Manufacturers' Monthly February 2012

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961

February 2012

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The right level measurement for your application

INSIDE Recruitment & Training >> Motors & Drives >> Test & Measurement Design Innovation >> Warehousing >> Automation & Robotics Industry Opinion >> New Products >> Manufacturing Events

10 MINUTES WITH MIKE DEVEREUX >> Does Holden have a future in Australia?

Holden's MD talks.

Servicing the Manufacturing Industry for 30 years Hydraulic and Industrial hose and fittings 90 Service and Supply Centres Australia wide National fleet of 320+ fully stocked mobile service workshops Rapid response time, 24 hours 7 days All Service and Supply Centres ISO9001:2008 accredited NATA certified hose testing facility Registered training organisation Nationally accredited and certified technicians National pricing policy

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Inside FEBRUARY 2012

For daily news visit manmonthly.com.au

8

4 Editorial ■

Should automotives be saved?

Holden Australia’s managing director speaks about the likely effects of the carbon tax and the future of the Elizabeth plant.

6 Comment ■

Save energy with combustion analysis techniques.

34

8 Analysis News ■ ■ ■ ■

10 minutes with Mike Devereux (image, right).

Manufacturing job vacancies.

Technology key to Endeavour Awards.

Australian food manufacturers take steps to stay on shore.

12

14 Skills & Training ■ ■

Industry’s future in young hands.

Industry urged to improve talent retention.

28 Motors & Drives ■ ■

18 Design Innovation ■ ■

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3D printers a boom for designers.

Twelve years of business growth; one ERP solution.

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Products to boost output.

Test and measurement. manmonthly.com.au

ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961

February 2012

The right level measurement for your application

INSIDE Recruitment & Training >> Motors & Drives >> Test & Measurement Design Innovation >> Warehousing >> Automation & Robotics Industry Opinion >> New Products >> Manufacturing Events

10 MINUTES WITH MIKE DEVEREUX >> Does Holden have a future in Australia?

Holden's MD talks.

Reducing operating expenses.

High-power drives.

Geared motors for rolling mills.

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CMM raises the bar for forging dies.

Portable linear, gantry milling machines.

Fixturing table for welding accuracy, speed.

38 Automation & Robotics

34 Metalworking & Machine Tools

22 What’s New

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Publisher Michelle Graves michelle.graves@reedbusiness.com.au Group Editor Sarah Falson Ph: (02) 9422 2480 Fax (02) 9422 2722 sarah.falson@reedbusiness.com.au Deputy Editor Annie Dang Ph: (02) 9422 2964 Fax (02) 9422 2722 annie.dang@reedbusiness.com.au Editor-at-large Alan Johnson Ph: (02) 9422 2325 Fax (02) 9422 2722 alan.johnson@reedbusiness.com.au Graphic Designer Ronnie Lawrence ronald.lawrence@reedbusiness.com.au Creative Director Julie Coughlan Production Co-ordinator Mary Copland Ph: (02) 9422 2738 mary.copland@reedbusiness.com.au VIC/Overseas Sales Michael Northcott PO Box 3069 Eltham VIC 3095 Ph: 0448 077 247 michael.northcott@reedbusiness.com.au NSW Sales Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Ph: (02) 8011 3184 Mobile: 0414 644 664 anthony.head@reedbusiness.com.au QLD Sales Sharon Amos PO Box 3136, Bracken Ridge QLD 4017 Ph: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 sharon.amos@reedbusiness.com.au SA/NT & WA Sales Reed Business Information Ph: (02) 9422 2368 anthony.head@reedbusiness.com.au

Machine vision boosts productivity.

Regulatory compliance technology.

Evolving automation systems.

42 Materials Handling ■

Layer picker works a treat.

Behind the cover IFM’S new O3D Level Sensor uses an array of sensing elements to indicate true level. It is designed to evaluate size, shape and level in a range of applications. The compact, easy-touse sensor uses time-of-flight distance measurement to identify an object in its field of view and captures the entire object in three dimensions. The sensor is mounted above the product, monitoring the entire area of a hopper or

conveyor, versus a single point. It then averages out the ‘hills and valleys’ to provide accurate induction of level.

The sensor can be used indoors and outdoors with no impact from external ambient light. It can improve uptime in a range of processes and is the new benchmark in performance and value. ifm’s O3D Level Sensor will help improve your operation. ifm efector 1300 365 088, sales.au@ifm.com

sales

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Manufacturers’ Monthly FEBRUARY 2012 3

Editorial

SARAH FALSON – Editor

editor@manmonthly.com.au

Hail the shiny yellow vest The car industry has been given a new lease on life, with funding securing jobs for years to come – and it’s not just because our PM fancies herself in a yellow vest.

T

HE Australian government has pledged $34 million of its Automotive Transformation Scheme to help bail-out car manufacturer Ford and its local Broadmeadows operations. The sum makes up part of a $103-million-injection into the Falcon and Territory SUV production lines; the remainder is coming from Ford’s headquarters in Detroit.

The government is saying the plan will ‘safeguard’ Ford until 2016, creating an extra 300 jobs in production and R&D. The workers are obviously stoked, since just before Christmas there were rumours of job cuts across the board.

But some taxpayers don’t seem very jolly. ‘Let manufacturing die!’ they cry. Our Manufacturing Minister has been dodging some pretty hairy questions from the media, suggesting that Australia can’t support the funding in the long-term, and if automotive manufacturing is struggling, then shouldn’t we just let it die naturally (or put it out of its misery)?

Senator Carr and the Prime Minister actually struggled pretty hard to get that funding, and I’ll tell you why: the car industry employs 46,000 Australians, and another 230,000 jobs rely on it.

Carr and Gillard trecked over to Detroit, to plead with the big

4 FEBRUARY 2012 Manufacturers’ Monthly

Julia Gillard visiting Holden’s Elizabeth site when the Cruze was launched last year.

guns at Ford and General Motors to provide more funding for their Australian operations – and they got it. Well, they got it from Ford, and apparently they’ll get it from Holden too, within the month.

They told the US execs that the Australian government would also put its money where its mouth is, because car manufacturing is really that important.

Correct me if I’m wrong, but didn’t they do a good deed here?

There are only 13 countries that build cars from the ground up, and we’re one of them. It’s actually pretty tough making cars – you need a lot of skilled people, a lot of new technology and a lot of other car manufacturers

around you so that your supply chain costs don’t hit the roof.

We’ve done OK for the last 100 or so years – we’re just going through a tough run right now.

So why are automotives suddenly not worthy of being saved?

When the government forked-out for the textiles, clothing and footwear (TCF) industry, people cheered. The poor TCF sector was (is) on its knees and government funding helped some of those companies pay for new capital equipment, re-think their production lines and their capabilities, put plans in place to become more environmentallyfriendly, save some energy, and ultimately gear-up to take-on the

big leagues in China.

Maybe it’s all a matter of perception. Maybe, more Australians felt sorry for ailing TCF manufacturers because many of them are family-owned – and none of our automotives are. But think about all the families of all those factory workers whose husbands, wives, brothers and daughters will still have a job in four years.

That’s a pretty good deal; I’d be happy with that.

Taxpayers should be able to appreciate what’s just happened here. Any funding that will help keep skilled people in the country is good. And according to Senator Carr, the average Joe won’t even notice the cost; no more than a football ticket, he said, whereas in the US each person is paying more like the cost of a week’s rent to prop-up their automotive industry.

It’s a positive move to help manufacturers and Australia should be grateful (especially after what the government did to stick us with the carbon tax).

Now, if only the Opposition would get on-board and both sides would stop arguing about who is wearing a yellow vest, are they wearing the vest for the right reasons, and who is ‘hanging up’ said yellow vest. Because giving money is one thing, but being honestly concerned about the future of manufacturing is about more than just a vest.

But alas, I’d probably have better luck rallying the TCF manufacturers to get into the shiny yellow vest business – it’s booming at the moment.

manmonthly.com.au

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Comment

PAULA HOLLYWOOD – ARC Advisory Group Senior Analyst

editor@manmonthly.com.au

New technology to save you energy Improved combustion analysis techniques can reduce energy consumption.

W

HILE energy prices continue to fluctuate, energy remains the second leading cost pressure (behind only raw materials) currently affecting most manufacturers.

Some of the biggest culprits are incinerators, crackers, process heaters, and other energy-intensive combustion equipment.

The harsh operating conditions associated with combustion analysis applications can eat up a sensor in no time, resulting in inaccurate and unreliable sensor measurements. This can make it nearly impossible to control these processes adequately.

However, new analysis techniques, such as tuneable diode laser spectroscopy (TDLS), can improve efficiency, maximise throughput, reduce emissions, and improve safety in combustion analysis applications.

6 FEBRUARY 2012 Manufacturers’ Monthly

Most energy-intensive operations experience considerable variability in energy consumption due to changing operating conditions, equipment degradation, fluctuating market conditions, and inefficient control strategies. As a result, plants typically consume more energy than necessary, yet are unable to improve efficiency due to the inability to collect and analyse real-time performance data.

Tuneable diode laser spectroscopy (TDLS) contributes to a ‘triple bottom line’ strategy by helping increase throughput and reduce energy costs, while supporting safe and environmentally responsible operations.

Advanced process control systems require sensitive and accurate process measurements in real time, or near-real time. APC reduces process variability and

inefficiency, improves product quality, and provides for more stable operations. With few exceptions, current process analytical techniques lack the speed, accuracy, and sensitivity to provide reliable measurements for APC. On-line optimisation goes beyond advanced control to optimise a process based on an economic objective function.

Historically, obtaining reliable quality measurements in time to impact control has been an issue in combustion control applications. The current best practice utilises a Zirconia sensor for point measurement of oxygen. In applications requiring multiple measurements, point measurement cannot provide a representative sample, making it errorprone and potentially dangerous.

Inefficient combustion can be attributed to the air/fuel ratio.

Too much excess air (air rich) results in loss of efficiency and increased NOx emissions, while too little excess air (fuel rich) is downright dangerous. Carbon monoxide measurement provides an indication of fuel-rich conditions, while oxygen measurement indicate air-rich conditions. The optimum control point is the lowest possible excess air value that does not cause the system to enter into an unsafe condition or violate emissions limits.

TDLS enables high-performance measurements in real time, even in challenging process environments. Exact performance specifications may vary somewhat according to supplier; however, the benefits are universal.

To date, the most widely reported application of TDLS has been for combustion control. However, the technology potentially offers much wider applicability. phollywood@arcweb.com

manmonthly.com.au

EFIC DID MORE THAN FINANCE OUR EXPORTS

THEY TOOK US TO THE NEXT LEVEL. Michael Lavis, Managing Director, JML Engineered Facades Pty Ltd

Winning another contract in the Middle East was an exciting step for our business. After working on the Dubai Airport we won the contract to manufacture the glass façades on the Doha International Airport. However our bank required full cash cover for the million dollar bond demanded under this latest contract – locking up valuable funds that could otherwise be used on other business ventures.

So we turned to EFIC for support. EFIC focused on what it would take for us to succeed. They were able to draw on their relationships with international banking networks to establish a structure for a local bank in the Middle East to issue a bond to us in Qatar, secured with a guarantee by EFIC. EFIC’s assistance allowed us to use our capital to keep expanding our operations while fulfilling a key contract that helped us gain an even stronger position in the Middle East.

Overcoming financial barriers for exporters.

Visit efic.gov.au/mm

AnalysisNEWS 10 minutes with Mike Devereux

BY SARAH FALSON

FEBRUARY 27–28: Integrated Planning and Optimisation Summit 2012 Schneider Electric and SolveIT Software’s Adelaide Summit focuses on effective, enterprise-wide decision support and addresses integrated planning and optimisation. www.IPOS2012.com

T

HE future of Australian car-makers has been a hot topic of conversation in manufacturing circles this past month. We spoke with Holden Australia managing director Mike Devereux about the likely effects of the carbon tax, the future of Holden’s Elizabeth plant and its employees, and asked whether the mining and manufacturing industries could co-exist.

