman and passionate Australian, has produced an enormous amount of in-the-field research with high school students proving that hands-on applied learning is more effective than conventional classroom teaching methods.

REA has been leading Australian industry to understand just how important STEM education is to Australia’s future for the past 17 years.

In particular, it has been showing how important STEM knowledge is to the future of our children in a world of dramatic change from disruptive technologies.

“STEM is not about more maths and more science. STEM is curriculum based on the idea of educating students in four specific disciplines – Science, Technology, Engineering and Mathematics -in an interdisciplinary and applied approach.

“Rather than teach the four disciplines as separate and discrete subjects, STEM integrates them into a cohesive learning paradigm based on real-world applications and real world problem solving.

“STEM education is a dramatic paradigm shift in education creating manmonthly.com.au

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dramatically more capable students and catalysing innovation in dramatically more enjoyable learning environments,” Dr Myers explained.

“Since we began our journey to promote STEM in 1998, we have been beating the drum for the need for more STEM skilled young people in industry with the capacity to catapult innovation. We then went a step further by implementing STEM programs in schools across Australia that make these goals a reality.”

So far REA has mentored over 500,000 Australian students through these STEM activities with tremendous success.

“We have taken our Australian students onto the world stage and they have proven themselves to be the best STEM students in the world,” Dr Myers said.

Engineering programs REA has pioneered a number of innovative engineering and manufacturing programs for students.

Of these, the F1 in Schools Technology Challenge, is the oldest and largest having been started in 2003 and having more than 45,000 students mentored each year with another 300,000 benefiting from the technology outcomes by making use of the 3D CAD/CAM software, simulation software, 3-axis

“

watchmakers and jewellers or high quality bearings.

CNC machining centres, designed specifically for classroom use, enable students to understand the connection between design and manufacture. The machined cars are assembled and aerodynamically tested in desktop smoke and wind tunnels.

F1 in Schools is not just about designing and making the car. The car is the initial ‘attraction’ to the mathematical and scientific discipline of engineering and manufacturing, and gives the students the reason to learn.

They start with the outcome, the quickest and most energy efficient F1 car of the future, and then go in search of the necessary tools to achieve that outcome.

Students who have had little interest in STEM subjects suddenly work through lunch periods and ask teachers if they can stay back in the evening and work through their school holidays.

The program incorporates team building, project management, marketing, design innovation, being able to explain the engineering and manufacturing outcomes in a detailed 20-page portfolio, and writing and presentation skills. At regional, state and national finals the teams are judged in 11 areas by engineers, academics and industry professionals.

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CNC machines but not engaged in the competition itself.

F1 in Schools is the biggest technology program on the planet involving 17,000 schools in over 30 nations and more than 9,000,000 students.

Students are tasked with designing and building miniature balsa F1 cars capable of reaching 0-80kph in under 2 seconds. They are powered by a common CO2 canister.

The students must master 3D design and aerodynamics software and are able to increase the aerodynamics and performance of the cars by designing and making 3D printed parts such as nose cones, winglets, spoilers, wheels.

They can also reduce friction by utilising tiny precious stones from manmonthly.com.au

In order to deliver STEM-based projects to even younger students and develop their excitement for designing products, REA has introduced a primary age version of the F1 program.

REA has also introduced, an even greater challenge for F1 in Schools “graduates”, a completely different design-to-manufacture discipline; 4X4 in Schools.

Dr Myers also has many other programs on the drawing board, including subs in schools, solar railways and an energy-focused program, all designed to encourage students to engage in an engineering future.

Re-Engineering Australia Foundation 1300 204 478 www.rea.org.au

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Metalworking& MACHINE TOOLS Controlling mechanical loads in milling In milling operations, choices of tooling and cutting parameters affect the generation, absorption, and management of heat in the interrupted cutting conditions that characterise the milling process. Patrick de Vos writes.

Thermal challenges Metal cutting generates temperatures as high as 800°C - 900°C in the zone where the cutting edge deforms the work piece material and shears it away. In continuous turning operations, the heating occurs in a steady linear fashion. In contrast, the teeth of a milling cutter intermittently enter and exit the work piece material and the temperature of the cutting edges alternately rises and falls.

The elements of the machining system absorb the heat created in metal cutting. Typically 10 per cent of the heat flows into the work piece, 80 per cent into the cut chips and 10 per cent into the tool. It is best when the chips carry away most of the heat because high temperatures shorten tool life and can damage the part being machined.

The differing thermal conductivity of work piece materials, as well as other operational factors, has significant influence on the distribution of heat. For example, the thermal conductivity of superalloys is poor. When machining work pieces with poor conductivity, an increased amount of heat transfers into the tool. Further, harder materials produce more heat than softer materials when machined. And, in general, higher cutting speeds increase the production of heat while higher feed rates broaden the area of the cutting edge that is subject to higher temperatures.

Arc of engagement

Carbide cutting tools, particularly, are composed of powder metal that is hard but brittle.

Temperatures higher than a certain minimum level increase the toughness of powder metal materials and reduce their tendency to fracture. In contrast, when cutting temperatures are too low, the tool remains brittle and the result is breakage, chipping, or edge build-up. The goal is to maintain an ideal zone of cutting temperatures.

Chip thickness and thermal issues The prior article in this series examined the roles of radial depth of cut, the cutting edge angle, feed rate and chip thickness as contributors to mechanical loads in milling. The same machining factors, with the addition of cutting speed, also influence the thermal loads of milling.

Chip thickness affects thermal conditions and tool life at both extremes. If chips are too thick, the

Due to the intermittent nature of the milling process, the cutting teeth are generating heat for only a portion of the total machining time. The percentage of time the teeth are cutting is determined by the milling cutter’s arc of engagement, which is influenced by the radial cutting depth and the cutter diameter.

The various milling processes have differing arcs of engagement. In slot milling, for instance, the work piece material surrounds half of the cutter during machining; the arc of engagement is 100 per cent of the tool diameter. The cutting edges spend half the machining time engaged in the cut and heat builds up rapidly. That situation is distinct from side milling, in which a relatively small percentage of the cutter is engaged in the work piece at any one time and the cutting edges have a greater chance to dissipate heat to the air.

Excessive heat build-up in the tool degrades tool life by causing accelerated wear or deformation. Conversely, many cutting tool materials must be applied at temperatures above a critical minimum level to achieve full efficiency.

20 SEPTEMBER 2015 Manufacturers’ Monthly

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Metalworking & MACHINE TOOLS >>

resulting heavy loads can generate excessive heat and chip or break the cutting edges. When chips are too thin, cutting takes place on a smaller portion of the cutting edge and increased friction and heat result in rapid wear.

The chips produced in milling continually change in thickness as the cutting edge enters and exits the work piece. Consequently, tooling suppliers utilise the concept of “average chip thickness” to calculate cutter feed rates that will maintain the most productive thicknesses.

Determining the correct feed rate involves factors including the cutter’s arc of engagement or radial depth of cut and the cutting edge angle of the cutting edges. The greater the arc of engagement, the lower the feed rate required to generate the desired average chip thickness.

Similarly, with lesser cutter engagement the feed rate must be higher to achieve the same chip thickness. The cutting edge angle of the cutter also affects feed requirements. Maximum chip thickness occurs with a cutting edge angle of 90 degrees, so lesser cutting edge angles require a higher feed rate to achieve the same average chip thickness.

To keep the chip thickness and temperatures in the cutting zone at the same value as those for a fully engaged cutter, tool suppliers have developed compensation factors that call for increasing cutting speeds as the percentage of cutter engagement shrinks.

As an illustration, if the speed factor for a fully engaged (100 per cent of diameter in cut) cutter is 1.0, the speed compensation factor for a 90-degree cutting edge angle cutter with 20 per cent of its diameter engaged in the cut is 1.35. Therefore, if the cutting speed for the fully engaged cutter is 100 m/ min, the cutting speed needed to maintain optimal chip thickness for the cutter with only a fifth of its diameter in the cut is 135 m/min.

From a thermal load point of view, if the arc of

engagement is small, the time in cut may not be sufficient to generate the minimum temperature needed to maximise tool life. Because increasing cutting speed generally results in greater heat generation, combining low arc of engagement with higher cutting speed can help raise the cutting temperature to the preferred level. Higher cutting speed also reduces the amount of time the cutting edge is in contact with the chip, which in turn reduces the amount of heat that is transferred into the tool. Overall, higher speeds also reduce machining time and increase productivity. On the other hand, lower cutting speeds reduce machining temperatures. If the heat generated in an operation is too high, reducing cutting speed can lower the temperatures to an acceptable level.

Cutting edge geometry The geometries of the milling cutter and its teeth contribute to the management of thermal loads.

The basic geometry of the cutter determines how the tool is positioned relative to the work piece.

Cutters that position cutting edges at a positive rake (with the top of the cutting tooth sloping back from the work piece material) produce lower cutting forces and generate less heat while also permitting use of higher cutting speeds. However, a positive rake tool is weaker than a negative tool, and the hardness of the work piece material and its surface condition may dictate use of negative rake cutters. Negative rake tools generate greater cutting forces and higher cutting temperatures.

The geometry of the cutting edges themselves initiates and controls the cutting action and cutting forces, and thereby affects the generation of heat. The edge of the tool where it meets the work piece can be chamfered, rounded or sharp.

