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Inside NOVEMBER 2011
For daily news visit manmonthly.com.au
4 Editorial ■
7
When protection becomes protectionism.
6 Comment ■
Tax Forum breakdown.
8 Analysis News ■
Aussie dollar down, manufacturing up? ■ 10 minutes with Terry Davis. ■ Free technology for MM readers. ■ Conservative manufacturing.
36
16 Sustainability ■
Pathways for the automotive industry.
12
18 IT Systems ■
CAD battle gets serious. ■ Innovative design now the clincher.
Coca-Cola Amatil’s big boss reveals his views on the carbon tax, and issues obtaining government funding.
22 New Products
30 Motors & Drives
36 Metalworking
■
■
■
Pumps & valves.
28 Automation & Robotics ■
Streets ahead with process automation.
CELEBRATING 50 YEARS Years
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November 2011
Print Post Approved PP255003/00324
Publisher Michelle Graves michelle.graves@reedbusiness.com.au Editor Sarah Falson Ph: (02) 9422 2480 Fax (02) 9422 2722 sarah.falson@reedbusiness.com.au Journalist 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) 9422 2368 Fax: (02) 9422 2722 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
INSIDE Management Software >> Conveyors & Pallets >> Metalworking Automation & Robotics >> Motors & Drives >> Pumps & Valves Industry News >> New Products >> Industry Opinion
DESIGN WARS >> CAD providers battle it out for number-one product
Innovation drives motors forward. ■ Quick action saves XXXX brewery millions. ■ Washdown gear units.
Sheetmetal processing.
40 Materials Handling ■
Conveyors, pallets & warehousing.
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Manufacturers’ Monthly NOVEMBER 2011 3
Editorial
SARAH FALSON – Editor
editor@manmonthly.com.au
When protection turns bad Anti-dumping: one small step for manufacturers, or one giant leap onto the slippery slope of protectionism? Sometimes, too much of a good thing can turn it bad.
T
HE government’s commitment to improving Australia’s anti-dumping regulations is a welcome act of support for local suppliers doing it tough on the export market. But, when teamed with new content transparency mandates for large projects, is this beginning to smack of protectionist policy from a government so hell-bent against it? Last month, the government announced it would support local companies by reforming Australia’s anti-dumping policies. This includes fast-tracking dumping investigations, and ensuring stronger compliance measures are put in place in areas where Australian businesses have suffered as a result of foreign products dumping. The government sought help from the Productivity Commission to review these operations. They also consulted with manufacturing businessowners, workers, producers, importers, members of parliament, industry associations and trade unions to come up with a number of reforms that would be more beneficial to local business. According to the folks involved, the anti-dumping reform will ensure more contracts are handed to local manufacturers, which will help them
Imagine if we could no longer export? Free trade agreements are the lifeblood of our industry.
move to a modern, high-skill, high-tech, clean energy economy, creating more Australian jobs into the future. Anti-dumping has been on the industry’s radar more than usual over the past six months, due to the pressures on Australian manufacturers from the high dollar, which makes it more difficult for some of them to export. Meanwhile, Julia Gillard has ruled that projects receiving government funding over $20 million must list their Australian suppliers, which will encourage (or shame) big resources companies to use more local content. The move comes after pressure from trade unions, including the
Australian Manufacturing Workers Union (AMWU), to put policies in place to ensure Queensland's coal seam gas and other major resources projects deliver skilled jobs to locals, and create apprenticeships for our young people. Australia's mining industry has been a consistent target of late, with industry bodies blaming the sector for choosing cheaper Asian materials and labour over locally-made products. At the Future Jobs Forum in Canberra in October, Gillard’s local content ruling was met with applause from the AMWU. The mining sector is reeling of course, because they could be
put in the position where they have to choose between keeping up appearances, and sourcing from overseas which, in most instances, is cheaper. Our Trade Minister Craig Emerson has long been against protectionism, claiming it flies in the face of our commitments to free trade. And he’s right, it does: we can’t move to limit foreign imports into our country when we expect other nations to happily import our goods into theirs. Practise what you preach. We complain when other countries adopt such policies. Only recently, Holden announced it was re-thinking its lucrative export program to Brazil due to raised import taxes in the region. What's Brazil doing? It's protecting its national interest, by making it harder for foreign car-makers to do business in the area. But by the same token, Australia’s manufacturing industry can’t survive without exporting. We rely on a level playing field overseas. But we can’t have our cake and eat it too. We need to draw a line in the sand indicating where protection ends, and protectionism starts. Are local content mandates and a renewed focus on antidumping sign-posting the beginnings of protectionist policy, or are these just natural reactions to the difficult climate manufacturers are working in today? Are import tariffs next? Or are we just protecting Australia's manufacturing future? Tell us what you think by emailing us at the above address.