Q. What is the best thing about being MD of Holden?

Holden is one of those great iconic Australian brands. I travel across the country in my role meeting a variety of people, and more often than not people have a Holden story or memory to share. Holden is an ingrained part of Australian culture. As managing director, I get to come to work every day to lead this brand and its people, and that is something I am very proud of.

Q. Is GM impressed with Holden’s Australian operations?

We have regular visits from our GMIO leaders. GMIO president, Tim Lee, visited recently and shared with me how impressed he was with the level of engagement our people have in our business.

Q. How much time do you spend in Elizabeth?

I am at our Elizabeth site regularly. We host monthly business meetings with the Holden leadership team at the plant.

Q. What is the one asset that the Elizabeth plant couldn’t live without?

Without a doubt it is our people. We have a team of about 2,500 employees onsite at our manufacturing operation in Elizabeth. Every day and with every car that goes down the line, our people are the defining part of the process ensuring that we are building the best cars for Australia and the world.

Q. Last year you raised the number of units coming off your production line. How many are 8 FEBRUARY 2012 Manufacturers’ Monthly

EVENTS

Holden is absolutely committed to manufacturing in Australia: Devereux.

you producing now?

For a plant our size and building the cars we do, I have been on the record stating that an annual output of about 100,000 units is ideal.

As a business, we have been able to set our operations up in a way that we are able to adapt to what customers are telling us they want. As of the end of October (2011), we currently are building at Elizabeth two of the top five highest-selling cars in Australia.

Q. Recent media reports claim the carbon tax could force Holden to re-think its Australian operations. Is this true?

Holden is absolutely committed to manufacturing in Australia.

Q. Holden received a lot of support (government and trade unions) for the Cruze. Is the Government doing enough to support other manufacturing sectors?

In October, Prime Minister Gillard and Senator Carr announced a new Manufacturing Taskforce of which I have been invited along with other industry and union representatives to be a member of.

As outlined in the government’s media release, the highlevel Taskforce will map out a shared vision for the future of Australia’s manufacturing sector

and help strengthen local firms as they adapt to changes in our economy, including the rise of Asia.

Q. Do you think the mining and manufacturing industries can co-exist?

Absolutely. The Australian economy needs a diverse range of industries and trade to ensure that as a nation Australia continues to develop its skills base and enhance the economy.

Q. Which Australian manufacturers do you admire, and why?

I have great admiration for any Australian manufacturer that has been able to innovate and prosper in the face of the challenging conditions manufacturing has experienced in recent years.

Q. Which kind of Holden do you drive?

While my family car is a HSV, I am lucky in that I am able to drive and evaluate vehicles from across our portfolio. Recently I have spent some time in our new SRi-V 1.4-litre iTi Cruze and thought it was a fantastic car.

It has great fuel economy, is well specified and it was really fun to drive.

My wife drives a Holden Captiva as she often has a lot of cargo and the kids in the car and its versatility and value is unmatched.

Holden Australia 1800 033 349, www.holden.com.au

27–29: Introduction to Instrumentation and Process Control (HART) Professional Development Course This practical course at the University of Sydney will provide a basic background on the role of instrumentation in maintaining a stable and controlled process. www.cce.usyd.edu.au/course/iipc 29: Vision 2020 Series This inaugural series in Melbourne includes Australian and international leaders who present and discuss major issues, trends, scenarios and challenges that affect their industry sectors. www.ausinnovation.org

MARCH 6–June 7: Rockwell Automation On The Move Visitors in Melbourne, Sydney, Brisbane and Perth will experience new technologies, products and services and talk to industry experts in automation, process control and safety solutions. Incorporates the Safety Automation Forum. au.rockwellautomation.com 6–8: Occupational Health and Safety Summit The Queensland Summit will cover day-to-day business safety, future predictions, new legislations, and new technology. www.ohsstrategy.com.au 14–15: Boilers & Burners Forum 2012 The Melbourne Forum will include small to large boilers and burners with a focus on selection, safety, legal obligations and additionally, the nuts and bolts of boiler and burner design. www.idc-online.com

manmonthly.com.au

Business advice brings 40% boost

BY FIONA SIMMONS

ECOYA is an Australian home fragrance and body care business based in Sydney. The company uses only natural, sustainable, environmentally-friendly ingredients in its 'eco-luxe' products.

Ecoya’s owner, Craig Schweighoffer, was looking to grow Ecoya into a $30 million business in five years by developing its export market and growing local share. This was achievable, however Ecoya had to revaluate its processes, technologies, manufacturing and services.

“Our ‘hand made’ approach was no longer meeting demand.

We had no spare resources to investigate alternative machinery or develop in-house solutions,” said Schweighoffer.

The company was referred to Enterprise Connect business adviser, Terry O’Riordan.

“The business needed to significantly ramp-up manufacturing and consider automating, innovating and improving process flow,” explained O’Riordan.

O’Riordan connected the team with the Technology and Knowledge Connect service, which identified a number of potential design partners. He also encouraged Ecoya to apply for Enterprise Connect’s Tailored Advisory Service.

“Through the Tailored Advisory Service we contracted Coleby Process Consulting to assist in production capacity planning, risk assessment and designing a production layout plan for our new premises,” said Schweighoffer.

Ecoya moved its premises, revised its layout and installed new automated equipment and machinery. Productivity growth has increased 40% and sales

Is it possible... for local manufacturers to access the world’s leading travel management company?

Ecoya had to re-think its production process, moving from hand-made beauty products to an automated process using machinery.

turnover from $10 million to an estimated $16 million this financial year, exceeding expectations. The Ecoya team has grown from 25 to over 60 staff, and has expanded its export market to the USA, UK, Asia and the

Middle East.

[Fiona Simmons is Enterprise Connect’s project officer – program management and communications.]

Enterprise Connect 131 791, www.enterpriseconnect.gov.au>>

Yes it is.

After a year long journey, FCm Travel Solutions has been awarded the title of the World’s Leading Travel Management Company at the 18th World Travel Awards in Doha.

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1300 558 041 fcmtravel.com.au Better travel ideas. Greater savings.

Australian OpCo Pty Ltd (ABN 20 003 279 534) trading as FCm Travel Solutions. Licence numbers NSW 2TA002547, VIC 32360, ACT 18800566, QLD 3124259, SA TTA192799, WA 9TA1362, TAS TAS160, NT LTA149.

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Manufacturers’ Monthly FEBRUARY 2012 9

AnalysisNEWS

Technology key to Endeavours RECOGNISING the crucial role new technology plays in our industry, SMC Pneumatics Australia has signed-on as sponsor of the Technology Application of the Year award at the 9th Annual Manufacturers’ Monthly Endeavour Awards.

“For over 50 years, SMC have focused on one simple strategic corporate goal: to be the world’s leading manufacturer of pneumatic equipment and automation components,” said SMC Pneumatics Australia national marketing manager, Peter Newfield.

“We have built our marketleading position through innovation and client engagement.

Today, with more than 11,000 core products and in excess of 600,000 product variations, we are able to offer one of the broadest ranges of pneumatic and automation solutions available in the market.”

The Endeavour Awards program was designed to recognise companies and individuals for

MILLIONS

Peter Newfield – national marketing manager, SMC Pneumatics Australia.

BY SARAH FALSON

their contributions to moving Australian manufacturing forward. In 2012, the Technology Application of the Year category will reward a local company for the successful application of new technology in its manufacturing process.

“While we work across many industries in Australia, the manufacturing industry is a key sec-

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Industry job vacancies at highest level

tor for our business. Like us, our partners in the manufacturing sector value innovation and through the deployment of our technology, are creating value to their businesses on a daily basis,” said Newfield.

“Sponsoring the ‘Technology Application of the Year’ category in Manufacturer’s Monthly magazine’s Endeavour Awards is one of the ways that we contribute to and celebrate the success of an industry that is critically important to the economy of our country.”

Nominate your company for an Endeavour Award Anyone involved in manufacturing in Australia can enter the Endeavour Awards. To enter the Technology Application of the Year, or any of the other 12 categories, all you need to do is fill-in an entry form, which can be found on our website (URL below).

The Endeavour Awards is the perfect way to have your business, your colleagues or yourself recognised in front of Australia’s manufacturing elite – and there are great networking opportunities available for entrants, too.

Winners will be presented at a dinner ceremony on Wednesday 9 May 2012, at Sydney’s Doltone House, during National Manufacturing Week 2012.

SMC Pneumatics Australia 1800 763 862, www.smcaus.com.au Endeavour Awards 02 9422 2480, www.manmonthly.com.au/awards

EVEN though the total number of job vacancies across Australia was at its lowest level in 16 months, the number of jobs available in the local manufacturing sector rose in November last year, according to figures from the Australian Bureau of Statistics.

This is good news for the manufacturing industry, suggesting more companies are hiring new staff, and more skilled jobs are available for workers.

According to the statistics, 11,000 jobs were available in the manufacturing sector in November. This figure grew from August 2011, when only 10,400 jobs were available.

In May 2011, there were 10,700 positions vacant in the manufacturing industry, and in February there were 12,100, showing the figure fell sharply around midyear but is on-the-rise again.

The number of manufacturing jobs available across manufacturing sectors in Australia was at its highest in two years back in August 2010, when 14,000 jobs needed filling.

The Australian Bureau of Statistics shows the figure was at its lowest in November 2009, when there were only 9,800 jobs available in manufacturing.

The latest November statistics, show there were more jobs available in manufacturing than in mining, with 10,300 positions vacant in mining compared to 11,000 in manufacturing. This is also good news for manufacturers, suggesting they are on par with mining in terms of providing job opportunities, regardless of the resources boom.

The figures show how quickly the mining industry has grown, with only 4,100 jobs available in November 2009 compared to over 10,000 two years later. www.abs.gov.au Comment at manmonthly.com.au manmonthly.com.au

>>

Register to visit >> nationalmanufacturingweek.com.au

AnalysisNEWS

Australian food manufacturers take steps to With the high Australian dollar, the threat of off-shoring, and the looming carbon tax, local food and domestic products manufacturers are taking steps to ensure they stay viable and competitive, as Angela Welsh reports.

T

RADE in processed foods, which accounts for around 18% of manufacturing employment, has grown considerably over the last decade, according to the Federal Government’s Australian Trade Commission.

However, with increasing global competition and the strong Australian dollar, many foodmakers have chosen to manufacture off-shore where labour and production costs are lower.

To stay competitive, the industry has had to respond quickly to consumer demands, such as more convenient, healthier foods with minimal storage time. Australia has responded to this challenge by developing new food processing and packaging technologies.

Bikkie giant vows to stay Australian made Earlier this year, biscuit giant Campbell Arnott’s announced

12 FEBRUARY 2012 Manufacturers’ Monthly

The Australian Trade Commission claims it has been working with industry to compete with overseas producers.

plans to invest $67 million in upgrading its Virginia bakery in Queensland. The move brings the company’s total investment in

the site to more than $100 million over the past two years.

The Virginia bakery currently produces more than 40% of all Arnott’s biscuits found in Australian homes, including Shapes, Cruskits, Monte Carlo, Scotch Finger, Shortbread Cream and Family Assorted. The investment aims to ensure the firm’s Queensland manufacturing site stays competitive, and also signals the company’s ongoing commitment to local manufacturing.

The company will allocate around one-third of the total investment to installing a new biscuit production line that will be operational this year. The remainder of the $67 million will be used to automate sections of some existing lines to improve efficiencies, enhance product quality and introduce safer handling procedures on-site.

Campbell Arnott’s vice president supply chain Asia Pacific, Craig Funnel, says the company’s Virginia bakery sources around 25,000 tonnes of flour and 10,000 tonnes of sugar from Queensland producers. The biscuit giant also sources around 125 million biscuit trays and cartons from Queensland-based companies.

“The flow-on benefits to the State of an investment of this

magnitude are significant," Funnell said.