Chamfered or rounded edges are stronger, but once again produce higher cutting forces and more heat.

A sharp edge, while not quite as strong, reduces cutting forces and runs cooler.

The T-land behind the cutting edge directs the chip and can be positive or negative, with the same trade-off of lower operating temperatures for the positive design against the stronger but higherheat-generating negative arrangement.

Because the cutting action in milling is interrupted, chip control features of milling tools generally are not as important as they are in turning.

However, depending on the work piece material and arc of engagement involved, the energy involved in forming and directing the chip can be significant. Tight or hard-breaking chip control geometries immediately curl the chip and generate higher cutting forces and heat. More open chip control geometries produce lower cutting forces and operating temperatures, but may not be appropriate for use with some combinations of work piece material and cutting parameters.

Cooling questions Manipulating coolant application is another way to manage temperatures generated in metal cutting operations. Excessive temperatures cause a cutting edge to wear rapidly or deform, so heat must be controlled as quickly as possible.

To lower temperatures efficiently, cooling has to be directed to the source of the heat. However, it is extremely difficult, if not impossible, to inject coolant into the high-temperature cutting zone where pressure between the chip and cutting edge is in the neighbourhood of 20,000 bar. In addition, coolant evaporates instantly in such a severe environment. Coolant may not be fully effective in removing heat in such a situation, but it may help to some extent.

Exactly how much difference a stream of coolant makes is unclear; coolant effectiveness is a subject on its own. It is like a religion; you believe in it or you don’t. In general, if excessive heat is anticipated, coolant can be applied. In slot milling, for example, coolant use generally will not be harmful. It can help but how much is a subject for discussion. In side milling, however, where cutting temperatures can remain low, it is probably best not to apply coolant.

Conclusion The multiple factors that together create the loads present in metal cutting operations do not operate separately. They influence each other throughout the machining operations. This article has discussed thermal issues in milling operations and how they relate to mechanical factors. Familiarity with the individual elements that comprise metal cutting loads as well as the overall results of their interaction will help manufacturers optimise their machining processes and maximise productivity and profitability.

[Patrick de Vos is Corporate Technical Education Manager, Seco Tools] Seco Tools 1300 55 7326 www.secotools.com/au 22 SEPTEMBER 2015 Manufacturers’ Monthly

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Automation& ROBOTICS The rise of robot collaborators More and more factories are seeing the appeal of collaborative robots.

Brent Balinski spoke to Dr Esben Østergaard and Dr Rodney Brooks, both CTOs/co-founders of the two leading “co-bot” companies, about the development of the category, what it offers, and what the future might hold.

T

HE growing interest in a fairly new set of flexible, safe, userfriendly robot automation solutions – often called “collaborative robots” – is undeniable.

According to market research from ABI released in June, the number of units sold annually will rise from 1,781 in 2014 to 40,036 in 2020 (an increase of more than 2,200 per cent).

The popular press has taken notice of the trend as well, and cagefree robot co-workers seem to have captured the imaginations of many.

“Demand is pretty strong and we see that in Australia and we see that more or less all over the world,” Dr Esben Østergaard, co-founder and CTO of Universal Robots (UR), told Manufacturers’ Monthly.

“And it’s a little bit about giving more responsibility to the people working near the robots instead of these robots only being able to be touched by the experts.”

In the increasingly frequent stories about the category, the two companies often mentioned in the same breath are Østergaard’s Universal Robots and Boston-based Rethink, both of which have some claim to being pioneers.

However, both companies will tell you their products are very different.

Humanoid or tool Collaborative robots are usually pitched in terms of their ease of use.

A line worker can manipulate UR’s or Rethink’s robot arms, with this movement repeated by the robot (with a few simple interface inputs along the way).

UR’s products have caught on, “Because of the flexibility and ease of use of the robot,” offered Østergaard.

Similarly, Rethink’s products are designed to be easy to set up and to reprogram.

“Our goal is – maybe this is the 24 SEPTEMBER 2015 Manufacturers’ Monthly

best thing to say: our goal is to make it frictionless to put the robot into a new task in the factory,” Dr Rodney Brooks, founder and CTO of Rethink Robotics, told Manufacturers’ Monthly.

The word “training” is often used in the company’s literature in place of “programming”, which is in keeping with their robots’ positioning as a friendly, human-like presence.

“The Universal Robot is a great robot, but to me it’s more of a conventional industrial robot,” offered Brooks of the difference in approach.

Baxter’s humanoid appearance was not the starting point, coming after other versions were tried out. The display/face provides its human coworkers with feedback on the robot’s progress in tasks (for examples, it will look confused if it is interrupted during a job, look at where it is about to move to, and its screen will turn red to let a human know Baxter is aware a person is nearby.)

The design also has to do with the ability to switch a person and a robot between certain jobs.

Baxter has a reach similar to a human’s for this reason, though with slightly longer arms (to compensate for a lack of hips to bend from).

Both companies have seen their products being viewed to some degree as team members within factories.

For example, UR’s machines are sometimes referred to by human names by floor workers at a BMW assembly plant in the US. This does not indicate that they are viewed as being human-like, said Østergaard.

“There is a tendency that companies name the robots, I think a little bit, yes, but the robot as I see it is more like a tool,” he said.

“Do you name your electric screwdriver? Probably not. But at some point, when the tool becomes sophis-

ticated enough, you feel it should have a personality, and that’s why you invent a name for it.”

Both companies are also quick to volunteer that their robots are there to aid human workers rather than replace them.

For Østergaard, the robot-as-a-toolfor-workers approach helps counter any “machines vs. jobs” argument.

“Nobody says that an electric screwdriver steals jobs,” he pointed out.

“So if we can get the same kind of view of robotics then at least...by making them accessible to people, they are less feared.”

As well as flexibility – suitable for low-volume, high-mix output – a large part of the appeal of collaborative robots is the ability to take away repeti-

tive jobs such as machine tending or picking/placing small loads. Neither was practical with heavy industrial robots of the kinds seen in automotive factories.

“Baxter and Sawyer, they’re not dexterous, they’re not able to do cognitively demanding things; they do really boring tasks,” said Dr Brooks.

“And the workers are often the ones that come up with them. And certainly in the US and China, by the way, it’s not like people are lining up to get factory jobs. So the popular press says ‘robots are going to take away all the jobs’ – [but] that is just not the case.”

Another worker-friendly aspect of both companies’ robots is their level of safety. manmonthly.com.au

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Again, there are big differences in how each company approaches this.

Both stop when met by a certain level of force, though Rethink has embedded force sensors in its robots’ joints, while Universal ascertains a certain level of force by measuring disturbances in current.

“I’d gladly put my head in front of Baxter when it’s running at full speed and I’m still okay,” offered Brooks. “I would not put my head near a Universal Robot.”

Other differences include repeatability levels (more an emphasis for Universal, which has a higher level of precision, with Rethink concentrating on the ability to work in semi-structured environments); the American company’s machines come with builtin vision systems (these are integrated later if needed with UR); and degrees of freedom in robot arms.

Despite creating very different robots for very different tasks, both companies have a legitimate claim on inventing “collaborative robots” as a category or piece of nomenclature.

What led to co-bots? Østergaard made his first robot at age four, out of Lego, possibly the most archetypically Danish way to get started (see The Last Word, p. 42).

A robotics prodigy and a holder of more than 30 patents, Østergaard completed research positions in the United States and Japan before returning to Denmark.

As a PhD student at the University of Southern Denmark (Odense), Østergaard teamed up with two other students (Kristian Kassow and Kasper Støy) on a task set by the Danish government: bringing more automation into the food and beverage industry.

Initial research was carried out in 2003, the idea for a company formed in 2004, and UR launched in 2005.

Their first non-prototype robot – arguably the first “co-bot” sold – was sold in 2009, and they have sold over 5,000 units of their UR10, UR5 and UR3 machines since then. According to their CTO, they are now heading up to 300 units a month moved.

The company was acquired in May

by Teradyne for $US285 million (plus performance incentives).

Dr Brooks was born in Adelaide, manmonthly.com.au

“By making them accessible to people, they are less feared,” said Dr Esben Østergaard. completed a masters at Flinders University (pure mathematics) and a Doctorate at Stanford University.

His interest in robotics was piqued at around eight by the How and Why Wonder Books on the topics of electricity and robots.

He has achieved considerable successes in academia, spending a quarter of a century on the faculty at MIT, and as an entrepreneur, co-founding iRobot (see Manufacturers’ Monthly’s May edition.) Among many achievements is an Advance Global Australian Award for Advanced Manufacturing, announced in July.

His entry into industrial robotics was influenced by what he picked as a looming shortage of labour in China (where iRobot outsourced production of its hugely popular Roomba machines) and a desire to bring manufacturing back to the United States.

Since launching, there have been over 1,000 Baxters sold.

Whatever the co-bot term – now used by several companies to describe their robots – means, who popularised it?

“It’s my view – you might ask the other companies, they may tell you something different, but I think we sort of introduced the category and people are seeing that technology makes it plausible today and it’s actually worthwhile doing,” claimed Brooks.

“So from that point of view, it’s a great artistic success.”

Robot rivals?