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4 NOVEMBER 2011 Manufacturers’ Monthly
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Comment
HEATHER RIDOUT – CEO Australian Industry Group
editor@manmonthly.com.au
Manufacturing and the Tax Forum The pressures of our two-speed economy will be addressed by a new Working Group; now we just need to see those policy results. Heather Ridout writes for MM.
A
I GROUP was determined that the pressures of the multi-speed economy on manufacturing would be at the forefront of the Tax Forum held in Canberra in October. The Treasurer's announcement of the Business Tax Reform Working Group to develop immediate and longer-term business tax reforms has recognised this important policy area and the role the tax system can play as part of a wider solution. The tax system is critical to the ability of businesses across the economy to play a role in transforming our economy and society. Our system of taxation should not penalise risk taking; it should not impede organisations from restructuring, relocating and reorganising.
6 NOVEMBER 2011 Manufacturers’ Monthly
More than this, our tax system should encourage the engine rooms of business transformation – research and development, entrepreneurship, the emergence of new businesses, and the commercialisation of new ideas. The multi-speed economy was a fundamental consideration of the Henry Tax Review panel, of which I was a member. Its main proposal in this regard was the reduction of the company tax rate to 25% – a move that would have brought us into line with many other smaller OECD economies. Our thinking was that this would help attract investment into those sectors on the wrong side of our lopsided economy and partly offset the disadvantages that arise from this.
For me, it was a cornerstone reform proposal of the review panel and it continues to be a major disappointment that we've been so frustrated in moving forward with it. There are, however, important additional measures with particular relevance to the multi-speed economy that can and should be pursued. The Henry Review recommended a loosening of our tight rules around the treatment of tax losses to reduce the bias against risk-taking in our tax system. Some important steps have been taken in relation to certain infrastructure investments. Costs associated with setting up new businesses and restructuring existing business should also be able to be expensed in
the year the costs are incurred. The major beneficiaries would be businesses that are reinventing themselves in the face of the major structural changes that we are seeing, particularly in the non-mining trade-exposed sectors such as manufacturing. Ai Group is very interested in the capacity of these companies to reinvent themselves, and we believe there should be an exploration of the possibility of improving and extending tax measures designed to facilitate the development of a strong, early-stage capital market. Certainly, Ai Group believes the Tax Forum was worth the trip to Canberra. But while the dialogue was useful, we will need to see the policy results before we can judge the true worth of these two days of talk. www.aigroup.com.au Comment at manmonthly.com.au
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AnalysisNEWS AUD down = manufacturing up? BY SARAH FALSON
A
FTER months of banging on about how low the manufacturing industry is feeling over how high the Aussie dollar is getting, last month’s news that it has suddenly fallen to a 10-month low against the USD is a beacon in the night for our manufacturing businesses. Manufacturers could have the recently-rocky US economy to thank, as trading conditions for some Australian companies will get a whole lot better. Drops in US stocks might have been caused by the Federal Reserve’s expression of concern the economy’s health, with chief executive Ben Bernanke raising announcing a new strategy to drive the country’s low interest rates even lower. China’s flagging fortunes might also be to thank for the lower Australian dollar, with falling
manufacturing production in the region leading to the selling of the AUD, driving it down. Manufacturing in China shrank for the third month in a row in September, with turbulence in the US and Europe hurting exports in the region. The Chinese manufacturing economy actually hasn’t grown for eight months now, with the rate of contraction merely slowing or rising throughout the period. Rising electricity costs and worker wages have also been blamed for Chinese manufacturing’s fall from grace. India has been taking up some of the slack, with analysts claiming it is heading for a production boom. Regardless of the reasons, one thing’s for sure: there is hope on the horizon for Aussie manufacturers, who this year have been hit by some of the hardest business conditions on record.
The Aussie dollar fell to a 10month low in October, raising hope for manufacturing.
Yes, the carbon tax has been passed; the resources sector will keep growing; skills are getting harder to pin down; and cheap imports will always be a concern. But finally, the AUD is down, and that’s good news for many companies.
Now is the time for manufacturers to get prepared for futhur fluctuation, through risk management, succession planning, and business continuity. Because, as manufacturers know only too well, what goes down must come up (er... you know what I mean).