The company confirmed that though the decision had no immediate impact on the 900 full-time workers employed at Virginia, there will be a reduction in the number of roles onsite. From December this year to June 2013, as the automation component becomes operational, around 140 full-time and 50 casual roles will have to be dropped.

Funnell acknowledged that potential redundancies made automation a difficult decision to make, but stood by the move.

“Around 99% of all Arnott’s biscuits we sell in Australia are made in Australia. To keep it that way, we have to find ways to compete more effectively in the marketplace, especially against cheaper imported products,” he said.

R&D endeavours The Australian Trade Commission stresses that industry and government have been working collaboratively to provide solutions that compete more effectively with overseas producers. Opportunities for Australian processed foods exist in every market – with Japan number one, followed by the USA, Korea, Indonesia and New Zealand.

To ensure the industry’s export success in future, Australia has a few key attributes on its side.

The nation’s sustainable safety credentials, as well as its diseasefree status, are backed by a strong regulatory framework as well as innovations in traceability, quality assurance and supply.

Australia has research and development (R&D) capabilities in food processing at Food Science Australia (FSA), the dairy industry through the Dairy Cooperative Research Centre, and the wine industry through the Australian Wine Research Institute (AWRI).

These capabilities are reinforced by successful spin-offs from universities. R&D in food manmonthly.com.au

stay on shore processing is also being conducted by companies and through private research organisations.

NZ dairy chooses Sydney Last year, New Zealand’s A2 Corporation chose Sydney to expand its milk processing operations. In July, it began constructing a $7.5 million processing plant in south-western Sydney, which will be operational soon. Initially, the plant will be geared to process up to 10 million litres of milk per year.

The move is part of a growth strategy that has seen the company transform its intellectual property into a commerciallyviable, fast-moving consumer goods (FMCG) business. “Our a2 Milk business in Australia continues to grow rapidly and the development of our own processing facility will allow for the continued expansion of the business. Sales growth has exceeded expectations in the six months to 30 June 2011,� A2’s Chairman Cliff Cook said.

Food packaging initiatives Packaging will always remain an essential part of the industry, as it keeps the food safe. Packaging maintains the quality of food after processing is completed, enabling it to be sent long distances from its point of origin.

The design and construction of packaging also influences shelf life as well as aesthetic appeal.

Traditional materials used in packaging include glass, metals, plastics, paper and paperboards.

A wider variety of plastics is now available both in rigid and flexible forms and packages often combine several materials.

In balancing today's heightened social and environmental consciousness and stricter regulations on pollutants and disposal of solid waste, many companies are turning towards more biodegradable packaging that has less environmental impact.

Please buy local As small Australian manufacturers come under increasing pres-

sure to maintain their presence in supermarkets, local brands are pushing sustainability as a point of difference. Queensland manufacturer of green household products Orange Power and Actizyme, Aware Environmental, says with supermarket shelves loaded with products made overseas, consumers should question the quality of their purchases. “We have Australian-made ecoresponsible products that have no associated ‘carbon miles’

and questionable raw materials,� said managing director Andrew Chaney.

The company recently eliminated plan oil ingredients from its products to prove its reputation as a 'green' brand, he added.

But Chaney laments, “Unless consumers continue to support us and purchase Australian made products the shelves will eventually fill with private label offers and be dominated by one or two multinational brands.�

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Manufacturersâ&#x20AC;&#x2122; Monthly FEBRUARY 2012 13

AnalysisMANAGEMENT Industry’s future in young hands Manufacturers are being urged to think about internships and partnering with local work placement groups to overcome the present, and future, skilled workers shortages in Australia. Alan Johnson writes.

A

NY manufacturer who expects the present skills shortages to ease within a year or two, should only look at the resources industry’s growth forecast for the next decade – the reality is skills shortages are here to stay while ever the mining boom continues.

Much has been written about up-skilling existing workers, which is a great short-term fix, but long-term it’s the youth of today who must be nurtured and encouraged to join the manufacturing industry.

One attractive program that many manufacturers might not be aware of is an internship. At UTS (University of Technology Sydney) for example, engineering students, as part of their course, are available for industry placement for two six-month periods. Mary McGovern, industry liaison manager (Engineering Programs) at UTS, says the program is very popular with companies, with a 99% success rate.

“For companies who do engage with this program there are a number of benefits, it can be very cost effective as a shortterm resource for the business, for example if a company has an increased work load, this program is a very good way to cover that extra need,” she told MM. “Plus it’s a flexible resource as well, where the students can move around different areas of the business. The course requirement is for two six month blocks, but a lot of companies actually retain that person, with around 60% of the students continuing a relationship with the company.”

As with any new worker, companies are responsible for training the student, “but normally they are able to contribute and be productive in a short amount of time,” said McGovern.

“Companies can be very surprised by the considerable contributions our students can make 14 FEBRUARY 2012 Manufacturers’ Monthly

Industry needs to get the message across to the next generation that it is no longer a hot, dirty and dangerous place, that is physically demanding, low-paid and offers no career prospects.

to the company. We have had a high number of great successes.

We had one student who was able to make a cost saving for one company of half a million dollars last year, by developing a software solution. There have been a number of cases where students take responsibility for major projects, planned or unplanned.”

McGovern says UTS alone has up to 700 students on placement over a year. They are placed in a wide range of companies, from small to large multi-national organisations, in a broad range of work experiences.

There are two groups of internships at different stages of the degree: first internship (Junior) which is early to mid-stage, and second internship (Senior) for students who are approaching the end of their degree. Senior students will be close to qualifying as an engineer and can undertake challenging projects, frequently leading to final-year collaborative Capstone Research projects. They are often in high

demand with many offers of employment after their second internship.

McGovern admits some companies do raise concerns regarding protecting their IP, “however the student normally becomes an employee of the company, then the student, like any other employee, has to conform to the rules and regulations,” she said.

“So if there are concerns regarding IP, then the normal policy would apply, or there could be confidentiality or IP agreements signed as the case may be. However, with this internship it’s more project-driven rather than research-driven in most cases, so there is very little chance of worrying about IP. And as an employee, they are covered for workers comp and insurance.

She says that though payment is not compulsory, the university strongly supports payment of the students, but says the rate is negotiable with the student.

However, the university does give recommended pay rates, based on students’ previous earnings.

“It’s a great program; UTS prides itself on working close to industry. We want to produce work-ready graduates, and this is a great way to achieve that,” McGovern said.

“There are numerous benefits for both the student and for the companies involved. And in the longer-term we are trying to maintain our skills levels for the future and are hoping to address the skills shortages, especially in the engineering area. Programs like this can help and contribute to an effective workforce for the future.”

Partnering Studies have indicated that young people want learning opportunities that challenge and engage them. Partnerships that involve educational providers, business, industry and the community assist young people to excel and to reach potentials above and beyond what they thought was achievable.

One such partnership that highlights the benefits of >> manmonthly.com.au

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Analysis MANAGEMENT Industry urged to improve talent retention ANPOWERGROUP has released a new Insights paper ‘Hire and Retain the Best Talent With Success Mapping’, which details key approaches for aligning the core workplace competencies, culture, values and career paths of candidates within the right roles.

“Employers must upgrade onedimensional job descriptions and supplement them with detailed

competency requirements and a framework for how to succeed in a designated role and function,” said Lincoln Crawley, managing director of ManpowerGroup Australia and NZ. “It’s the responsibility of employers and candidates to collaboratively refine the most critical skills and mindsets needed in today’s fast-changing workplace.

To guide this effort,

ManpowerGroup advocates using ‘Job Success Profiles’, a template for mapping essential hard skills and workplace competencies against expected outputs.

“In the Human Age, the fast pace of workplace change implies that employees will need to unexpectedly transfer their skills to a new role, function or organisation in a new industry,” said Crawley.

“Individuals with flexible mindsets and agile skills and competencies are essential for leading and operating a business that must adapt to new market conditions daily. Job seekers looking for opportunities in this environment must be able to show how their skills transfer to other roles and industry sectors.”

collaboration is the Metal and Engineering Apprentice Recruitment Strategy (MARS) in the Macarthur region of South Western Sydney, where there are strong partnerships between schools and industry.

MARS is designed to attract young people and their parents to metal and engineering trade career pathways, in particular in sheetmetal, fabrication and fitting and machining.

MARS provides industry visits, engaging young people and their parents with the opportunity to

explore three different manufacturing companies in the region: Nepean Engineering, Advanced Metal Products and Broens.

Other members include Ai Group, the Department of Education and Training (VET in Schools – South Western Sydney Region), Catholic Education Office, school teachers, South Western Sydney Institute of TAFE, MG My Gateway, and MWLP. The visits include OH&S introduction, and guided tours in smaller groups with staff from

each company. Employers are able to share information about what is being manufactured, how products are made, the production process, and what types of jobs are available.

Though the industry has undergone some technological changes over the years, it is still perceived in a bad light by many, thinking it is still a hot, dirty and dangerous place as well as physically demanding, low paid with no career prospects.

MARS however showcases the many career opportunities for

advancement within a diverse and global industry.

Apprentices gain valuable, transferable skills that are sought across the world.

MARS has a clear message for young people, giving them a taste of what the industry is about. The message includes: ‘local earning, local learning, global prospects with your metals career’; ‘Do the right thing – earn while you learn’, and ‘Make it in Manufacturing’.

M

ManpowerGroup 132 502, www.manpowergroup.com.au

UTS www.feit.uts.edu.au/industry/internships MARS 02 4625 1863, www.mwlp.com.au

Hills Holdings “ We helped hoist international airfare savings * by $171,000.”

Is your manufacturing business looking to save on the cost of travel? No matter how large or small your operation, Corporate Traveller can show you how to achieve cost savings across all aspects of your travel program.

Corporate Traveller manages the business travel programs of over 400 of Australia’s leading manufacturers. With a business travel expert on board our manufacturing clients receive: y personal account management and a dedicated booking team y preferred contracts with over 40 of the world’s leading airlines y over 40,000 contracted hotels around the world y a guarantee that we will not be beaten on any airfare^ or hotel room rateY y 24/7 worldwide emergency assistance.

To discover how you can achieve significant cost savings across your complete travel program, simply use your smart phone’s QR Reader to scan the code below or visit our website to download your FREE copy of ‘23 secrets to cutting your business travel costs’.

Call 1300 133 019 corporatetraveller.com.au

*These savings are based on Corporate Traveller’s internal benchmarking system. ^Applies to genuine quotes from airlines and Australian registered businesses and websites for travel that originates/departs from Australia. Quote must be in writing and must be presented to us with your price beat request prior to booking.

Fare must be available and able to be booked by the general public at the time of booking. Fares available due to membership of a group or corporate entity, subscription to a closed group or exclusive arrangements with suppliers are excluded. Must be for same dates and flight class. The fare comparison excludes payment processing fees and also excludes service fees applied in accordance with the terms of your service contract. We will beat price by $1.00. If we are required to beat your airfare quote and we don’t then you Fly for Free. YA written quote must be provided to your travel manager prior to any booking being made. Stay for free guarantee is based on identical products available on the same dates within Australia. If we do not beat the price by $1 you will stay for free. Excludes client negotiated volume discounts, industry rates and other closed user group pricing arrangements. Please direct requests for stay for free bookings to your travel manager.

For full terms and conditions see www.corporatetraveller.com.au. Australian OpCo Pty Ltd (ABN 20 003 279 534) trading as Corporate Traveller. Licence numbers: NSW 2TA002547, VIC 32360, TAS TAS160, ACT 18800566, QLD 3124259, NT LTA149, SA TTA192799, WA 9TA1362.

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16 FEBRUARY 2012 Manufacturers’ Monthly

manmonthly.com.au

Pilz offers expert training solutions for machinery and equipment safety.

Machinery Safety Training

Our training is based on AS4024.1-2006 Safety of Machinery and the new harmonised Work Health and Safety legislation.