Both companies were founded by gentlemen successfully able to bring innovations out of academia and

“...it’s a great artistic success,” said Dr Rodney Brooks (pictured with Sawyer and Baxter).

into the commercial world. And both have strong links to local, world-class clusters of robotics expertise.

Rethink’s home is in the robotics hotspot of Boston, in the city’s Innovation District. Brooks is not the only MIT alum on the board, and much IP generated at the university – such as their robots’ series elastic actuators, which add to its safety while operating alongside humans – can be found in Baxter/Sawyer.

Asked if Teradyne’s HQ being near Boston’s robotics ecosystem had any influence in selling, Østergaard said the location was handy, but not crucial. UR will be keeping its R&D in Odense.

“It’s not a bad thing to have a strong connection to the Boston area, for sure, but it was not part of the decision,” he answered.

Odense boasts an impressive technology ecosystem of its own. According to Innorobo, there are over 70 robotics specialist firms in the southern Denmark city, with over 1,800 employees. There are also more than 10 relevant research institutions, and four high-tech incubators.

Neither company identified any sort of rivalry when asked and suggested that they both sold very different offerings suiting different tasks.

“Theirs is a fairly conventional sort of programming system with a graphics layer on top, ours is a taskbased-run, coordinate-based system; and we’ve got built-in cameras and things,” said Brooks.

“So in my view, it’s different.”

The term under which both businesses marketed their products was a

broad one. Both companies addressed different problems, said Østergaard.

“I don’t think there will be a lot of applications where there will be competition between our products,” he added.

“Anyway, the market is big, so we just welcome more players,” said Østergaard.

According to UR’s CEO, Enrico Krog Iversen, the addressable market might be worth as many as 1 million units a year, and too big for one company to try and tackle on its own.

“There is a lot of room for innovation… There’s a lot of room for new start-ups. I don’t know how many arms we will need.”

In the world of co-bots, there’s a definite excitement.

And as with industrial robots in general, demand will only go up in a labour-constrained and increasingly tech-heavy manufacturing world.

“When we started talking about it, no one else was, and the major companies are all saying ‘we’re doing that too,” said Dr Brooks.

“So we’ve got to run really fast!

Because [now] they all know this is a good idea.”

[Brent Balinski has been a journalist at Manufacturers’ Monthly since 2012.

He is particularly interested in 3D printing and innovation] Universal Robots www.universal-robots.com Rethink Robotics www.rethinkrobotics.com Manufacturers’ Monthly SEPTEMBER 2015 25

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Made IN AUSTRALIA As a marketing tool this logo is a bargain buy Manufacturers have to spend a lot on marketing. According to Alan Johnson, they would do well to take advantage of one of best promotional tools around – the Australian Made logo.

W

HILE Australian manufacturers make some fantastic high quality, innovative products, research over the years has continually found that marketing of these products has often been the weak link. Which is surprising when manufacturers have access to one of the most cost-effective marketing tools available: an Australian Made logo.

True it does cost some money to use the logo, but at a starting point of just $300 a year, it must be one of the bargains of the decade.

Ben Lazarro from the Australian Made team admits there is mis-information in the marketplace about the cost of using the logo, explaining that the logo’s licence is tiered to the turnover of the product that carries it.

“The minimum fee is just $300 for 12 months, and that’s for products that are turning over $300,000. That’s only one tenth of one per cent. You can’t buy an ad in your local paper for that,” Lazarro told Manufacturers’ Monthly.

“Obviously, the higher the turnover, the higher the licensing fee.”

“It’s a really good marketing tool and enjoys enormous recognition in the marketplace. Research shows it’s recognised by 98.9 per cent of consumers and maybe more important is that 88 per cent of consumers trust it.”

However, while consumer recognition is high, those figures do not carry over to businesses, with the organisation’s research revealing only 20 per cent of companies have a firm policy or preference to buying Australian made goods.

“It’s very disappointing, but we are working on it,” Lazarro said.

John Jones, Sales and Marketing Director with Melbourne manufacturer AK Reels, is equally disappointed, saying that while the logo does help and has had great support from the public that’s not the case with Government departments and major public services.

“Unfortunately they are not tuned 26 SEPTEMBER 2015 Manufacturers’ Monthly

Mumme Tools puts the Australian Made logo on all its marketing material and products, where relevant. in to this thinking due to the ‘outsourcing’ of supply,” Jones said.

However, Jones said the acceptance of the company’s new Safety Barrier Tape Reels by major mining companies around the world was enhanced by the Australian Made and Owned status of the company.

“We are all for Australian Made goods and services with the logo recognised as an assurance that Australia is the origin of the reels they are buying and the standards meet their needs and expectations,” he said.

Solution for both sides Lazarro said the logo is a solution for both consumers and manufacturers, and has an association with quality.

“It’s a quick and easy way for manufacturers to demonstrate that their products are Australian made, plus it is easy for consumers when they are making that purchase whether it’s in a supermarket, hardware store or a business sourcing components for their own manufacturing purposes,” he said.

“It also provides a mark of authenticity, be-

cause it’s 3rd party accredited through the Australian Made Campaign.”

Lazarro said the logo has a good global reach and is used by more than 2300 companies on 15,000 products both here and around the world.

“While we don’t conduct awareness campaigns overseas, there is tremendous anecdotal evidence from licensees saying it is recognised in many countries,” he said.

“In China for example, where it is a registered trade mark and provides a legal framework for licensees, the logo is perceived to be the official brand of Australia.”

He said the logo is also a registered trade mark in the US, Singapore and South Korea, with plans to expand into seven other countries in SE Asia in the near future.

“By being a registered trade mark in these countries, counterfeiters who copy an Australian made product with an Australian Made logo are breaking the law of that country, and can be prosecuted there, providing extra protection for Australian manufacturers,” Lazarro said.

“Plus companies can demonstrate that it’s genuinely Australian and demand a premium for their products overseas.”

Using the logo Mumme Tools, a long term user of the logo, produces a wide-range of forged hand tools in South Australia and is Australia’s leading mining tool manufacturer.

Mumme Tools spokeswoman, Alexandra Felgate, said the company puts the logo on all its marketing material and products, where relevant.

“The cost of using the logo is not an issue for us because it’s such an important part of our marketing and branding, and who we are as a business,” she said.

“We find it’s a real point of difference. It gives the consumer a reason to purchase our product over someone else’s.

“We export quite a lot of our products and find the logo helps with sales, especially in Asia. It shows us as a quality manufacturer.”

Gary Krix, Managing Director of high quality loudspeaker manufacturer Krix, agreed saying the logo resonates with consumers, both locally and overseas.

“A few years ago, we inadvertently didn’t put the logo onto one shipment of our products to Hong Kong. The distributor was very quick to complain, so it meant a lot to them as it was a point of difference,” he said.

He said the logo is something people look for.

“When customers register with us, after they have bought a product, we ask them the reasons why they manmonthly.com.au

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bought Krix. Often it’s things like sound quality and the overall quality of the product, but a lot of them do tick the Australian Made box,” he said.

Krix said the company had been using the logo for over 20 years. “Way before I arrived here, but obviously not on the whole range, as some are manufactured overseas for us,” he said.

He said it also depends on the product. “For example, we put the logo on the packaging and the product itself for our consumer products, but on our commercial cinema products we just put the logo on the packaging as they are high volume products and the decision has already been made.”

Krix said he doesn’t want people to buy his products just because they are Australian made.

“We M Awant 0 6 1them 5 _ to 0 0buy 0 _Australian T RU made because it’s a well-made and

well-engineered product, and the Australian Made logo gives them that final reason to buy the product,” he said.

Danielle Lindsay Woodridge from Lindsay Pie-Making Equipment, manufacturer of the ‘Simple Simon’ bakery equipment, said the Australian made logo is essential to all the company’s marketing, both here and overseas.

“We are proud to design, manufacture and sell pie machines that are sold in over 14 countries. We have been members of the Australian made campaign from the beginning as we recognised that the logo represents Australian made quality; which is known to be the best in the world,” Lindsay Pie-Making Equipment uses the logo she said. on all its pie machines.

“We use the Australian Made logo on our website, on all of our marketing materials and at trade shows Food labelling and events, so that when a buyer is To overcome problems of country-ofresearching our bakery equipment, origin labelling for food, the Australone of the first things they will see ian Made, Australian Grown logo is to 1is that 2 0we 1 5are - Australian 0 5 - 2 7 TMade 0 9 :certi5 0 : 0 be 7 +incorporated 1 0 : 0 0 into new country-offied. origin food labels.

The Government’s proposed new country-of-origin labelling system for food will, for the first time, incorporate a bar chart showing what proportion of ingredients come from Australia, and will also include – for those products made and grown in Australia – the Australian Made, Australian Grown kangaroo logo.

Australian Made Campaign Chief Executive, Ian Harrison, said the new system will help consumers make informed choices based on the ‘Australianness’ of products.

However the system will not say where those remaining contents come from due to global supply chains that can change on a regular basis.

The proposed new ‘contents symbol’ will be mandatory for most (but not all) food products and the roll-out will commence next year – following consultation with the States and Territories – with a phased implementation period for small business.