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Manufacturers’ Monthly NOVEMBER 2011 7
AnalysisNEWS
Steel sector Endeavours for innovation BY SARAH FALSON
T
HE metalworking sector is often referred to as the ‘backbone of industry’, and the 9th annual Manufacturers’ Monthly Endeavour Awards will showcase some of the country’s most innovative products made from Australian steel. In 2012, one of the country’s largest steel-makers, BlueScope Steel, will once again sponsor the Steel Innovation Award*, helping local manufacturers receive industry recognition for their efforts. “Our sponsorship of the Steel Innovation Award is representative of BlueScope Steel’s commitment to the Australian manufacturing industry, where we encourage innovation and collaboration amongst Australian manufacturers resulting in a focus on activity that promotes growth and competitive advantage,” BlueScope manager manufacturing markets, Steve Gregson, told Manufacturers’ Monthly.
8 NOVEMBER 2011 Manufacturers’ Monthly
“The manufacture of steel in the domestic market gives Australian manufacturers the confidence of dealing with a local, reliable and consistent supplier that is committed to the Australian industry. “Additionally BlueScope Steel products are designed for Australian conditions and our high-tech manufacturing facilities and quality control processes means they are able to reliably meet (or more likely exceed) Australian Standards. This is not always the case with imported product that may not comply with Australian Standards.” For Gregson, the Endeavour Awards is an important calendar event for the manufacturing industry, as it provides a possibility for like-minded Australian manufacturers to meet and collaborate. “At BlueScope Steel we support awards programs because they provide a platform to recognize the efforts of other manu-
Local content provides a competitive advantage: Gregson.
facturers and encourages innovation through process, products, designs and projects,” he said. “We will be interested to see examples of how Australian manufacturers, big or small, build a competitive advantage while providing Australian consumers with a choice of competitive locally manufactured steel goods,” he said. For BlueScope, 2012 will be a big year for innovation, too. “At BlueScope Steel we have recently announced a major restructure of Australian operations and have a renewed commitment to prioritising our resources and efforts towards
even better service for our domestic customers,” Gregson said. “The industry is seeing a record high Australian dollar and intense competition from imported finished goods. There is a genuine desire amongst local manufacturers to collaborate in the development of innovative solutions that best suit Australian market requirements. “BlueScope Steel is specifically excited to be working on the next generation of coated products for our customers.” Entries are now open for the 2012 Manufacturers’ Monthly Endeavour Awards, so follow the contact details below to have your company recognised for its manufacturing success. [*If you want to sponsor an Endeavour Awards category in 2012, contact Michael Northcott on 0448 077 247 or michael.northcott@reedbusiness.com.au] Entries & Info: Margaret Tra 02 9422 2759, margaret.tra@reedbusiness.com.au, www.manmonthly.com.au/awards
manmonthly.com.au
EFIC DID MORE THAN FINANCE MY EXPORTS
THEY GOT BEHIND THEM. Bob Wright, Chief Executive Officer, Environmental Systems & Services
When we won a contract to install advanced satellite tracking ground stations with the Polar Research Institute of China, it should have been a dream come true. The complication was that as a new client, they wanted reassurance that we could fulfil the contract. With our reputation gaining momentum in the region this was a contract integral to our growth. We needed a solution that enabled us to support our ongoing business while pursuing overseas opportunities. EFIC provided more than just a financial solution, they took the time to get to know our business and considered
our performance risk as well as our experience in delivering on past projects. EFIC supported us with an advance payment bond as well as a performance and warranty bond, enabling us to reassure our buyer and successfully fulfil the contract. EFIC were focused on helping us realise our export ambitions. This deal transformed our business, and we’ve gone on to win multiple contracts in the region.