Our updated course offerings include: MachineSAFE Introduction (1 Day) This popular course has been designed to provide a basic knowledge on how to make machinery safe. It has been updated to include the key points of machinery safety with reference to the new WHS legislation, and Australian Standard AS4024.1-2006 Safety of machinery.

MachineSAFE Advanced (2 Day) This newly developed course is a follow on from the Introduction Course and has been specially put together for technical staff who are given the very important task of building safety features into new machinery or upgrading the safety features on existing machinery. It delves into much more detail on the key aspects of mechanical and electrical safety design for machinery.

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the spirit of safety

TechnologyIT@MM

Main: 3D bio-printers are now able to produce tissue construction and organ replacement parts; Inset: a sculptural fashion piece made using 3D printers.

3D printers, a designer’s dream 3D printing adds a whole new dimension for industrial designers, and has the potential to revolutionise the manufacturing industry. Alan Johnson reports.

W

HILE 3D printers were actually created way back in the mid-1980s – using a technique called stereolithography – it was not until quite recently that additional, much cheaper options for manufacturers, dramatically improved.

Today, 3D printers are much more affordable and are designed to operate in an office environment. Plus, they allow designers to spec-out parts in 3D CAD that would be impossible or at least very difficult to manufacture using normal tooling techniques. For example, the

18 FEBRUARY 2012 Manufacturers’ Monthly

new Airbus A380 contains a hydraulic valve housing in the wings which would require complex (expensive) machining however, with 3D printing, the part was designed to achieve the best strength and performance, and not restricted to design-for-manufacture principles.

Though the majority of 3D printing applications in Australia are still for rapid prototyping purposes only, as material quality has improved to more durable engineering plastic with balanced mechanical properties and fine-feature surface resolution,

end-use applications are evolving. This is particularly the case for Selective Laser Sintering (SLS) technology, which uses a nylon material. Surface finish for this technology was always an issue, due to the raw powder form, but improved materials have tackled this issue.

Applications 3D printing allows designers to quickly turn concepts into 3D models or prototypes that require good durability and strength, and allows for rapid design changes. The technology

also allows manufacturers to produce products on demand, rather than in large production runs, thereby improving inventory management and reducing warehouse space. These might include medical parts that require USP Class VI compliance or must be sterilised; complex, thin-walled ducts; enclosures and housings; parts with snap-fits and living hinges; and automotive dashboards, grilles and bumpers.

3D printing has the potential to save money and material over traditional manufacturing techniques in which material is cut, drilled, or shaved off, as very little raw material is wasted.

The technology has the potential for consumers to produce their own objects. They could simply download files for printing 3D objects in their homes.

Presently physicians are using 3D printing to make prosthetics, hearing aids, artificial teeth, and bone grafts, as well as models of organs and tumours from CT scans in preparation for surgery.

In the printed electronics industry, 3D printing technology is being used the printing of layered circuitry or devices. This may lead to one day users being able to print out a future generation of gadgets from 3D plans rather than buying them.

Already 3D printers are being used in food preparation, to apply items in liquid or paste form such as cheese, icing, and chocolate. According to printers, scanners, and projectors analyst, Tony Hoffman, the French Culinary Institute has been using a Fab@Home open-source 3D printer developed at Cornell University to prepare artistic delicacies.

“3D food printers could conceivably even match the Star Trek replicators, found in Starship mess halls throughout the galaxy. These fictional food printers can fabricate most any food item on demand. If 3D printing lets doctors someday print a heart or kidney with internal structure, printing a steak or other foods should be a snap – though probably not costeffective,” he told MM. manmonthly.com.au

“At any rate, we're likely to see a far greater range of food products made by 3D printers at all levels of the ‘food chain’: food manufacturers, restaurants, and home kitchens,” Hoffman said.

Late last year, in a major medical breakthrough, an Australian company developed the world’s first commercial 3D bio-printer, helping organisations working on tissue construction and organ replacement. Start-up company Organovo and Melbourne-based Invetech were awarded the Engineering Innovation Award for their 3D bio-printer.

On the runway One unexpected industry to recognise the sustainability benefits of 3D printing is the fashion industry, which is increasingly using the technology to produce 3D-printed fabrics.

Designer Jiri Evenhuis, in collaboration with Janne Kyttanen of Freedom of Creation, was one of the first to use 3D printers to create textiles.

manmonthly.com.au

“Instead of producing textiles by the meter, then cutting and sewing them into final products, this concept has the ability to make needle and thread obsolete,” Evenhuis said.

3D Systems ‘Freedom of Creation’ designer-researchers are now using software that converts three-dimensional body data into skin-conforming fabric structures.

Furthermore, 3D printing has sustainability benefits for the fashion industry. The emerging technology, which uses ultraviolet beams to fuse layers of powdered, recyclable thermoplastic into shape, leaves behind virtually no waste.

Its localised production and one-size-fits-all approach also racks-up markedly fewer travel miles, requires less labour, and compresses fabrication time to a matter of hours, rather than weeks or months.

On the runway at last year’s Melbourne Spring Fashion Week was Amelia Agosta modelling a

sculptural piece. Inspired by the Architectural style Deconstructivism, the model wanted to achieve sculptural garments that were sturdy but also sculpted to the female body.

3D printing gave her the ability to explore and prototype three dimensional outcomes that cannot be achieved in traditional manufacturing – steering away from traditional cloth fabrics and breaking free of model-making techniques to create an innovative one-off piece.

Agosta worked in collaboration with Natasha Fagg, using 3D body scanning facilities to work on the exact measurements of a female size 6–8 as a template in the 3D modelling software. The piece was complex and time-consuming to draw up, however patience and persistence went a long way.

Agosta then contacted 3D Systems RP Consultant, Chris Murray, who identified a number of fabrication issues that he resolved before converting the

CAD files into a 3D printable format.

Murray decided that SLS would be the most suitable process to manufacture the part.

Additional engineering challenges were realised, such as a method to affix the two piece assembly together in a way that was invisible from the outside.

Murray used his innate knowledge of the process and materials to design a suitable mounting plate for the two pieces that would comfortably fit the model and be simple to put together.

The parts were finally loaded into 3D Systems’ new sPro SLS machine and fabricated overnight.

The parts were given a highquality finish and painted a flat matte white to match the aesthetics Agosta requested.

“The intricate shapes and sculptural nature of the piece definitely achieved a bold structural silhouette,” Murray said.

3D Systems Corporation Asia-Pacific 03 9819 4422, www.3DSystems.com.au

Manufacturers’ Monthly FEBRUARY 2012 19

TechnologyIT@MM

ERP allows 12 years of business growth

I

T WAS around ten years ago when management at Reln, one of Australia's manufacturing success stories, decided to invest in a new ERP system, the Sage ERP Accpac suite of business software modules. The software was deployed to help track and manage orders from the time they are received at Reln’s customer centre through to despatch, delivery and invoicing.

Sydney-based Reln employs 100 people and is renowned for the design and manufacture of water management products.

Reln’s finance manager, David McDonald, says the company uses most of the ERP capabilities including general ledger, accounts payable, accounts receivable, foreign currency, order entry, returned materials authorisation.

“Plus we have an electronic funds transfer add-on module developed for us by our reseller,” McDonald said.

“All of our larger customers such as the major hardware stores place their orders electronically using EDI. Others generally send their orders by fax or phone. As the orders come through they are scanned and attached to the sales order documentation as an image file.”

Sales information then flows through the system to the appro-

20 FEBRUARY 2012 Manufacturers’ Monthly

The integrated nature of the software has allowed Reln to create an extensive array of reports to provide intelligence about the company's business.

priate warehouse where the goods are picked and prepared for despatch. The system produces delivery dockets and invoices, and the goods are shipped. For customers who don’t use EDI, invoices are sent via email, fax or mail.

To complete the process, all delivery dockets are scanned and attached to the original sales order, ensuring that all documentation regarding the transaction is maintained in one place.

The integrated nature of the software has allowed Reln to create an extensive array of reports to provide intelligence about the company’s business. Many of the reports have been developed in

Crystal Reports, while others simply require Microsoft Access.

Continual improvement In the 12 years since Accpac was deployed, Reln’s business has doubled in size. The system has evolved alongside all these changes, providing Reln with multi-company functionality during acquisitions and delivering multi-currency capabilities to support its growing business.

“The software offers plenty of room for growth and it's quite easy to add a new company to the system. We've developed our own tailored user manual with screen shots, screen dumps, and work flow diagrams to assist new

companies as they come to grips with a change of system,” McDonald said.

At present the company is introducing an Accellos warehouse management system (WMS) which is allowing Reln to introduce scanning technology and hand-held data capture devices into the warehouses.

McDonald is confident this will reduce the potential for errors in the warehouse, speed warehouse responsiveness and improve record keeping as all information will be fed directly from the devices into the Sage system.

Customer relationship management (CRM) is another technology that McDonald has plans to introduce with the WMS. “We will be rolling out Sage CRM in the future. The probable users will be our mobile sales force, customer service staff and accounts,” he said.

“The real opportunities for us are in providing more information to sales before they make their calls and in capturing feedback after the calls.”

McDonald also hopes to introduce a new customer service management solution. Interfaced to the CRM, it will enable reporting and measure activity against key performance indicators.

Sage Business Solutions 02 9921 6500, www.sagebusinesssolutions.com.au

manmonthly.com.au

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Electric-stainless IP69K actuator MOTION Technologies has released a full servo actuator to replace air cylinders in hard to control or arduous applications where predictable and controlled motion is essential and where maintenance and surface degradation is an issue such as food, pharmaceutical and chemical industries.

Unlike air cylinders, there are no seals to wear out. There are also no plated surfaces as construction is all 316 stainless. A water jacket is included for extra cooling in higher dynamic

applications. Peak forces are up to 88kg, and strokes are available up to 1,000mm.

The LinMot Stainless actuators can be configured as standalone systems or can be integrated into most PLC/Industrial Comms Systems including SercosIII, EtherNet ip, EtherCAD, ProfiNet, Powerlink, Profibus DP, DeviseNet, and CanOpen RS232/485.

Up to 255 separate Motion commands and up to 15,000 motion profile

The full servo actuator is designed for hard to control or arduous applications.

set points can be stored in the drive system itself.

Motion Technologies 02 9524 4782, www.motiontech.com.au

Mobile welding fume extractor AIR movement equipment provider Fanquip has released a welding fume extractor, built on castors so it can be moved around the worksite.

The mobile fume extractor filters and clears air to 0.3 micron, and is suitable for use in facilities working with welding equipment, as well as in the food sector as a general air cleaner for dust,

Fanquip says.

The system can be supplied with 2, 3 or 4m arms at 150 or 200mm in diameter.

The welding fume extractor was developed to cater for facilities that donâ&#x20AC;&#x2122;t have a built-in extraction system for welding and other fumes.

According to Fanquip, welding

fumes are highly toxic and potentially carcinogenic, however as they are not easily seen by the naked eye, they are not given the required attention they deserve to keep plant workers safe.

The new units from Fanquip can be used to safe-guard personnel who perform mobile welding work on location.

Fanquip 1300 224 308, www.fanquip.com.au

A range of accessories is available, including an arc welding lead set.

3-in-1 welders CIGWELDâ&#x20AC;&#x2122;s Transmig 200i and Transmig 250i single-phase, MultiProcess Inverters with power factor correction (PFC) perform three welding processes from the one unit, including GMAW/FCAW (MIG), MMAW (Stick) and GTAW (Lift TIG).

The 200i and 250i are reportedly ergonomic to use, incorporating Cigweldâ&#x20AC;&#x2122;s TWECO Fusion MIG gun which ensures smooth feedability.

Users can also plug in an optional TIG torch for stainless or mild steel.

The units are equipped with an integrated wire feed unit, Voltage Reduction Device (VRD) when in STICK mode, power factor correction (PFC) energy saving technology, and digital voltage and amperage meters.