Australian Made 1800 350 520 www.australianmade.com.au

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Manufacturers’ Monthly SEPTEMBER 2015 27

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Made IN AUSTRALIA Australian made means ‘Australia suitable’ Buying Australian isn’t always about ‘supporting’ local industry. Often it’s more about checking what’s available and realising the locally made product is better than the import. Matt McDonald writes.

T

HERE are several imported ride-on mowers available on the Australian market. Most were made in North America and designed for the ‘grooming market’.

In other words, they are intended for already established lawns, manicured parks and so forth.

However, they are not suited to Australian conditions.

“InMAustralia A 0 9 1 5the _ 0application 0 0 _ L O for G ride on mowers is rural and regional

Packaging

Seasoned Team

areas and typically what we call bush blocks and native paddocks,” Cox Industries Managing Director, Ken McColl 1 2 0 told 1 5 Manufacturers’ - 0 8 - 2 6 T Monthly.

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often used for mowing native grasses in rough, rugged terrain. The machine has to be much stronger than the US 0import 8 + 1 generally.”

0 : 0 0 In contrast, said McColl, a Cox mower has no trouble handling uneven terrain and native grasses.

“It will go straight through it even if it’s knee-high and sometimes wet,” he explained.

And, he said, this is why these locally made products have been successful in this country. Put simply, Australians buy them because they cut their grass well.

How does Cox achieve this extra strength and durability?

“Fundamentally by engineering design,” McColl explained. “[We use] heavier gauge steel to make them stiffer…proper welding…not just spot welds like in automotive manufacturing but fillet welds.”

The largest ride-on mower manufacturer in Australia, Cox industries was established by engineer and inventor Owen Cox in the 1950s. Today, the company produces 5000 products a year at its factory in the Brisbane suburb of Acacia Ridge.

Of course, things have changed in the company’s 60 years of operation. “[Over the past 10 years] we have automated the welding and purchased three welding robots,” McColl said. “About 10 years ago we had over 50 manual welders, people welding

28 SEPTEMBER 2015 Manufacturers’ Monthly Quarter LogiCamms Advert.indd 1

with welding masks and welding rods around the factory and today that number is one.”

That one welder is basically on board for any odd jobs which need doing.

There are more changes in the pipeline. The company is looking to invest in more high speed laser cutters in the next couple of years. According to McColl, factors like natural product growth and staff attrition mean these changes will not have a significant effect on the company’s core factory staff of about 30.

Research and Development The company prioritises research and development. As McColl explained, in R&D terms there’s a parallel with the automotive industry.

“About every five years or so we have to have major product upgrades and new models… the lifeblood of this business is our R&D section,” he said.

“We have a team of very highly skilled and qualified engineers who are developing new products all the time and we release a new model about every five years.”

He said that while R&D is hugely expensive for the company, it is also “one of the keys to the future” and something Cox excels at.

When asked what changes he expects to see in the market, McColl manmonthly.com.au

24/08/2015 10:28 am

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nominated regulatory changes in the areas of carbon emissions from 4 stroke engines and evaporation of petrol from petrol tanks.

In addition, he said he expected there will be changes in noise reduction legislation at some point down the track. Though he added that noise is not a big issue in Australia because the mowers are generally found on large rural blocks and don’t tend to bother anybody.

In terms of technological changes, McColl said robotic mowers will be the next big thing.

“Robots are already used in domestic applications. A bit like the robot vacuum cleaners that are readily available now,” he said.

The future

The ‘Lawn Boss’ – one of four models of ride-on mower available from Cox Industries.

Like many, McColl finds it hard to be optimistic when he looks at the Australian manufacturing sector.

“I don’t think our governments have woken up what the demise of manufacturing is going to do to this country. I don’t see them in the short termMdoing A 0 9anything 1 5 _ 0 that’s 0 0 _ going M U Mto help manufacturing,” he said.

However, he does see a bright He nominated payroll tax as somefuture for Cox industries and said the thing in particular that he finds hard lowering of the Australian dollar has to stomach. been a relief.

“Governments talk about jobs, “There was a time there a couple jobs, jobs…every night of the week, of years ago when the dollar was very but as soon as you start employing people buying the throw 1people 2 0 they 1 5 -charge 0 8 - you 1 4payroll T 1 4 :tax,” 1 8 : 2 high 6 + 1 0 : 0were 0 away product that’s available from he said.

off shore and we see a trend in them going back to buying solid, durable Australian made product from ourselves.”

“Our products last for years and years. Sometimes we get products that have been in the market for decades. We have people ringing up wanting spare parts for mowers from the1970s and 80s.”

The company does export around five per cent of its products to New Zealand, South East Asia, and the Pacific Islands. It doesn’t export to the northern hemisphere, simply because the shipping is too expensive.

That leaves most Cox mowers right here in Australia, where they are just right for those nice big bush blocks and those tough native grasses.

[Matt McDonald, a Manufacturers’ Monthly journalist, writes on a broad range of topics. His special interests include Safety and Industrial Relations] Cox Industries 1300 857 282 www.coxmowers.com.au

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Manufacturers’ Monthly SEPTEMBER 2015 29

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Auto COMPONENTS Stepping up to the challenge The writing is on the wall for Australian car component makers. But, while some will surely die in the next couple of years, others are redirecting their energies to new challenges.

Hartley Henderson writes.

A

LTHOUGH many component suppliers to the automotive industry are confronted with significant challenges, some are finding new opportunities as car manufacturing grinds to a halt.

Such a transition often needs an entirely new business strategy and mindset to be developed, including a preparedness to seek new niche opportunities, and to be flexible and adaptive to new production and marketing requirements.

Precision Components in the Adelaide suburb of Beverley is a tier one automotive manufacturer to Holden, Ford and Toyota including the supply of high strength light weight complex stampings and sub-assembly automotive components.

The company now also manufactures heliostats and renewable products for HeliostaSA which designs, installs and commissions major solar energy projects.

The unique heliostat technology utilised by HeliostatSA was developed by CSIRO and consists of clusters of mirrors linked to a computer controller to track, reflect and concentrate the sun’s heat onto a single receiver point to in turn create superheated steam to drive a turbine and generate electricity.

According to the CSIRO’s Solar Research Leader, Wes Stein, CSIRO has been working on the development of advanced heliostat technology as a critical part of the next generation of solar for over 10 years.

“Our commercialisation strategy involves starting with the energy market, then working back to develop the individual components such as heliostats. We have long held the view that this technology could not be successful without the expertise of the manufacturing industry,” he said.

“In 2009, a Newcastle manufacturing company, Performance Engineering Group, built 450 heliostats to our design for one of our research fields.

30 SEPTEMBER 2015 Manufacturers’ Monthly

CSIRO’s Wes Stein in a heliostat field.

We also have a project, funded by the Australian Renewable Energy Agency, partnering with another automotive parts company, Diver Consolidated Industries, to develop heliostats for remote areas.

“Low cost, high precision heliostats are essential for the development of competitive medium to large scale solar power projects, not only for solar electricity but also for making transport fuel. CSIRO’s heliostat design is unique in that it is smaller than conventional heliostats to benefit from mass production and uses an advanced control system to get high performance from inexpensive materials. Companies like HeliostatSA are crucial for the future of solar energy.”

HeliostatSA was formed early in 2014 by Precision Components Managing Director, Darrin Spinks, as an automotive diversification initiative into renewable energy products after the announcement to withdraw from Australia by Holden, Ford and Toyota.

Chief Executive Officer at HeliostatSA, Jason May, says renewable energy is one of the largest and fastest growing industry sectors in the world.

“We hold the licence in Australia for CSIRO’s heliostat technology and control system and have established

a strategic long term relationship with the organisation as our technology partner. As well as technical support for projects, and research and development of solar technologies, the relationship includes the development of IP retained in Australia,” he told Manufacturers’ Monthly.

“Precision Components owns a 50 percent shareholding in HeliostaSA, May Brothers (an energy project development company) owns 20 percent, UniSA as the R&D partner has 15 percent, and Enersalt (a product developer) has 15 percent,” he said.

“The federal government is supporting Precision Components with a $1M Automotive Diversification Programme grant for retooling to produce heliostats, whilst Precision Components has contributed $1.78M. “A major beneficial factor in our diversification and transition from the auto industry is that the press lines and robots needed for auto manufacture have similar applications in the renewable sector.”

HeliostatSA secured its first heliostat array export order with MHPS Japan in the first 6 months of its operation, but May says a key challenge is establishing an Australian company in the global renewable market,

retooling, and retraining staff.

“Our technology is superior, our quality is second to none and we are competitive on price, but getting this message across takes time and money,” he said.

“Our people are highly trained in using the latest equipment to produce ultra high volume quality products. Also, we have the perfect formula for success with government support for the next few years essential in securing a stake in the $5 trillion renewable market.

“HeliostatSA operates in the 1 MW to 10MW industrial scale sector, and in the 50MW plus utility scale sectors. Although HeliostatSA deploys photovoltaic technologies, the market is saturated, so our strategy is to adopt emerging technologies like CSP (concentrated solar power) and CSPV (the new super PV cells).

“We will continue to develop new technologies, as well as secure technologies through partnerships and acquisition.

“A global presence is progressively being developed with a prime focus on key markets in India, Africa and Australia. The aim is to grow HeliostatSA to a $1 billion company over the next five years.”