Overcoming financial barriers for exporters Visit efic.gov.au/mm
AnalysisNEWS
Free technology offering for readers BY ALAN JOHNSON
W
HILE there might be no such thing as a free lunch, Frank Chara of Mini Driveway Grader & Earthworks is offering Manufacturers’ Monthly readers some free, exciting new technology. This is set to have a dramatic impact on a new generation of earthmoving equipment. Yes, free. That’s zilch, nothing, no cost at all. “Taking the technology to the next stage is just too big for me,” Chara told Manufacturers’ Monthly. “It all started with a chance discovery of a mechanical device when we were developing a small earthmoving machine, the TA-37, for our radio controlled business,” he said. “Now we would like to share it with others to develop it further so that it can be applied to other machines such as a snow plough,
10 NOVEMBER 2011 Manufacturers’ Monthly
grader, aircraft or speed boat,” he said. The mechanical device is a simple secondary independent short lift arm attachment that, when fitted to a small skid steer loader, rotates the machine forward while it is pushing or digging material. This rotating motion automatically increases the downward force on the machine. This results in a substantial traction increase with less wheel spin, because the ground pressure on the machine remains constant on all surfaces. As a result, the machine is able to increase the pushing and digging limits that are currently the bane of other machines on the market, according to Chara. But on final completion of the TA-37 machine, using traditional methods, it was found to be quite expensive to produce. Chara says this is mainly due to the complex and increased
functionality of the small earthmoving machine. However, Chara believes that using lean manufacturing techniques and roll forming, with a supplementary press brake, manufacturers can minimise production costs to make the machine price competitive. “We have developed the machine so that 70% to 80% of
the superstructure, including the upper, middle and lower sections together with the transmission housing, oil tank, front lift arm and mounting plate, is manufactured from roll forming,” Chara said. For more information on the TA-37 or the short lift arm attachment, call Frank Chara of Mini Driveway Grader & Earthworks on 0427 661 550.
Top Tweets in October (chirp!) What you missed last month on Twitter... • Is the mining boom causing complacency? <Visit: bit.ly/q6EtKI> • Godfrey Hirst closes yarn making factory; 37 workers to be left jobless <Visit: bit.ly/p3dXxa> • Thales to make better and more lethal rifle under $8m upgrade program <Visit: bit.ly/nOGJft> • Online tool to calculate workers compensation costs <Visit: bit.ly/nN1Wvz> • Coca-Cola Amatil begins bottle self manufacturing in SA today <Visit: bit.ly/nanFoO> Never miss out again! Follow us @manmonthly for all the latest news, product information and comment pieces from the industry.
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AnalysisNEWS EVENTS
10 minutes with Terry Davis BY SARAH FALSON
7: CarbonExpo Australasia 2011 Australia’s premier, industry-hosted Trade Fair & Conference for emissions intensive business and low-carbon economy product and service providers across Australasia, at the Melbourne Convention & Exhibition Centre. www.carbonexpo.com.au 10 & 16: Project Management for Automation Engineers – Melbourne & Brisbane This course covers the identification of automation benefit opportunities, scoping projects that will deliver real benefits to operations, and justifying the projects for corporate approval. www.iica.org.au 5 & 12: ProEdge Manufacturing Excellence Program ProEdge is a five-day program that provides the tools to improve your manufacturing efficiency. Hosted in Bundaberg and Mackay, Queensland.
www.qmisolutions.com.au/events 15: AS 4024 Safety of Machinery Workshop – Melbourne Participants learn the vital components of this standard by engaging in relevant exercises guided by a key member of the AS 4024 standards committee. www.iica.org.au 14: Invensys OpsManage’11 Next stop is Brisbane for Invensys Operations Management’s annual series of user and industry events. http://iom.invensys.com 22–24: Practical Process Control Techniques Course – Brisbane This three-day course covers the basics of PID feedback control, fault patterns and troubleshooting, design of Advanced Regulatory Control schemes, and an introduction to higher level technologies. www.iica.org.au 25: HIMA Australia facilitated TÜV Functional Safety Program The course provides skills and knowledge for professionals working in fields requiring safety protection systems. The course also offers TÜVapproved certification. www.hima.com.au/tuv
12 NOVEMBER 2011 Manufacturers’ Monthly
T
ERRY Davis, Coca-Cola Amatil group managing director, talks to Manufacturers' Monthly about the carbon tax, the difficulties obtaining government assistance, the company's new preform bottling line, and how he always takes the drinks to his mates’ BBQs. Q. What's the best thing about being group MD of CCA? The ability to encourage and motivate people to be the best they can be at work. We have more than 15,000 staff across the Group (Australia, New Zealand, Indonesia, Papua New Guinea and Fiji) and we have tried hard to create an environment where staff come to work motivated and enthused about delivering the best possible service to our customers as possible. Q. How much time do you spend at CCA production facilities, and which is the most fun? I spend as much time outside the office as I can visiting our facilities across the Group – we have 15 in Australia, eight in Indonesia, five in New Zealand and one each in Papua New Guinea and in Fiji, as well as hundreds of distribution centres. We are currently undertaking the biggest and most comprehensive capital infrastructure and equipment investment program across the Group in the past 10 years, so reviewing the progress at any of our facilities which are installing our high-tech ‘blow fill’ bottle self-manufacturing technology onto the production lines has been very important. Q. What's the one piece of technology/equipment that CCA production facilities couldn't live without? The self-bottle manufacturing, or ‘blow fill’ technology, which has revolutionised our bottle manufacturing processes in that we are no longer fully dependent on suppliers of PET beverage containers. ‘Blow-fill’ enables us to design our PET bottles to our own unique designs, using less PET resin, and reducing the requirement to transport pallets