The 200i and 250i also come with a range of accessories, including a COMET Argon regulator, feed rolls, contact tips, a TWECO Fusion MIG welding gun and arc welding lead sets.

Cigweld Thermadyne 03 9474 7329, www.thermadyne.com.au

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22 FEBRUARY 2012 Manufacturersâ&#x20AC;&#x2122; Monthly

manmonthly.com.au

Pantograph-style reach truck NISSAN has developed its first pantograph-style reach truck, the SRX Platinum Series, available in three capacities ranging from 1,360kg to 2,000kg.

According to the company, the truck was developed with the help of operator input, to ensure its acceptance into the highly-competitive reach truck market in the USA. For example, the entry and exit is simplified due to a low step height. The side stance design is said to provide comfortable forward or reverse driving and includes a gently sloped floorboard, which sits atop four vibration isolators, offering a relaxed driving position throughout a standing shift.

The reach truck also features a dual spring suspension system in the caster design, which is said to add to the smoothness of the rise and also offers a more stable operation over uneven or rough driving surfaces.

The truckâ&#x20AC;&#x2122;s dash includes an LED display to communicate truck status and warnings to the operator including:

WHO IS LOOKING AFTER YOUR PACKAGING DESIGN, IMPLEMENTATION AND SUPPLY CHAIN EFFICIENCY? DO THEY NEED FORMAL PACKAGING QUALIFICATIONS TO IMPROVE YOUR BOTTOM LINE?

Three capacities are available, ranging from 1,360kg to 2,000kg.

travel speed, battery capacity, hour meter, parking brake warning and steering wheel position.

Powerlift Material Handling 1300 550 607, www.powerlift.com.au

Smart packaging solutions NUPAC is now providing packaging, processing and material handling equipment designed to help manufacturers streamline their production lines and make them more versatile.

NUPAC distributes Bosch Packaging Machines, Russell Finex, Oli and Cremer brands in Australia.

The company says Australian manufacturers should be looking at working smarter, not harder; they supply a range of single machines that can also

cover a range of packaging requirements.

A Bosch packaging machine produces a variety of bag styles, including Doy Packs, Resealable Tape Packs, Block Bottom Corner Edge Packs and Pillow and Gusseted Bags.

The company can provide complete turnkey installations, as well as upgrades of individual machines in existing lines.

NUPAC 03 9584 8111, www.nupac.com.au

Are you aware that the AIP can assist you with internationally accredited formal pack aging training?

Did you know that you can complete a Certificate in Packaging on-line in less than two years?

Did you k now the AIP can offer you an on-line Diploma in Packaging Technology?

The AIP can also customise half day training courses just for your company. The courses can be delivered on-site to your marketing, supply chain, production and technical staff to promote a broad understanding of current and potential pack formats that suit your manufacturing equipment and processes.

Ask the AIP how we can help your staff with their packaging education.

PH: 07 3278 4490 info@aipack.com.au www.aipack.com.au manmonthly.com.au

Manufacturersâ&#x20AC;&#x2122; Monthly FEBRUARY 2012 23

What’sNEW Unmanaged ethernet switches WEIDMULLER has released a new range of high-performance, unmanaged industrial ethernet switches and media converters specifically designed to perform in harsh environments.

The new industrial product range includes fast ethernet and gigabit unmanaged switches, and 10/100 media converters.

Weidmuller says products in the range are resilient, robust and high quality. All switches are housed in

metal casings, which act as a heatsink, reportedly eliminating the need for fans and case venting. This delivers IP40 protection and stops any foreign objects from penetrating the device and causing failures.

The switches can withstand operating temperatures up to 85ºC as well as high vibration, and deliver EMC protection.

Weidmuller 02 9671 9999, www.weidmuller.com.au

Products in the range are housed in tough metal casings.

Handheld barcode reader INTERMEC’S SG10T handheld barcode reader, designed for small-tomedium businesses, reportedly provides superior performance in a simple ‘point and shoot’ form factor.

The new imager uses solid-state imaging technology to read all common 1D barcodes and is suitable for entry-level counter-top reading needs.

The system is designed for businesses requiring accuracy and efficiency in tracking the storage, movement, accounting and sales of inventory and assets. The unit is suitable for a range

Tough LED lamps

of environments, including manufacturing, logistics and other industrial.

According to Intermec, the barcode imager can be used right out of the box, providing intuitive point and shoot trigger ergonomics to eliminate the need for training.

The system is compatible with Intermec’s EasySet PC programming tool, meaning that in a few clicks, the Windows-based utility will produce the programming barcodes necessary for custom applications.

Intermec 02 9330 4400, www.intermec.com.au

The barcode reader can be used right out of the box.

A NEW work lamp from Narva produces a powerful white light output of 2,000 lumen from six 3-watt LEDs. The compact rectangular lamp has been designed for tough environments with its die-cast, powder-coated aluminium housing, polycarbonate lens and maintenance-free, long-life LED. The 9-64V multi-voltage lamp is sealed to an IP66 rating, making it ideal for forklifts, transport and construction machinery and agricultural vehicles.

A marine version is also available.

Narva 03 9730 6000, www.narva.com.au

DOORS THAT WILL AMAZE YOU . . . .

Fo F For or over ove ver er 4 e 40 0 year yea s, DMF DMF F Inter Inte nter tern na nati a atio ati tion ona Pty Ltd onal d hass b be bee e n prov pro rov ro ov oviid idi idin d g so soluti luti uti ut u ttiion ons o n to to busy u y door us doo oo ways oor way , fo or prrot otec ote o tec te tio on of on th op the th ope oper per pe p er eratin ati a at tin ttiin ng en nvir viro vi viron iro on nmen nm m nt men nt .

The The he pro prod p ro rrod od o duct u rang ang ng ge has has gr g own own from rom m tthe eh hum mbl ble e PVC PV str stri s st ttrri r p ccu urta rta rt rtai tai a n, ai n, tto o the h sophiistic tic tica ic cated ated d high high sp h peed ed d roll doo do doo door oor oor os s,, that ha h at at no not o only pro provide vide vid ide de e cli climate mate e cco ontrol oll, bu ut also after afte af fter h ho hours ours urs sec se rity secu rity.

DM DMF D M MF F manu manufact fac ure re e mostt of o th thei eirr ow wn prroduc odu ducts ts s in Aust Aus A ust stral r a, and ra rali nd d are proud proud to also so be the e excllusiv siv sive ive a an nd nd lillice iice icce censed nsed d a age ag ent nt for for the the Efaflex faflex range range off d doors oor ors fro fr m from Germ rm many any.

DM ca DMF DM can supp supply ly and and insta insta nstallll doors o oo tha at ca an achie eve an incredi eve ev r ble 4m/sec operating re red redi speed, spee d, with with high highly ly sensi ensitive tive tiv iive ve v e saf safety ety sen ety sens ens nsor ors to en enssu sur ure yourr pers erssonnel, and equipment, are r prot pro ected d.

With par partner tners tner s th throug throug roug ughout hout o t Aus Au A tra alia, al alia ia, iins ia inst nsta nstalla alla allati atio tion ion an an servic and vici vic c ng g iis available in most areas.

What hatever ever eve er yyo er ou urr budget bu udget, DMF D DM MF ha as a solu as olution t n, n, and so oc ca cal a l us today. ayy.

DM DMF DM MF F IN IN INTE INT NTE NT T TE ER RNAT RNA RN NATIONA A IION IONA ONA ON NA N AL PT PTY LT LTD 3/8 3 3/88 /88 /8 88 8 Ma Mag Mag agowa ow o owar war wa arr R a Rd Rd, d Gi Gir iirrrra raw ra rrawe awe a wee we ween en en, n n, Sy Sydn S dney dn ey, y NSW y, NSW, SW W 2 2145 21 Ph 02 Ph 02 9 96 6365 36 3654 654 654 466 66 Fa Fa Fax ax x0 02 29 96 688 688 68 881 8 81 8153 531 5 31 Web Web We b ww www w.d w. .dmf.co f m.au

BULK FLEXIBLE STRIP AND SHEET PVC VISIFLEX STRIP DOORS SWINGFLEX DOORS TRAFFIC DOORS AUTO BiFLEX DOORS RAPID AUTO ROLL DOORS HIGH SPEED EFAFLEX DOORS LARGE FOLD UP DOORS DOCK LEVELLERS SPECIALISED CUSTOM DOORS SERVICE

Ph 02 96365466 Victoria enquiries Premier Plastics Pty Ltd ph 03 9357 8477 fax 03 9357 8938 www.premierplastics.com.au

www.dmf.com.au Australian agents for

Sales and service throughout Australia, NZ and SE Asia 24 FEBRUARY 2012 Manufacturers’ Monthly

manmonthly.com.au

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What’sNEW - Test & Measurment Monitor machine status on your TV CONTROL Logic has released the Red Lion ProducTVity Station, described as a solution for collecting, recording and displaying critical key performance indicators (KPIs) and machine status messages on any TV, monitor or projector equipped with a DVI/HDMI interface.

The device is able to collect data from a wide range of automation components. Using a library of over 200 communications drivers, the ProducTivity Station can communicate to PLCs, VSDs, energy meters, barcode scanners and more.

Additionally, the device can be expanded with I/O modules, allowing it to directly accept digital and analog inputs from a range of sensors.

A fully-programmable graphical interface allows users to create highdefinition visual management displays.

A built-in data-logger can record key performance indicators, as well as alarms and events for later review. It can synchronize the log files with any FTP server and/or Microsoft’s SQL Server for further analysis.

The device is able to collect data from a wide range of automation components.

Control Logic 1800 557 705, www.control-logic.com.au

Wall-mounted bump test stations CAC Gas & Instrumentation’s BTS Series wall-mounted bump test stations are designed to simplify the process of using gas testing instruments.

Bump testing is the process of applying a calibration gas mixture to an instrument, then allowing the instrument to respond to the gas and for the instrument alarms (audible/visual/vibra-

tion) to engage accordingly.

The CAC-BTS bump test stations are available as one, two or three gas stations, and are programmable for the length of time the gas flows (1 to 60 seconds) and the flow rate.

Once these are determined, the box is locked and the green button is pushed to have the gas flow to the instrument for a quick bump test.

One-button operation ensures the bump test stations are simple to use, and increase worker compliance.

The CACBTS-101(single), CACBTS201(dual) and now the CACBTS301(three) channel systems are available for use with 60L, 103L or 112L cylinders with all gas mixtures.

CAC Gas & Instrumentation 1300 097 553, www.cacgas.com.au

The bump test stations are one-button-operated for easy use.

Take a vibration expert along

SLIGHT

MODERATE

SERIOUS

EXTREME

Fluke 810 Vibration Tester The simple way to identify machine problems Finally, an easy way to check the health of your machines and get instant answers. With the Fluke 810 Vibration Tester you can assess the level of mechanical wear in motors, water pumps, compressors and the like without the need for historical data. The Fluke 810 simply displays the severity of the condition so you can decide if action is needed.

See it for yourself at: www.fluke.com.au +61 2 8850 3333 26 FEBRUARY 2012 Manufacturers’ Monthly

manmonthly.com.au

IR inspection window FLIR has developed IR Windows to protect technicians from serious injury when opening electrical cabinets to perform IR (infrared) and visual inspections of live components.

Compatible with all thermal cameras, the device eliminates the need for opening enclosures thereby safeguarding technicians from the risk of a hazardous arc flash incident from energised equipment.

Said to be easier to install and use than other brands, IR Windows is designed to help users to work faster with greater confidence, perform inspections more efficiently, reduce the threat of arc flash injury and stay within compliance regulations.

All IR Windows feature a secure, permanently-hinged cover that is said to open easily with one hand.

The IR inspection window is designed to reduce the threat of arc flash injury and stay within compliance regulations.

The device's broadband crystal lens allows cameras to capture visible light pictures as well as thermal images. It also allows LED and laser illumination

to pass straight through for clearer visual assessments.