The many challenges Multi Slide Industries is another Adelaide-based company making a transition from the automotive industry. The company currently makes the rear seat frames for all Australian built Holden vehicles as well as the spring wire boot lid torsion bars and jack handles for Toyota.

Walker exhaust hanger brackets are also supplied for Holden, Toyota and Ford, and other components are provided to the auto industry for use in items such as rear view mirrors and air cleaners.

According to Multi Slide Managing Director, Rod Rebbeck, currently the sales value for all of the compamanmonthly.com.au

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ny’s auto products is 49 per cent of total sales, whereas a year ago it was 58 per cent. At its height, the company ran two shifts with 158 employees, but now has 34 employees.

“It will be difficult to fully replace our automotive sales dollars, but we have recently engaged an external marketing consultant and employed a new sales engineer to search for new markets and to increase sales in existing areas,” he told Manufacturers’ Monthly.

“We already supply the agricultural and building industries with a range of products and want to expand that into aquaculture. Also, we are having to change our thinking from high volume, which has been the norm, to more low volume higher profit items, such as those used in niche furniture manufacture for example.

“In relation to manufacturing equipment, we need a new high tech CNC bending machine that is more easily programmable and capable of moreMintricate A 0 9 1 shapes 4 _ 0 0in0 larger _ P I diamE eter material than we currently can

manmonthly.com.au

a range of equipment which can be readily adapted to new product, and we are financially sound.”

(Left to right) Multi Slide Industries Managing Director Rod Rebbeck, Senator Simon Birmingham, Federal Treasurer Hockey, and Liberal member for Hindmarsh Matt Williams, during a visit to Multi Slide Industries. that previously provided Multi Slide handle. This would help open up new markets in the lower volume areas we with services have shut or moved.

“For example, heat treatment and are concentrating on. plating is becoming a problem in that “To assist us in the way forward, we now often have to send product we have submitted a one-for-one interstate for processing, which adds grant application to the federal to costs,” he said. government through the Automotive “This business will survive Diversification Programme for such because we are diversified and can a machine. At present we are not that strategy. We 1receiving 2 0 1 government 4 - 0 8 - 1 assistance.”

2 T 1 1 : 1 8 : 3 continue 3 + 1 0 :to0develop 0 have a large customer base already, Rebbeck says other businesses

[Hartley Henderson has been a regular contributing writer to Manufacturers’ Monthly for the past eight years, covering industry developments in Victoria and South Australia. Prior to that, he held senior positions in government, semi-government and business enterprises and was National Program Director with the Productivity Promotion Council of Australia] CSIRO 02 4960 6094 www.csiro.au HeliostatSA 08 8409 1430 www.heliostat.com.au Multi Slide Industries 08 8374 1422 www.multislide.com.au

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Warehousing The rise of manufacturing warehouses Manufacturers are seeing value in rolling out intelligent software platforms that deliver optimised visibility and control across the entire supply chain; from manufacturing right through to delivery. David Rubie writes.

T

HE warehouse has traditionally taken a back seat to the manufacturing operation of a business when making investments, however in recent years, manufacturers are changing their approach and seeing value in finding efficiencies and savings in their warehouses.

This alignment of the importance of both the manufacturing production and warehousing operations has led to a much higher degree of integration of technology and systems.

For instance, manufacturers are seeing value in rolling out intelligent software platforms and supporting technologies that deliver optimised visibility and control across the entire supply chain; from manufacturing right through to delivery.

There are a number of external factors encouraging this investment, with an evolving market placing strong demand on manufacturing supply chains to deliver goods more rapidly and flexibly.

Consumers and retailers now demand access to a larger range of products and they want to be able to shop through a number of channels – in-store, online, click-and-collect and more.

Manufacturers are also now competing in a global market, where retailers can more easily source products from producers world-wide.

This increasingly globalised supply chain means local manufacturers have to maintain cost competitiveness in a much larger pool of producers, that, due to differences in geography and legislative requirements, have very different space, labour and operational costs.

Overcoming the challenges Australian and NZ manufacturers are looking to overcome these pressures by increasingly focusing on integrat32 SEPTEMBER 2015 Manufacturers’ Monthly

ing their systems, from production right through to logistics.

The greater visibility of their operations that manufacturers have, the better they are positioned to make accurate operational decisions to further optimise their supply chain.

Many manufacturers are reshoring their logistics operations inhouse, in order to have better control over inventory as retailers demand a wider array of products, as well as a higher frequency of delivery.

The priority for manufacturers is increasing efficiency, productivity and visibility, through automating more processes.

The motivation for automation has arisen because it has been proven that the more a business eliminates ‘operator touches’ within the supply chain, the more cost effective it is and the safer for staff.

Due to the nature of the Australian and NZ market, full automation isn’t always realistic, however warehouses should be using labour effectively and automating repetitive tasks, heavy manual work, or work in environments that are harsh and difficult for workers.

While in the past manufacturers had a large network of warehouses, we are now seeing many manufacturers consolidate to fewer warehouses, or a single warehouse, integrated into the manufacturing location.

This is due to the growing issue faced by manufacturers of the increasing cost and availability of land.

New technologies There are a number of technologies that manufacturing warehouses are considering in order to reduce the amount of physical space their facility occupies, as well as to increase automation where possible.

Many manufacturers are investing

Many manufacturers are investing in high-bay warehouses with automated storage solutions to meet both their space and automation goals. in high-bay warehouses with automated storage solutions to meet both their space and automation goals.

Others manufacturers are increasing their automation with Goods-toPerson (GTP) solutions that enable warehouse workers to build orders at an ergonomic work station in order to increase efficiency, throughput, accuracy and operator health and safety.

Warehouses are also increasing automation to maximise operational resilience, reliability and performance through automatic guided

vehicles (AGVs), and palletising robotics to build complex mixed-case customer pallets.

Those manufacturers that automate to drive efficiency, productivity and visibility throughout their operations will be best placed to rise to the challenge of staying competitive in a rapidly evolving global supply chain.

[David Rubie is Industry Logistics Manager with Dematic] Dematic 02 9486 5555 www.dematic.com manmonthly.com.au

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Moving the warehouse into the cloud Cloud computing can assist manufacturers to effectively respond to increased order volumes and complexity, as Mark Troselj writes.

A

USTRALIAN warehouse operations are undergoing significant changes that are forcing many manufacturers to re-evaluate how they manage them. With the rapid rise in omni-channel commerce, as well as many manufacturers now selling direct to consumers, orders are rapidly growing in volume, speed and complexity as consumer purchasing behaviours continue to change.

Previously, warehouses were able to satisfy demand by managing orders by the pallet, but as digitalisation continues to shift the way manufacturers need to operate, they must now process a large volume of smaller orders, often as individual items.

Adding to this complexity, order cycle times have reduced from days or weeks to a matter of hours as the pressure for same day fulfilment increases.

Successful manufacturers are embracing change and understand the generational shifts in process and technology they need to make to remain relevant and competitive.

Purely implementing an efficient manufacturing or warehousing solution isn’t going to future proof a manufacturer; they need to integrate and automate all of the business processes and data needed to move forward as a successful manufacturing organisation and remain competitive.

To achieve this, they need the ability to operate and have complete visibility of their entire manufacturing operations in real-time, gaining deep insight into every interaction, transaction and relationship occurring in their business, anywhere in the world.

This is where cloud computing plays a crucial role in helping manufacturers respond to order volume, velocity growth and increasing demand for automation.

Not just warehousing Cloud provides the ability to operate in global markets in real-time and establish a core platform for manufacturing, warehouse management, distribution, customers and supply chain, which they can access from anywhere and at anytime using the Internet.

Businesses can have all of these components in a single, integrated cloud business management system, which can completely transform, automate and modernise warehouse operations.

Cloud gives all manufacturers, regardless of size, the opportunity to access a complete solution manmonthly.com.au

By switching to the cloud, manufacturers can reduce order-to-shipment cycle times by as much as 70%. for manufacturing resource planning, integrated inventory and dynamic replenishment, warehouse management, financial accounting and costing, customer and partner relationship management, and ecommerce.

The real-time operations and financial visibility they gain enables manufacturers to better plan and manage inventory, as well as provide more accurate product delivery estimates to customers faster.

No longer do manufacturers need to spend countless hours of work associated with data entry, organisation and fulfilment. Integrated cloud manufacturing solutions can convert forecasts to orders, orders to shipments, and shipments to revenue with unprecedented efficiency. They also enhance warehouse order fulfilment, packing and shipping processes, as well as being integrated with leading logistics and freight companies.

Access to real-time reporting on all aspects of supply-to-distribution processes gives management added flexibility for logistics planning and maximises cost effectiveness of shipping. It also improves inventory management efficiency by eliminating redundant labour processes associated with inventory shortages.

By switching to the cloud, manufacturers can reduce order-to-shipment cycle times by as much as 70 per cent; reduce delays and back orders by as much as 90 per cent; and reduce labour costs by as much as 40 per cent.

By automating processes such as order processing, fulfilment, shipping and collections, manufacturers can often accelerate their quote-to-cash cycles as well. Many businesses are able to create orders on the fly instead of keying them in manually, and have reduced the need for adjustment or rework due to fewer errors.