Flir Systems Australia 03 9550 2800, www.flir.com

Pressure calibrating gauge BESTECH Australia has released the LEX 1 digital pressure calibrating gauge from Keller for both calibration and testing applications.

The standard LEX 1 microprocessor-

manmonthly.com.au

controlled instrument has a precision grade of 0.05% full scale, but precision options up to 0.01%FS are available.

The lowest range of the LEX 1 digital manometer is from -1 to 2Bar with

0.1mBar resolution, and the highest range is from 0 to 1000Bar with 100mBar resolution.

Bestech Australia 03 9540 5100, www.bestech.com.au

Expandable gas analyser A NEW gas The analyser can analysis device be controlled and from WITTcalibrated via a PC. Gasetechnik, the MFA 9000, can be used to determine the composition of 13 mixtures from two gases.

The MFA 9000 analyses the common technical gases of nitrogen, carbon dioxide, argon, hydrogen, helium and methane. In the digital display, the measuring result will be shown in percent in respect of the gas combination, or as ppm share (parts per million).

The analyser is made of stainless steel, meaning it doesnâ&#x20AC;&#x2122;t rust. It offers alarm functions, detects measuring errors, and delivers its data via an RS232 interface on a PC by which the device can be completely controlled and calibrated.

The unit comes with an outlet with 4-20 mA, allowing it to be expanded.

WITT-Gasetechnik, www.wittgas.com

Manufacturersâ&#x20AC;&#x2122; Monthly FEBRUARY 2012 27

Motors& DRIVES

With the cost of energy continuing to rise, manufacturers are advised to look

itability, especially while the cost of energy continues to rise.”

But he says it should be recognised that availability of equipment and productivity go handin-hand.

“For instance, our Perfect Harmony medium voltage drive, which is used in the manufacturing and processing industries for motor powers starting at 150kW, features a system that allows the drive to continue operation after an internal fault,” he said.

“This is due to a unique modular topology where the power section of the drive is divided into multiple, partially rated power modules that can operate independently from each other.

“If one of the modules fails, the drive shuts that module down and isolates it from the circuit so the rest of the drive can continue to run.”

In relation to motors, Neurohr says that efficiency is not necessarily the prime objective for customers and that, depending on the application or the supply infrastructure, efficiency has to take a back seat to more important requirements such as higher starting torque and lower starting current.

towards alternative technology to help them reduce their utility costs, and

EC technology

The latest glass-reinforced composite blades are said to be lighter and up to 10% more efficient than steel and aluminium blades.

Reducing operating expenses improve operational efficiencies at the same time. Hartley Henderson reports.

I

N the continuing push for greater energy efficiency in the manufacturing industry, there is now a strong focus on optimising efficiency of the components that make up entire

28 FEBRUARY 2012 Manufacturers’ Monthly

power delivery systems, including the gearbox, the motor and the power electronics.

Matthias Neurohr, engineered drives and motors product manager with Siemens Australia,

believes that in terms of energy efficiency of individual equipment, such as transformer and variable speed drives, the ceiling has almost been reached, and that most of these products are now hovering around 98 to 99% efficiency.

“Rather than investing much more time and effort or by using highly-sophisticated materials that would blow out the final cost and outweigh many of the benefits of fractional improvements, we recommend taking a step back and looking at an overall energy efficient solution,” Neurohr told Manufacturers’ Monthly.

“After all, energy efficiency is all about saving money while maintaining or improving productivity, thus increasing prof-

Simon Bradwell, managing director of ebm-papst A&NZ – a major supplier of industrial fans, motors, actuators and drives – says opportunities for reducing energy consumption through Electronically Commutated (EC) technology are huge.

But, he says, EC motors shouldn’t be confused with basic DC motors.

“Basic DC motors rely on carbon brushes and a commutation ring to switch the current direction, and therefore the magnetic field polarity, in a rotating armature,” he said.

“The interaction between this internal rotor and fixed permanent magnets induces its rotation.

“In an EC motor, the mechanical commutation has been replaced by electronic circuitry, which supplies the right amount of armature current in the right manmonthly.com.au

When support beyond your product warranty matters.

ABB Lifecycle Support.

1800 222 435 (24/7)

ABB offers world class products as well as entire lifecycle services. Depending on your needs, we can provide programs with initial commissioning assistance, on site services, premium spare parts, upgrade kits, plus remote monitoring.

When you want a supplier who is able to provide more than just a product and initial warranty, ABB can help. www.abbaustralia.com.au

ABB Australia Pty Limited Phone: 1800 222 435 www.abbaustralia.com.au

Motors &DRIVES EC drive solution

Rather than using highly-sophisticated (and expensive) materials, many companies are focusing on overall energy-efficient solutions.

efficiency impeller with high efficiency motor and speed control provides a total system solution that is powerful and energy efficient.”

Integrated approach

The controllable synchronous motor is designed for applications with quadratic torque.

A NEW mains-powered EC drive solution from ebm-papst, called VarioDrive C, is said to be an intelligent alternative to IEC-standard motors with frequency inverters.

The controllable synchronous motor is designed for applications with quadratic torque.

Three sizes are available, M3G 084/112/150, all of which feature an enclosed and compact design with integrated electronics.

Models in the power range between 500 – 3,000 W offer variable, closed-loop speed control, and allow torques of 1.0 – 20.0 Nm. The robust mechanical design, which features IP 55 protection and insulation to class F, reportedly a long service life, despite tough ambient conditions often found in manufacturing facilities.

Mounting options for the drives are based on the familiar B14/B5 flange variant, allowing simple connection to varying applications. ebm-papst A&NZ 03 9360 6400, www.ebmpapst.com.au

30 FEBRUARY 2012 Manufacturers’ Monthly

direction at precisely the right time for accurate motor control.

“EC technology is a more cost-effective alternative to AC technology, and it is also environmentally beneficial, reducing carbon emissions by at least 30%.”

He explains that AC motors are designed to operate at a certain point in their performance curve which coincides with their peak efficiency.

“However, either side of this operating point, the efficiency can drop off considerably. EC

motors on the other hand have an almost flat efficiency curve which varies relatively little across the speed range,” he said.

“Examples of how innovative motor technology and ventilation technology optimally complement one another are our Hyblade and RadiCal fans with a hybrid material structure.

“We have moved from steel and aluminium to glass-reinforced composite blades, which are lighter and 8 to 10% more efficient.

“This combination of high

Tony Sculpher, Nord's regional sales manager for Victoria, Tasmania and SA, says Nord follows an integrated approach with the drives supplied with optimised overall efficiency.

“The energy efficient AC motors comply with all current standards and can be adapted to future standards,” Sculpher said.

“Also, all Nord gearboxes are manufactured according to the UNICASE principle which ensures wear-free and efficient operation because there are no sealing surfaces that could deflect under the effect of torque.

“With helical inline gearbox units, the rolling motions are optimised in order to limit losses from mechanical friction to a minimum.

“Efficient geared motors can be combined with several lines of frequency inverters which feature an automatic magnetisation adjustment option.

“This integrated function allows users to reduce magnetisation as required during partial load operation, thereby preventing unnecessary losses in the motor and considerably reducing power consumption.” emb-papst A&NZ 03 9360 4600, www.embpapst.com.au Nord 03 9394 0500, www.nord.com.au Siemens 03 9721 2000, www.siemens.com.au Comment at manmonthly.com.au

manmonthly.com.au

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services

Gearing you up to keep costs down Energy Efficient Solutions from SEW-EURODRIVE

Rising energy costs and an increased ecological awareness are the main reasons why industry must focus more and more on energy-efficient drive technology. SEW-EURODRIVE’s energy saving concept can help your plant reach its energy saving potential, all the while lowering overall production costs. SEW’s energy saving solutions are based on the proven SEW modular concept, from electronic motors and industrial gear units to highly sophisticated servo technology. While one individual energy efficient drive component can achieve satisfactory energy balance, it’s only the optimized combinations adapted by SEW’s professional engineering team which can turn energy efficient drive components into impressive energy savers.

Energy efficient solutions from SEW-EURODRIVE. Just another way SEW delivers more.

1300 SEW AUS Melbourne (HQ) I Sydney I Adelaide I Perth I Brisbane I Townsville

www.sew-eurodrive.com.au

Motors &DRIVES

Geared motors for mills NORD has supplied 2,500 geared motors for a heavy plate mill which produces sheets for the ship-building industry. Romain Class writes.

R

Variodrive C Motor s Highest

efficiency IE4 with inbuilt speed control s Simple control high efficiency over 90% of speed range s Full communication MODBUS, full communication dialogue

The engineer’s choice. www.ebmpapst.com.au

Ph: 1800 764 440 or (03) 9360 6400 32 FEBRUARY 2012 Manufacturers’ Monthly

OLLER table drives are essential parts of a steel mill’s equipment. They need to be fully reliable, or else entire production lines threaten to stand still, which may result in irreparable damages to the equipment if freshly cast goods stay on the roller tables for too long.

The drives must withstand harsh environments, extremely irregular operating modes, heavy loads, and maximum temperatures.

Roller drives must deliver high torques. They must be able to instantly reverse the rolling direction and feature variable speed adjustment.

This entails high electrical, mechanical, and thermal stress on the drives.

In Baosteel’s Pudong rolling mill, steel slabs are rolled into sheets. The slabs, freshly cast in a continuous caster, are transported into a reheat furnace via roller tables. The furnace spits them out red-hot. They pass through a high-pressure descaler which removes the mill scale. Because of the spray water, the drives in this area provide IP66 protection.

Next, after the slabs have been tapped, the pieces are rolled to the required thickness and size. The sheets then pass through an accelerated cooling line to a cooling bed, and to customisation. The roller tables for slab transport have rollers mounted with one meter distance between them, each powered by one geared motor. The load torque must be high enough for the motor to stand in for a neighbouring machine in case of a breakdown. To ensure that the roller tables do not come to a standstill, five to seven drives per ten rollers must be powerful enough to transport the rolled stock.

Hot rolled stock after the cooling line.

More than 800 helical shaft motors alone were installed at the roller tables in the shearing lines which require up to 500 switches per hour and accelerations of up to 3.4 m/s2. Baosteel uses geared motors from NORD in the hot area, for instance in the descaler and as roller drives, but also in the accelerated cooling line.

For maximum loads, NORD supplies industrial gear units which generate torques of up to 200,000 Nm, suitable for applications in the cooling bed, on chain conveyors, and on guide rollers.

To support the changing loads and often fast accelerations, roller tables in the steel industry require drives with high starting and breaking torques. If a steel slab gets stuck, the drives must withstand the resulting overload. Because of the demanding tasks with changing duty types and high ambient temperatures, steel factories often prefer ‘time-honoured’ roller table motors, i.e. motors with ring fins which not only provide excellent self-cooling through convection, but are dirt-repellent when mounted horizontally.

NORD’s straight-finned TENV motors have been designed for frequent reversals and provide perfect protection from dust, dirt, and

spray water. Featuring a larger amount of material and bigger bearings and shafts, these specific motors withstand great loads and have a long service life.

The motors for Baosteel were fitted with a special winding with a temperature sensors and an incremental encoder. For an efficient cooling in rugged environments, they employ natural convection (totally enclosed non-ventilated – or TENV – models) or forced convection (totally enclosed fan cooled – or TEFC – models). The nonventilated design provides perfect protection from dirt and water.

The new IE2 motors from NORD furthermore allows for innovative drive systems layouts and afford savings opportunities. They generate less heat loss than the preceding generation, and depending on the size, they can, if necessary, permanently be operated at a 150% performance factor without reducing the availability of the drive system. In addition to large power reserves, IE2 energy saving motors from NORD feature increased starting and breaking torques, higher speed, and typically require less power for the rated output.

Nord Drivesystems Aust 1300 006 673, www.nord.com.au manmonthly.com.au

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Metalworking& MACHINE TOOLS

Waddell Engineering’s operators claim the Brown & Sharpe Global 7.10.7 CMM is easy to operate and program.

CMM system raises the bar A new CMM that facilitates highly-accurate forging die work has resulted in a renewed sense of confidence for this engineering company. Ian Martin writes.

W

ADDELL Engineering is a Melbourne-based general engineering company that specialises in highly-accurate forging die work for the brass forging and water reticulation industries. Having been in business for over 20 years and currently with a staff of five, Waddell are now well-placed to take advantage of any new opportunities in the market.

In mid-2010 Waddell Engineering took delivery of a new Brown & Sharpe Global

7.10.7 CMM, supplied and installed by Hi-Tech Metrology in a purpose-built room. The new machine and the enhanced capabilities that it would give the organisation were eagerly anticipated by the team at Waddell.

The bulk of Waddell's business is supplying forging dies and other associated tooling, including ejector pins and machining jaws. The company’s customers require efficient and rapid supply, at 100% accuracy.

According to Waddell manag-

ing director, David Waddell, during the 18 months the CMM has been installed at the Highett facility, it has become a mainstay of the business with a number of operators – including the apprentices – all able to operate and program the machine.

Waddell says the CMM has become a critical component during production. It has allowed the company to manufacture single forging-die die halves – as opposed to pairs of die halves – as it accurately measures the die

halves rather than relying on core pins and other physical means to line-up the two halves in an assembled condition.

Now, the company can very accurately determine the overall condition of each die half so that when the die is fitted back into the bolster of the forging press there are no resulting problems, such as premature die failure, excessive die flash thickness and wear of trim tools.

For a recent job, the team was required to measure a groove down a large diameter bore in a tool, very accurately and with positional precision. The team used the CMM to perform the job, and had complete confidence that the part that they were giving to their customer was 100% correct and fully compliant with the specification.

“I thoroughly research when it comes to making large capital purchases. I evaluate the machinery and buy the best I can and I place a lot of emphasis on the returns from the machinery purchase and the best return in the long-run,” said Waddell.

“I also employ the best people possible with the most experience and I promote a clean, safe and enjoyable working environment.”

The future for Waddell Engineering is bright, and the business looks forward to attracting new customers and business from the market.

[Ian Martin is Hi-Tech Metrology’s managing director.]

Hi-Tech Metrology 03 9702 3911, www.hitechmetrology.com.au

3D 5Axis Dedicated Tube Laser Cutting Up to 8.5M lengths processed by the pack or singles

RHS, Tube, Angle, Channel

P: 1300 134 462

E: sales@laserworld.com.au

W: www.laserworld.com.au

Fast,Accurate, Reliable,Affordable - Based in SA servicing the nation - Drawing on 15 years experience in Flat Bed Laser Cutting 34 FEBRUARY 2012 Manufacturers’ Monthly

manmonthly.com.au

Genius aids change in the fabrication sector SOMETIMES the simplest of changes to raw materials sourced by the fabrication sector can unearth a Pandora's Box of challenges. Andrew Bentrup, managing director of sheet metal machinery specialist Maxitec, sees fabricators experiencing these sorts of functional challenges on a regular basis.

Recently, he provided a genius solution for one such customer.

“Before, everything for this company was designed around a 2,400x1,200mm blank of sheet metal which was being cut in advance and kept as part of dormant inventory in case large orders came through the door,” said Bentrup.

“Guillotines were doing the cutting, followed by someone sorting out the parts manually, and a lot of hand presses were used to shape blanks into product. Management didn't really have the ability to change the floor layout on the production line because everything was hard tooled.”

So when a raw material supplier made a simple change to the coating on its sheet metal stock, it caused unforeseen process problems and a sudden bottleneck for Bentrup’s client.

“But this turned out to be a blessing in disguise. It made our client see very clearly that its outdated methods were not only less capable of dealing with changes to raw materials, it actually highlighted just how old their hardware and processes really were,” said Bentrup.

“Make no mistake, on a daily basis this company handles a huge number of sheet metal processing orders for the national market. But a simple and straightforward change by our client’s supplier to the coating on the sheet metal it used just changed everything.”

Because of the new coating, it lessened the gap between the work piece and the tooling on its manmonthly.com.au

machines to cause bruising to the coating and ruin it.

“But our tooling supplier, MATE, had a rethink of the tooling arrangement for this user and found a technical solution to overcome this challenge,” said Bentrup.

This small technological change, however, was just the tip of the iceberg for the fabricator.

Because of this experience, the company was able to take a step back from its busy operation and realise that its entire production line needed to change for it to remain competitive.

This stimulated a transformation from a predominantly semiauto production line into an automation-rich setup customised to suit its specific needs.

“The ultimate gain for the company was complete automation of its shearing and cutting as it moved away from a manual stranglehold and positioned its future work around a PrimaPower SG8 (Shear Genius 8),” said Bentrup.

“Now the possibilities are far less limited and the production line is not just automated for these processes; the line is now processing much larger blanks of 4300mm long x 1500mm wide.”

The MATE Shear Genius 8 is based on the integration of right angle shearing into high-quality, high performance punching. This integration helps fully utilise the manufacturing economy offered by efficient nesting programs.

Shear Genius systems feature automatic loading and work piece removal from the system, which Bentrup claims also helped reduce manufacturing costs through versatility, material consumption and time.

“Our client not only eliminated bottlenecks and changed its factory internally for the better, it can now get the bigger orders and run an overnight shift with excellent productivity,” he said.

Maxitec 02 8543 9900, www.maxitec.com.au Manufacturers’ Monthly FEBRUARY 2012 35

Metalworking &MACHINETOOLS Fixturing table for welding accuracy LEUSSINK Engineering has introduced a modular fixturing and holding table which has been designed to provide greater welding accuracy.

According to Leussink, the German demmeler Modular Clamping System’s design allows the use of CAD to create, as well as document, the fixture.

The system is described as versatile as it can be implemented into new working methods.

A typical system is said to feature a five-sided table with a regular pattern of bores located across the top and around the sides.

Table sizes range from 1000x 1000mm to 2000x4000mm, and are coated with a weld spray so that any wayward welding spatter will not stick to them.

The modular fixturing and holding table can also serve as the first in-process quality check for any loose pieces, Leussink says.

The table can be used to weld and/or assemble components into a precise fixture.

Where component part size exceeds the table surface, the modular design allows angles or extensions to be mounted to the sides to act as outriggers that extend the capacity.

The modular holding tables are suitable for use in industry

sectors where accurate and rapid assembly methods are required.

They can also be used successfully in areas where economic positioning, clamping, tacking and welding are necessary.

Leussink Engineering 02 4260 7777, www.leussink.com.au

Portable, linear gantry milling CLIMAX Portable Machine Tools has introduced a portable milling machine with a built-in split rail system that enables the machine to be configured to perform both linear milling and gantry milling.

The machine’s rigid, modular bed design reportedly allows shorter bed sections to be combined to fit the length of the work area as needed without losing rigidity, and to extend the bed by two or three times.

Two models, the Climax LM5200 and LM6200, are said to perform a number of machining projects. To convert from linear milling to large surface or gantry milling, simply remove the RAM, split the bed and saddle into two separate rails for gantry milling, and then reattache the RAM to the saddle and rails.

Applications include pump and motor mounts.

Austwide Tooling 08 9472 1855, www.austwidetooling.com.au

Modular milling machine HEADLAND is now distributing WFL’s M80 MILLTURN, a modular machine offering a variety of configurations for turning, boring and milling.

The machine ensures minimal distances between the tool and work piece, along with wide guideway distances, offering rigid performance for differing geometries. The unit is controlled by an internal Siemens SINUMERIK 840D SOLUTION LINE in combination with new Sinamic drives.

Boasting a heavy-duty boring bar changer and a U-axis, the MILLTURN is suitable for very heavy machining. Additional machining units can also be incorporated on a built-in top slide.

The tool magazine, which is reportedly compact, stable and maintenance-free, is accessible from the front of the machine.

According to Headland, a tool shuttle with rack and pinion drive is equipped with linear axes, thus avoiding any centrifugal forces caused by rotation – so even tools weighing 35kg are handled safely and quickly.

All center distances (except 1,000mm) are available in a double-spindle version and, for a further productivity enhancement, an additional tool turret can be purchased.

Headland 1300 592 061, www.headland.com.au

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WHY BUY A TECHNI WATERJET MACHINE? Coatings for iron, steel components

All three options are suitable for lean manufacturing operations.

Using mild, fume-free solutions, the process is reportedly easy and safe to work with.

When configured with an Ion Exchange system to recycle the rinse waters, it operates as a completely self-contained, zerodischarge process line.

The MICROLOK AO is designed to provide corrosion protection and break-in lubricity.

It is reportedly the ideal finishing process for tooling and machine components that donâ&#x20AC;&#x2122;t call for a black colour, but do require robust corrosion protection, break-in lubricity and galling resistance.

Birchwood Casey, www.birchwoodcasey.com

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The finishes are said to be safe and simple to apply, attractive, and suitable for lean manufacturing operations.

The TRU TEMP black oxide process operates at 200°F, without the hazards and high costs of ordinary high-temp black oxide, the company claims.

An in-house TRU TEMP line reportedly uses no EPA-regulated chemicals and can be safely installed in any plant. Its 30minute blackening time streamlines workflow.

The process produces a durable, satin black magnetite coating, 20 millionths thick (0.5 micron), with no effect on material hardness or tensile strength.

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Innovation Through Passion

Manufacturersâ&#x20AC;&#x2122; Monthly FEBRUARY 2012 37

Automation&ROBOTICS inspecting each jar under automation,” he explained.

“As the jars pass along the conveyor, the system takes a 2D monochrome photo and inspects for any imperfections on the glass with the aim of ensuring that only good quality glass goes through to the filler.

"This new automated vision system provides another element to our focus on total quality control, adding to the existing critical control point (CCP) safeguards, including X-ray machine checks at the end of the line."

Challenges

The system has to inspect 320 glass jars per minute as they pass through the gripper conveyor.

Vision boosts productivity Advances in machine vision technology for manufacturing environments can deliver significant quality control and productivity benefits, writes Hartley Henderson.

S

IMPLOT Australia, which offers a range of food products under well-known brands such as Edgell, Birds Eye, John West, Leggo's, Ally, Seakist, Harvest and Chiko, has six manufacturing facilities around Australia including at Echuca in country Victoria.

The company says there is a constant effort to maximise quality control systems and processes through new and innovative technologies.

At the Echuca plant, which employs some 140 people, machine vision technology from Omron has been installed as part of the quality control system on the glass line that produces Leggo's pasta sauces.

The design and implementation of the system was undertaken by an in-house team led by mechanical project engineer 38 FEBRUARY 2012 Manufacturers’ Monthly

Jimmy D'Alessio who advised the team. Other team members included electrician and programmer Paul Baker who was involved with the actual programming that needed to be coded, and control system engineer Wes Brown who was also involved with the programming codes.

Input to the project was also provided by electricians from the electrical department to wire the system, and fitters from the mechanical department to manufacture bracket fittings to support the system.

The system consists of a ZFXC15 vision controller with one camera connection, PNP, IP20, integrated 3.5” TFT LCD colour touchscreen, RS232, 422, USB2.0, ethernet outputs, 32 banks, and 24Vdc supply 1.5A, together with a FX-S vision monochrome cam-

era and a programmable logic controller (PLC, also from Omron) to automate the system at high speeds.

Other elements of the system include CCTV lenses to suit FZ series vision, a red LED backlight, a S8VS-12024 power supply, a photo-electric sensor, and a reflector for long distance photoelectric switching.

D'Alessio says that purpose of the vision system is to give even greater assurance on the quality of the glass jars containing the product supplied to customers.

“The system has to inspect 320 glass jars per minute as they pass through the gripper conveyor and if an imperfection is detected the system output displays the detected jar and signals the operator to physically inspect the item. The vision system is then reset to continue

D'Alessio points out that the team was faced with some significant challenges in designing and installing an effective vision system. For example, the speed of the conveyor that grips the jars can vary, which created issues.