Leveraging an integrated cloud-based application, manufacturers can lower total cost of ownership by eliminating costs associated with onpremise solutions, particularly licence fees, onsite IT support and ongoing maintenance.

Its open architecture enables easy system integration with a manufacturer’s supply chain and enhances mobile productivity. It also delivers rapid implementation, lower costs and a quick ROI. By integrating all core manufacturing processes in a single, unified system—manufacturers are positioning themselves to replace complexity with fluidity, and educated guesswork with real-time transparency and execution.

These are the ingredients that will define success in today’s volatile markets and help manufacturers’ to achieve optimum delivery performance, reduced costs and improved efficiency.

[Mark Troselj is VP and general manager of NetSuite ANZ] NetSuite ANZ 02 9464 6100 www.netsuite.com.au Manufacturers’ Monthly SEPTEMBER 2015 33

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Materials HANDLING Narrow aisle electric forklifts TOYOTA Material Handling Australia (TMHA) has introduced a range of narrow aisle battery-electric reach forklift trucks that are designed to provide safe, reliable and comfortable operation for a range of applications.

The 8FBRE Series models add to Toyota’s range of 8-Series counterbalance battery-electric and internal combustion engine forklifts. Lifting capacities range from 1.2 to 1.6 tonnes with a maximum lift height of 8.5 metres.

TMHA national sales and product manager Jim Lobow said the new 8FBRE Series reach trucks provide a versatile option for companies looking for a simple, practical reach forklift that gets the job done safely and efficiently.

“Many of our customers carry out a range of tasks over the course of their working day. We see this new range of reach trucks being well suited to small to medium sized businesses who would typically use the forklift during a single shift operation,” Lobow said.

“Some of the key features include the degree of control on offer and the fast and smooth operation.

“All fork movements are made via easy-to-use fingertip control levers, the pedal layout is similar to what you’d find in a car, and the electronically controlled 180 degree or 360 degree steering provides easy and precise manoeuvrability.”

Lobow said another key advantage of the new 8FBRE Series reach forklift is the degree of adjustability and customisation available to operators.

“Ergonomically sound design is the basis for good operator performance,” he said.

“The seat and steering console are fully adjustable by the operator, and the height of the cab floor can also be adjusted to three different positions if required,” he said.

“Operators can also customise the settings for maximum speed and acceleration, automatic braking and steering sensitivity.”

As with all Toyota forklifts, the new 8FBRE Series includes a number of important safety features as standard, including PIN-code start-up, automatic parking brake, clear view mast and overhead guard, tilting forks (available as an option) emergency cut-off and electronic speed control.

“Another feature is the regenerative braking technology that transfers brake energy back into the battery to provide extended run times between charging and help reduce operating costs,” Lobow said.

Toyota Material Handling 1800 425 438 www.toyotamaterialhandling.com.au

Lifting capacities range from 1.2 to 1.6 tonnes.

Diesel & gas powered forklift range

The forklifts feature a roomy and refined operator’s compartment.

34 SEPTEMBER 2015 Manufacturers’ Monthly

MANITOU Group has expanded its industrial forklift range with the introduction of eight new models, ranging from 5T to 10T for diesel-powered trucks, and from 5T to 7T for gas-powered ones.

These new models feature a roomy and refined operator’s compartment. Access to the cab has been improved through the addition of a handle to easy step-up, and non-slip steps on both sides.

Visibility has been increased through the addition of a wide mast opening, an open-work roof and profiled rear pillars for reversing.

The forklifts integrate CUMMINS QSB 3.3L stage 3A (or 3B according to the regions) for diesel version and PSI 4.3L for gaspowered version.

The forklifts are also equipped with Powershift transmission for optimal reliability.

The standard inching function is intended to deliver a jerk-free approach and optimise duty cycle times. It also includes an endof-stroke braking function.

Manitou Group www.manitou-group.com

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2015-08-19T10:37:08+10:00

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IndustrialAPPS The latest manufacturing productivity apps Nothing provides manufacturers and engineers with more flexibility and optionality than mobile apps. Like their consumer counterparts, the number and scope of manufacturing apps is growing by the day and to cover all of them would be near impossible, so Branko Miletic has highlighted the following selection. They can be used on a variety of mobile devices and across many different industrial sectors.

Corrective Action Request – HACCP Mentor Mobile App iPhone, iPad Android, Blackberry, PlayBook Windows, Windows Mobile, Desktop A perfect replacement for unreliable paper forms, this app allows instant capturing of corrective action requests right from the facility and in real time.

Investigate a problem that has happened, get specifics about date reported, person responsible, non conformance issues, and more.

Add detailed information on corrective actions, and root cause analysis and resolution to prevent recurrence. Upload photo evidence easily from the app and capture signature for instant validation. www.gocanvas.com

Life Cycle Cost iOS LCC is often used for option evaluation when procuring new assets and for decision-making to minimise whole-life costs throughout the life of an asset. autolean.com/apps/ 36 SEPTEMBER 2015 Manufacturers’ Monthly

LuxCalc Fluid Prop I Mobile iOS LuxCalc Fluid Prop I Mobile allows users to quickly and accurately (within 5 per cent) calculate the thermophysical properties of common fluids found in heat transfer books for a user specified temperature.

• Adapted from most commonly used reference books including: – Fundamentals of Heat and Mass Transfer (Incropera/DeWitt/Bergman/Lavine) – Introduction to Heat Transfer (Incropera/ DeWitt) – Principles of Heat Transfer (Kreith/Bohn) • Thermophysical Properties Results include: – Density – Specific Heat – Absolute Viscosity – Kinematic Viscosity – Thermal Diffusivity

– Thermal Expansion – Thermal Conductivity – Prandtl Number • Trend plot of each of the eight properties • Metric and Imperial Units • Over 20 common engineering fluids (liquid and gas) • Intuitive, simple screen navigation www.luxea.com

mecalQ Lite iOS mecalQ Lite is a mobile application for mechanical engineers.

This application resides entirely on the local device and does not require network connectivity (except to email). mecalQ Lite has over 10 topics. Each topic contains one or more formulas. In each topic the formula expression is displayed with concise explanation of the terms involved.

Each formula can be computed. For inputting values for the formula, the option to enter values in alternative units is available.

For input variables that are properties, values can be auto-populated from a list of commonly used materials or contexts. It has options to add formulas to favourites.

Computed results can be emailed. Recently

viewed formulas can be accessed from a tab bar button. Formulas can be searched as well.

The full version mecalQ adds many more formulas, more units and more properties. www.calqulo.com/mecalq

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Finger CAD iOS FingerCAD is the first CAD application for technical drawing with fingers assisted by computer.

With FingerCAD you can draw houses, bridges, floor plans, mechanical components, geometrical figures, anything that can be designed with a common PC CAD. The design possibilities with FingerCAD are endless and can all be done comfortably seated, standing or on the go. The ease of use makes FingerCAD very useful and immediate.

The final project can be saved in the portable device using standard formats (e.g. .DXF, .PDF, .OBJ 2D and 3D), sent via e-mail, shared using modern cloud systems or printed.

The zooming and panning, the customisation of the design, the common CAD tools, the ability to include measures and free text, auto-saving, the ability to continue operations even in subsequent sessions of use (at boot FingerCAD automatically loads the project saved in the previous session of use) make it really unique.

Using the “time machine” feature you can go back in time and remove objects from last to first (also in subsequent sessions of work).

The UNDO and REDO will help you to restore the previous state if you make errors. Plus, the edit features (scale, rotate, move, copy, mirror, select, delete selection, transform, move the control points by dragging a finger on the screen) will help you to modify existing designs using your fingers.

The “automatic acquisition of the nearest snap points” will simplify the drawing of adjacent graphics objects and the function “2x-wall” will allow the automatic design of walls (double line with desired thickness).

You can draw the objects using different colours (using the infinite available colours selectable with the colour palette, the colour picker or the four RGBA components) or fill the surfaces with a colour. www.ngcybit.it/ manmonthly.com.au

HVAC Professional iOS HVAC professional formulator includes all 200 formulas of the HVAC Formulator and adds 18 charts, as well as the complete International Mechanical Code.

A future upgrade (free for current users) will add the International Energy Code.

HVAC professional formulator is recommended for heating ventilating and air conditioning professional. The “PRO” version includes charts covering everything from Chimney Clearance to Refrigerant Classification.

Sections include: Air Change, Airside, Boilers, BTU Conversions, Ductwork, Energy Values, Heating Design, Heating Requirements, Humidity, Loads, Pumps, Steam, Temperature, Waterside Systems, Conversions and Area Calculations.

Heating Design calculations include formulas such as: electric heating calculations, electric baseboard, Heat Tracing Cable, Gas Fired Radiant Ceiling formulas.

The program also includes conversions calculations and Area Formulas. www.multieducator.net/formulator/hvacPro.html

OEE Monitor iOS Version: 2.3 Continuous improvement starts with understanding your processes and key performance indicators.

If your organisation can’t measure performance, how do you decide on which problems to solve?

To help identify which problems to work on, you need a metric that considers uptime, productivity, and product quality. autolean.com/apps/

iMachining iOS iMachining is an iPhone App designed for machinists, technicians, engineers and student to be used as a machining calculator and also a reference tool for a drilling, milling and turning (lathe). It is designed to be user-friendly at shops.