“Every jar has to be photographed, so operation of the system needs to be precise.

Initially, the sensor was positioned at an angle to the field of view of the inspection system, making it difficult to take an accurate photo.

“The solution was to move the sensor away from the camera field of view and relocate it 40mm away in a parallel line to the field of view.

“This eliminated the time delay fluctuations created by the gripper conveyor and enabled accurate detection of the following jar coming up close with a small gap, making both critical points parallel to cope with high speed inspection of each jar.”

High-speed time delay According to D'Alessio, another issue was that the main PLC was doing a lot of processing, which caused delays, particularly when the line was running at high speed. These problems were overcome by utilising a micro PLC with high speed time delay and programming it to deliver a high speed signal to the vision system from the photo-electric sensor, thus forming a close loop system away from the main PLC to deal with the highspeed operation. manmonthly.com.au

“If detection occurs, a signal goes out of the loop enabling the main PLC to initiate 'inspect jar condition', stopping the jar at a pre-determined inspection point.

The theory was to create a loop within a loop in order to automate each system under a deterministic time nature,” he said.

According to D'Alessio, total investment cost of the vision system, including labour, was $25,000 and significant productivity improvement benefits are flowing from the project, particularly by ensuring first time quality of all products and eliminating the need for rework.

Memory banks

Advanced technology

D'Alessio explains: “The biggest difficulty with the project was re-programming each product with different specifications, time delays and memory banks data under automation so that when a particular product was selected through the main PLC it also changed the selection at the vision system. However, with Omron providing support and assistance, we were able to get the system up and running.

“It was found that the best way to detect defects in the glass was to illuminate the jars from the back, and laboratory testing helped us determine which camera and lens needed to be used.”

Omron machine vision specialist, Panfilo Tarulli, says the ZFX Machine Vision Sensor includes everything from a camera with an integrated light source to an image processing unit.

“The ZFX can use a C-mount camera which enables you to choose the correct lens to match the field of view, and it can be used in combination with optical lighting, such as transmitted lighting, low angle lighting, and bar lighting to support different inspection types,” he said.

“The ZFX Machine Vision Sensor stores up to 100 files of image data in the main memory without slowing measurement

speed, and images data can be remeasured, so even with a highspeed line the results of the measurements can be checked at leisure afterwards.

“Omron's ZFX unique sensitive search capability can observe and detect the smallest detail in an object and display it on a screen, including smears, scratches, chips and burrs.

“The system can provide a valuable quality control function for a wide range of manufacturing industry applications.”

Omron recently released the new FZ4 Machine Vision Sensor which has a large touchscreen and many filtering features as well as code reading functions.

It also has HDR (high dynamic range) function and OCR (optical character recognition) capability, as well as remote access, which enables the user to log into the vision system to take full control, either from their office or offsite.

Profibus extender with surge protection THE new Profibus extender from Phoenix Contact is said to enable straightforward integration of remote Profibus devices at data rates of up to 1.5Mbps.

The extender has two DSL connections per device meaning that, in addition to point-to-point connections, they can also be used to establish line structures with up to 30 devices.

To protect the communications modules, surge protection is required for both DSL connections. The DIN rail-mountable DSL surge protector offers two a/b connections per screw terminal. For line structures, one surge protector per intermediate station is needed.

Phoenix Contact 1300 786 411, www.phoenixcontact.com.au

Omron Electronics 1300 766 766, www.omron.com.au

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Manufacturers’ Monthly FEBRUARY 2012 39

Automation &ROBOTICS

Evolving automation systems Intelligent software systems that can overcome challenges, self-heal, plan, learn, and ultimately prevent downtime and increase productivity are not that far from becoming a reality. Paul McRoberts discusses.

M

ANUFACTURING environments are rapidly evolving due to global competition and changing customer requirements. To maintain competitiveness, intelligent software control programs are required to operate at faster speeds; information integration becomes imperative in achieving timely and accurate data retrieval to support critical business decisions.

The notion of intelligent software has existed for a long time, but a paradigm shift is occurring in how critical and complex automation systems are designed, configured, and controlled.

To achieve ‘artificial intelligence or self healing’ would be the ultimate goal; a system where the intelligence of machines is such that traits like reasoning, knowledge, planning, learning, communication, and perception provide machines with the ability to move and manipulate objects to improve commercial outcomes.

While intelligent software still has a long way to go to achieve this, increasing embedded computing in distributed intelligent devices provides improved system operation.

Intelligent software devices that can evolve to overcome challenges and self-heal to prevent downtime are being actively

developed. This technology has proven to be widely adaptable to a range of complex systems and industrial applications.

Integrated safety and motion control Manufacturing plants are increasingly realising the importance of integrating safety controls to help minimise worker injuries and increase overall cost savings.

The safe control of motion has many benefits including efficient maintenance of an application without disrupting power supply to machinery, safe speed control and safe control of potentially hazardous movement. Efficient translation of data to produce an action, or exact motion to help maximise safety, continues to be the backbone of intelligent software advancement.

Control of intelligent agents that can interact with actuators and sensors provides the ability to address motion control in large, complex manufacturing systems. Relying on a single, central controller has significant limitations because damage to that controller or to the communication infrastructure used can result in a loss of controllability.

Safety hazards are inevitable when motion control is compromised. A distributed, survivable and adaptable architecture can be achieved by distributing the

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intelligence of the system among multiple controllers. Embedding standalone or multiple intelligent agents inside the controllers, results in an advanced level of motion control.

Energy efficient solutions Energy management is a complex but important factor in optimising production processes in manufacturing plants. Globally, manufacturers are putting systems in place to reduce water, air, gas, electricity and steam consumption – resources widely required by processing plants.

Recent advances in intelligent motor control, incorporating variable speed drives, intelligent software and networked motor condition monitoring devices allows for a measureable impact on energy use and operational efficiency.

Intelligent software can offer significant energy savings by improving process diagnosis, stability and consistency in operations and by improving the control response to operating changes.

Manufacturers can use energy consumption data to identify variables in energy costs across all equipment on the plant floor collectively and also with individual machines.

Energy management can be applied to machine design practices by improving efficiency of equipment components such as motors and drives or by attaching monitoring devices to assist with data collection. By collecting accurate energy consumption data, manufacturers can modify the OEE calculation to include energy efficiency, allowing them to achieve higher profitability while reducing greenhouse emissions.

Intelligent software leads manufacturing into the future Manufacturing environments are rapidly changing as a result of

increased global competition and changing customer needs.

Advances in intelligent software technology continue to provide manufacturing enterprises with the capabilities and flexibility to deal with these changes.

By coordinating and integrating production activities within a manufacturing enterprise, intelligent agents provide increased productivity and profitability.

Intelligent agents are increasingly able to incorporate logic and collaborative reasoning parameters to detect faulty components, process problems and inefficiencies in a manufacturing plant. By eliminating the need for centralised control, autonomous intelligent agents display the capabilities for predictive reconfiguration of production processes, thereby reducing downtime and increasing productivity.

With the manufacturing environment constantly evolving, the ultimate goal is to develop adaptive, self-healing systems that can react to their environment and modify their behaviour accordingly to maximise production efficiencies.

[Paul McRoberts is Rockwell Automation industry solutions manager – initiatives, South Pacific region.]

Rockwell Automation 03 9896 0300, www.rockwellautomation.com.au manmonthly.com.au

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MaterialsHANDLING layer picker until required.

As new pallets of stock are fed into the system, the layer picker selects the required layers and transfers the stock to one of four customer order pallets.

Any stock remaining on a pallet either forms the basis for another order via the system’s FreePICK Maximiser software, or is returned to the adjacent reserve storage bays for use at a later stage.

Building pallets

The 4-axis layer picking robot’s vacuum gripper head is suitable for picking up to 80% of Nestlé’s SKUs held at the DC.

Layer picker works a treat A smart robotic layer picker lifts Nestlé Australia’s safety, quality and productivity at the company’s national distribution centre in Sydney.

A

N integrated robotic layer picking solution is said to have transformed workplace safety and improved the quality and productivity of mixed pallet assembly at Nestlé Australia’s national distribution centre (DC) at Arndell Park in Sydney’s western suburbs.

The high volume DC stores and distributes several hundred SKUs from Nestlé’s consumer food and beverage, food service and pet food businesses.

The high demand for Nestlé’s leading household brands means most of the DC’s orders – around 80% – are distributed to customers as full pallets.

Picking the remaining 20% of orders – which are distributed in pallet layer and full case quantities – has involved the manual handling of around five million cases per year, creating a significant and ongoing OH&S challenge.

Nestlé’s innovative layer pick42 FEBRUARY 2012 Manufacturers’ Monthly

ing solution eliminates the need to manually handle around four million of those cases.

The layer picking system achieves very high throughput rates thanks to logistics systems supplier Dematic’s FreePICK Maximiser patented software.

By cross-matching orders and pairing those with compatible order profiles, FreePICK Maximiser enables around 20% – in some instances up to 50% – of goods for orders to be distributed without them being physically picked.

Picking and building layers Orders from Nestlé’s SAP warehouse management system are downloaded into Dematic’s PickDIRECTOR warehouse control system to initiate picking.

Interfacing with FreePICK Maximiser, PickDIRECTOR orders the stock required for layer picking in the sequence required to fulfil the next

wave of orders. This is retrieved from the adjacent bays of reserve storage by RF-directed forklift and loaded onto the induction conveyor spur.

As pallets are fed into the layer picker, they are scanned, and the control system directs the operator to remove the required amount of stretchwrapping from the pallet.

The pallet is then conveyed into the layer picker where it will go direct to one of four pick and put locations, or, if it is not immediately required, into one of eight buffer storage locations serviced by an automated pallet cart.

While the software requests pallets to arrive at the layer picker in a particular sequence to suit order assembly, the reality is that pallets occasionally turn up out of sequence.

The buffer storage locations enable such pallets to be temporarily stored online within the

With the supply chain running leaner, there is a general trend towards ordering smaller quantities of goods such as layers, rather than full pallets, or cases rather than layers.

Many customers also require pallets to be built in a certain way to suit further processing.

To maximise pallet building flexibility, the layer picking system has four order picking positions, which enables up to four orders to be picked concurrently.

An empty pallet station accommodates the production of multiple layer sandwich pallets.

The 4-axis robotic layer picker is equipped with a dual bellows and vacuum-gripping head capable of handling up to 80% of Nestlé product range, covering a broad range of packaging types from cartons to bags and bottled beverages.

Completed orders are conveyed through the integrated layer picking system being checkweighed, stretchwrapped and labelled on the way, until they exit ready for collection and transport to despatch by forklift.

Orders that require further case picks to be added to the layers then exit the system, where a barcode label is attached prior to their retrieval by forklift.

After the required case picks have been completed using the DC’s new voice picking system, the pallet is reinducted onto the system, checkweighed, stretchwrapped and labelled for despatch.

Dematic 02 9486 5555, www.dematic.com.au manmonthly.com.au

NOMINATION

ARE YOU AN INNOVATIVE AUSTRALIAN MANUFACTURER? Nominations are now open for the 9th annual Manufacturers’ Monthly Endeavour Awards – Australia’s national awards, celebrating manufacturing excellence.

The Manufacturers’ Monthly Endeavour Awards provide the industry with an opportunity to recognise and reward manufacturing excellence. Join us in celebrating the best of Australian manufacturing by nominating your business or employee!

AWARD CATEGORIES >> Technology Application of the Year >> Environmental Solution of the Year >> Safety Scheme of the Year >> Consumer/Trade Product of the Year >> Industrial Product of the Year >> Australian Steel Innovation Award >> Global Integration Award

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HOW TO ENTER DOWNLOAD A NOMINATION KIT AT: www.manmonthly.com.au/awards

FOR INFORMATION ABOUT ENTERING CONTACT: Tel: (02) 9422 2480 E: manufacturing@reedbusiness.com.au

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