Features: • Turning (Lathe) – Calculate RPM given Cutting Speed and Cutting Diameter – Calculate Cutting Speed given RPM and Cutting Diameter – Calculate Machining Time given Cutting Length, RPM and Feed/Turn – Metric and Imperial units (mm, inch) • Milling – Calculate RPM given the Cutting Speed and Tool Diameter – Calculate Tool Feed Rate given Feed/Tooth, Tool Diameter and number of tool teeth – Calculate Machining Time given the Feed and Cutting Length – Metric and Imperial units (mm, inch) • Drilling – Find RPM given the Cutting Speed and Tool Diameter – Find Feed Rate given the Cutting Feed (inch/rev) and RPM – Find Machining Time given the cut length and feed rate – Metric and Imperial units (mm, inch) • Reference Tool: Tap Size Charts – Interactive tap size charts – Fractional, Screw Size and Metric Standards – Coarse and Fine threads • Reference Tool: Drill Size Charts – Interactive drill size chart – Fractional, Letter, Wire Gauge and Metric Standards – Drill Size in mm and inches • Reference Tool: Machining Parameters – Interactive machining parameter charts for cutting speed and feed rates for different materials – Machining parameters for different tool materials: HSS and Carbide – Feed rates for milling and turning – Selection between metric and imperial units www.motionics.com Manufacturers’ Monthly SEPTEMBER 2015 37

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Industrial APPS 5S Audit

Manufacturing 360

Mechanical Engineer

iOS Version: 2.3 If you have identified that housekeeping deficiencies are causing inadequate performance then your organization should implement 5S. AutoLean’s 5S Audit app is the best way to benchmark your 5S performance. Ideal for manufacturing areas, offices, and work sites. autolean.com/apps/

iOS Version: 3.0 MFG 360 lets you experience digital manufacturing in an interactive factory environment.

Learn how to compete more effectively with next generation manufacturing technology, including advanced robotics and logistics simulation, closed-loop quality solutions, and the latest CAD/CAM software.

See how Tecnomatix and NX for Manufacturing can enable you to: • Create leaner, more flexible processes • Maximise performance of resources • Hit quality and schedule targets The digital manufacturing solutions from Siemens PLM Software let you run a more efficient and nimble business. community.plm.automation.siemens.com

iOS Mechanical Engineer, part of MultiEducator’s iPhone “Formulator” Line, is the perfect tool for any Mechanical Engineer or engineering student.

This app contains over 300 important mechanical engineering formulas, there are over 300 additional conversion formulas in the program as well as 70 area formulas.

Major areas covered in the program now include: Actuators Bearings, Belts, Boiler, Brakes, Clutches, Elevators, Gears, Fluid Power, Heat Transfer, Internal Combustion, Kinetic Energy, Metalworking, Plates, Plumbs, Power Plants, Refrigeration, Shafts Springs and Vehicle Drive.

All formulas can be saved. You can access recent or favorite formulas. You can also e-mail the results of any formula. www.multieducator.net/formulator/Mechanical.html

Takt iOS Version: 2.3 Don’t have a pulse on your manufacturing process?

Takt is a universal iOS app for iPhone and iPad that will allow you to quickly and effectively calculate takt time.

Kanban Size

autolean.com/apps/

Basic Order Form App iPhone, iPad Android, Blackberry, Windows Mobile, Desktop Make ordering easy for both of you with our basic order form.

Walk-in, online, or by mail, track the orders you receive and fill.

The basic order form includes customer contact information, shipping address and method, date, and an itemised list of goods ordered with cost, tax, shipping, and the grand total.

The Excel version computes the item cost, tax amount, and total automatically. www.gocanvas.com 38 SEPTEMBER 2015 Manufacturers’ Monthly

iOS Version: 2.3 A kanban calculator used to determine the ideal bin quantity of units within the kanban.

Great for any manufacturing process.

Safety Inspection-Lockout and Tagout Mobile App

autolean.com/apps/

Economic Order Quantity iOS Version: 2.3 Calculate economic order quantity to minimise total inventory holding costs and ordering costs. autolean.com/ apps/

iPhone, iPad, Android, Blackberry, PlayBook Windows, Windows Mobile, Desktop Lockout and Tagout is a safety procedure which is used to ensure dangerous machines are properly shut off and not started up again prior to the completion of maintenance or servicing work. It requires that hazardous power sources be “isolated and rendered inoperative” before any repair procedure is started.

This app helps you make sure your workers have a clear process for dealing with dangerous machinery. This app comes with date, time and signature capture, and can be easily customised to meet your company’s needs. www.gocanvas.com manmonthly.com.au

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2015-09-11T11:33:00+10:00

TechREVIEW Tough tablet pushes the boundaries Panasonic has a pedigree of ruggedised electronics – their Toughbook laptops are the stuff of remote mining site lore. Branko Miletic reviews the latest addition to this range, the Panasonic FZ-G1 Toughpad Tablet and finds that tough is as tough does, albeit with a few sensitivity issues.

The overview The Panasonic FZ-G1 Toughpad Tablet comes from the same stable as all of Panasonic’s toughened computing range. In fact, to prove (or disprove) this, I pulled out the heavy artillery: A 10-year old who thinks computers are to be trodden on, a small dog that like to chew on everything within snout’s reach and a backyard filled with strategically-positioned really big rocks.

The first part of the test – and in fact the main part if you consider what the FZ-G1 Toughpad Tablet was designed for - was to see just how tough this piece of hardware actually was.

So after two weeks of abusing the tablet with everything that gravity could muster, I followed up this testing with some more ‘hard surface impact experiments’ as I called them.

Even exposure to water and mud does not seem to bother this tablet – which is more than can be said for some of its competitors.

In other words, the FZ-G1 Toughpad Tablet was thrown from a 1+metre height onto hard surfaces over and over again. Thanks to its magnesium alloy chassis encased with ABS and elastomer corner guards, raised bezel for LCD impact protection, MIL-STD-810G specs and all-weather IP65 dust and water-resistant design, the result though was as expected and it passed with flying colours.

The specifications The 10.1” Toughpad FZ-G1 Windows 8 Pro tablet runs Windows 8 Pro 64bit. Powered by a Gen 3 1.9 GHz Intel Core i5 v Pro Processor, the tablet also has an HD daylight-readable screen, 4 GB HD and boasts a USB 3.0, a USB 2.0 and10/100/1000 Ethernet ports.

From a user point of view, the near 8-hour battery life is ably complimented by the Panasonic Partition Recovery functionality on the HD manmonthly.com.au

everything a mobile tablet should be but encased in a strong magnesium alloy cocoon.

The only downside was the sensitivity of the screen, which was less than that on an iPad. However, the caveat here is that this is the tradeoff for all that extra toughness. While it was a bit ‘sticky’ when it came to swiping, the function of Panasonic’s Toughpad Tablet is not be sensitive to petite little fingers but rather to survive big physical shocks.

The rating The Panasonic FZ-G1 Toughpad Tablet. which means it can be used for long periods of time and if a problem does a occur, it can be utlilised to reboot the entire system.

And it also has a stylus-type pen, which while I don’t particularly like to use, was quite useful for quick clinking from screen to screen.

All up, the tablet is as functional as any common tablet running Windows 8 with all the features of a Windows-flavoured machine.

audio combined with a vanilla-style speaker.

MA 0 9 1 5 _ 0 0 0 _ P E A Overall, the Toughpad FZ-G1 was

• Ease of use: 4/5 • Speed: 4/5 • Battery Life: 3/5 1• Functionality: 2 0 1 5 - 0 84/5 - 2 4 T1 0 : 5 4 : 0 1 + 1 0 : 0 0 • Overall Rating: 15/20

The results Starting up was fast and easy. Connection to my home Wi-Fi was as seamless as with any other device and navigating around the computer was as straightforward as any Windows device was meant to be.

Launching applications went smoothly and using the mobile device for both browsing and various other standard PC activities was almost instantaneous.

The ability to play music, videos and other multimedia comes standard with this tablet, while other options such as a GPS and microSD slot are available at extra cost.

For those that want to connect their Toughpad FZ-G1 to an AV device, [which was not tested] there is an HDMI port, integrated microphone and Realtek high-definition Manufacturers’ Monthly SEPTEMBER 2015 39

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What’sNew Roller door opener WEATHERDRIVE, a roller door opener from Merlin offers enhanced weather protection and energy efficiency, as well as product design and safety features.

Compliant with Australian and New Zealand standard AS/NZS 60335-2-95, the product has IP34 (Ingress Protection Rating) rated housing.

This measures the level of protection that electrical appliances provide against the intrusion of solid objects, dust, water and accidental contact.

In comparison, most comparable products currently have a rating of IP24.

Design is also a key consideration for Merlin’s The product comes with two research and development team. The slim model keyring remotes and one can be installed in a variety of shed types; requirwireless wall control button. ing a minimum side clearance of only 40 millimetres. The roller door opener has extensive safety features including nine ultrabright LED lights fitted in the opener to ensure visibility at all times, and a dual speed facility for greater performance and control. The automatic safety reverse function also means the door will stop automatically if obstructed.

In addition to being compliant with Australian standards, it offers a host of security features including an E lock system which allows users to lock the control panel buttons.

Merlin MA 0 9 1 5 _ 0 0 0 _ S I E 2 2 2 0 1 5 - 0 8 1800 - 2 638 7 T234 0 9 www.gomerlin.com.au

40 SEPTEMBER 2015 Manufacturers’ Monthly

Oil-free compressor with HST WITH the development of its new high-speed turbo (HST) technology, Boge is ushering in a new era of compressed air.

The company is achieving decisive improvements compared to the current state of the art by radically reducing the number of components and introducing an intelligent design principle.

With innovative turbo drive, the compressors produce 100 percent Class 0 oil-free compressed air – at the highest degree of efficiency and with minimal maintenance effort. Cost savings of up to 30 percent compared to conventional oil-free screw compressors are realistic.

The compressors are driven by a permanent magnet motor, which is characterised by a very high energy density.

In addition, the company has succeeded for the first time in using air-lubricated bearings in the drive shaft – which is The HST 110 compressor. a prerequisite for extremely high speeds of up to 120,000 rotations. Whether as a base-load or peak-load machine, the compressors are recommended for users who need a continuous supply of oil-free, high-quality compressed air.

The advantages of HST compressors can particularly be utilised in sensitive production areas such as the chemical, pharmaceutical, food, beverage and semiconductor industries, as well as in refineries, breweries and paint shops. There is also the option of attaching a heat recovery system, which uses the heat expended by the compressor for service water heating or space heating. The company intends gradually expanding the series.

Boge Compressors 03 5940 3266 : 4 5 : 2 9 + 1 0 : 0 0 www.boge.net.au

manmonthly.com.au

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Brought to you by

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Suitable for flush cleaning or burst rinsing and where hygiene, purity and efficiency are needed.

Spray head range THE re-designed Turbodisc range, available from Tecpro Australia, has several changes, aimed at improving efficiency, performance and long-term reliability.

The tank washers are suitable for small and medium process vessels, reactors, driers, granulators, storage tanks, tablet coating machines and IBCs. Constructed with high precision, they contain only one moving part which rotates freely on a hydraulic bearing to produce a dense spray of fast moving droplets.

The range MA 0 9 has 1 5a _sleek 0 0design 0 _ Kand EL improved backwash action that minimises

wash pattern interference and ensures purity and an ultra-hygienic clean by allowing no product to settle on the cleaning head.

There is a wide choice of models in 316, 316L stainless steel and Hastelloy C22, and is also available in chemical resistant, ATEX Certified carbon filled PTFE. With only one moving part, wear and tear is negligible and no replacement parts are necessary.

Tecpro 1 2 0 1 5 - 0 8 - 2 1 T 1800 1 4 :832 0 776 7 : www.tecpro.com.au

SCHNEIDER Electric has unveiled its new engineered-to-order Altivar Process Drive Systems, which include a new and innovative technology for lower harmonics.

The low-harmonics concept is based on 3-level technology that reduces the total current distortion factor THD to less than 5 per cent (in accordance with IEEE 519). A standard design compatible with traditional harmonic solutions is also available.

The common mode structure reduces voltage ripple and peaks, reducing stress on the motor’s insulation and bearings and extending motor life. The offer also includes dV/dt output filters as standard, ensuring the motor is well protected from harmful voltage effects.

The 3-level technology results in internal filter components that are much smaller than the conventional 2-level low-harmonic technology, allowing the Drive Systems to take up less space. During development, attention was paid to the simplicity of installation and operation. The result is a System 0 Drive 4 + 1 0 : 0that 0 is ready to connect, while fulfilling harmonic distortion requirements.

The drive systems are ready to connect.

The drive systems meet power needs of 110-800 kW at 400V, with plans to extend this to 1500 kW. Engineering starts with a base model, which includes standard equipment and is ready to connect.

The modular construction makes it possible to adapt the enclosure unit to individual requests. They are “services-orientated”.

The embedded ‘Internet of Things technology’ enables improvements to customers’ businesses through automation, real-time data management and connectivity for process performance, energy, and asset management.

Schneider Electric 1300 369 233 www.schneider-electric.com

Contact us for a FREE catalogue!

manmonthly.com.au

Manufacturers’ Monthly SEPTEMBER 2015 41

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The last WORD Safer, simpler robots The first company to release a ‘co-bot’, Universal Robots continues its expansion. Brent Balinski spoke to the company’s co-founder, Dr Esben Østergaard.

Lego, robot soccer and pepperoni The current market leader in the booming “collaborative robot” category celebrates its 10th anniversary this year.

Commanding a claimed six-tenths of the market, the Danish-headquartered Universal Robots’ (UR) goal is to get as many robots into as many factories as possible.

However, this wasn’t something co-founder Dr Esben Østergaard, who built his first robot out of Lego at age 4, grew up wanting to do.

“I think a lot of different research projects came together,” he told Manufacturers’ Monthly.

The development of a robot designed to be safe to work next to (the arms stop if met by a pre-set level of Force) and easy to set up was influenced by three major projects, starting with robot soccer. Østergaard’s passion is robot soccer, and he was a member of the Danish world champion team in the 1998 Federation of International Robot-soccer Association event, the FIRA cup (KheperaSot category).

Involvement in RoboCup Junior competitions – where children compete – gave an insight into how to make programming simple.

After this, his PhD involved a very complex transformer robot project involving 100 identical modular robots, which could self-assemble and form different structures.

“These were highly integrated machines with electronics, computing, actuation, communication and coordination very much built into the robots themselves,” he explained.

And thirdly, he and the two other UR co-founders were approached by the Danish government to find a way to get more automation into the food and beverage industry. Automating tasks such as putting pepperoni on a pizza were then only achievable via a half-tonne factory robot.

The trio set about creating a smaller, simplerto-use solution, which could easily be moved and reprogrammed.

The idea for a business came about in 2004.

This launched in 2005, and its first unit was sold in 2009. Revenue has roughly doubled every year in the six years since. UR predicts it will move between 9,000 and 10,000 robots in 2017.

“We are approaching 300 a month now,” Østergaard said of sales.

Not just for car factories In Australia, Universal announced its third local partnership in June (Andrew Donald Design Engineering), after launching only last year.

42 SEPTEMBER 2015 Manufacturers’ Monthly

Østergaard believes Universal’s 3, 5 and 10 kilograms payload robots are a natural match for the local SME scene.

“I’m not an expert on Australia but they could match very well with the culture,” he said.

“Especially for the small companies, they really appreciate being able to use the robot on their own.”

Dr Esben Østergaard believes Universal’s 3, 5 and 10 kilograms payload robots are a natural match for the Australian SME scene.

The stated aim of Universal, as with the other businesses that have sprung up in the category, is to lower the barrier to automation. In previous times, robots had been limited to heavy industry, led by carmakers (which are still the leading buyers of factory robots).

“The existing robots came from the automotive industry, where there [were] seven-day, three-shift operations, 24 hours a day for seven years running – and not a lot of adjustment,” said Østergaard.

“And if there’s adjustment, these companies can afford to have specialists in-house.”

And where traditional robots are heavy, dangerous and generally caged off, the newer breed of machines are tools for the hands of workers.

Pitching robots in such a way also helps nullify the argument that robots are there to steal jobs.

“You kind of take away that discussion, because nobody says that an electric screwdriver steals jobs,” said Østergaard.

“Even though it actually does, because you can screw in more screws with an electric screwdriver.”

An area where lightweight robot arms are being increasingly used is machine tending, enabling a factory to get more use out of, say, a CNC milling unit.

“So you can have the same machines working all night and then during the day [have] a little bit more flexible operations,” added Østergaard.

There are differing opinions on how much the newer category of industrial robots will grow in future, and what addressable market there is.

This year has seen established industrial robotics companies, such as Fanuc and ABB, enter the co-bot market. The sector is worth $US 100 million and expanding about 50 per cent annually, according to Teradyne, the NYSE-listed company that acquired Universal for $US285 million in May. Østergaard said there is also a community of third-party contributors emerging to offer add-on products, such as grippers.

“One company is making raincoats for the robots so they can work in harsher environments with water, and other things like this,” he said.

“There’s definitely an enormous potential for innovation and for start-ups.”

Teradyne predicts a sector worth $US1 billion by 2020. Robotics Business Review reports estimates of $US1.85 billion (Myria Research) and an even more bullish $US3 billion (Barclays) for the period.

Talkin’ ’bout a revolution There is capacity in UR’s Denmark factory, which it moved into last year and which can produce around 150 robots a day, to expand. Østergaard believes the company is part of another industrial revolution. Up to Industry 4.0, every industrial revolution has taken away the human touch of production, he noted.

Pre-the original industrial revolution, an artisan would make every item bespoke for a customer, whom they may have personally known. Everything was personalised and hand-made with care.

“But this kind of passion in the products has kind of been lost through the industrialisations,” he offered.

“So I definitely see a need to close this gap again, and by making machines that are usable by people on the factory floor, we can have the potential to close that gap again.

“And that’s one of the things I think is really important to look at in the future. So you can kind of say it’s the beginning of the fifth industrial revolution. I hope it is at least.” manmonthly.com.au

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