of empty bottles from the supplier to our production facilities. The technology has delivered a 20% reduction of the carbon footprint of each individual bottle. The preform facility, along with the bottle self-manufacture project, will deliver greater efficiencies in production, input costs and customer service, resulting in an estimated $90 million annualised total savings when the rollout is completed in 2015. Q. CCA didn't receive R&D funding for the perform technology. Is the government doing enough to support manufacturing R&D? For the preform and closure facility, we received only the standard customs duty concession for imported capital equipment for a new facility. The Federal Government has recently changed the rules for R&D, which we expect will limit the ability of our company to access tax relief for activities and projects that used to qualify for the R&D concession. It’s my view that the Government should consider reinstating reasonable R&D for the Australian food and beverage manufacturing industry. One of the biggest manufacturing sectors in the country, it is under sustained competitive market pressure from the strong Australian dollar and the influx of cheap, imported low quality produce. Q. What's your view on the carbon tax a) as a businessman b) as a citizen? My personal belief is the same as the one I hold for CCA: I believe strongly that all of us, individuals and large companies, must do all we can to decrease our carbon footprint and energy use. We all have a role to play in working to use the best possible mix of energy sources. At the same time we need to improve the energy efficiency of our manufacturing and distribution processes – which we are doing successfully at CCA, particularly with bottle self-manufacture; improving fuel use in
The government could do more to support R&D for the Australian food and beverage manufacturing industry: Davis.
our vehicles, installing a solar energy system in our Eastern Creek Distribution Centre, and supplying our customers with some of the most energy-efficient coolers in the world. However I remain concerned that a carbon tax will be discriminatory – it will impact negatively on input costs for Australian food and beverage manufacturers, which in turn will affect those who can afford it least, the farmers and growers. The cumulative effect of driving up manufacturing costs in Australia means that we become less competitive against imported goods and more reliant on importing food and beverages. In the event we get a carbon tax the Government should provide offsets, such as eliminating payroll tax for Australian manufacturers. This would send a clear message that this government is serious about having a strong manufacturing sector, because we will certainly need one after the mining boom – remember, mining contributes only 8.5% of Australia’s GDP, and Australian manufacturing contributes substantially more. Q. Do you always bring the drinks when you're invited to a BBQ? Of course – my mates hit me up for the drinks – and these days it’s alcoholic as well as nonalcoholic. We have a great range to choose from, more than 80 different beverages, so it depends on the occasion. I can bring everything from Jim Beam and Cola, Peroni or Bluetongue, through to Coke and Mother, and even Goulburn Valley juices and Mount Franklin for the nondrinkers. [To read the expanded interview, go to http://bit.ly/qGfujV] Coca-Cola Amatil 132 653, www.ccamatil.com manmonthly.com.au
Conservatism is a barrier to growth BY MARGARET TRA
A
USTRALIAN manufacturers might blame weak exports and a high dollar for the industry's decline, however a new white paper ‘Change or be left behind’ by Canon Australia identifies people and technology as key barriers preventing the industry from moving forward. According to the survey, one of the biggest contributions to these barriers is the ‘conservative’ nature of Australian manufacturing businesses. A high 77% of business leaders in the industry revealed fear of the ‘unknown’ as an immense barrier when implementing technology changes that could improve their business’ efficiency. It indicates Australian business leaders rank themselves 30% on their ‘willingness to change,’ behind China (86%), and India (53%), but ahead of Germany and the US. Over half of employees (59%) interviewed cited lack of trust in new systems and lack of trust in management directors as a significant factor to preventing change. Despite seeing the benefits of change and the role of technology in this change, people were identified as the main obstacle for driving change. The survey also revealed that around one-third of manufacturing employees and business leaders (34%) placed lack of vision and direction, or leadership, as the biggest barrier to the possibility of change. According to Canon Australia group product manager for solutions business, Luke Maddison, the survey’s findings are clear signs that the local industry needs to change how it conducts business. Reluctance to change on the part of many manufacturers has limited, and in some cases prevented, the implementation, adoption and delivery of new technologies and more efficient processes, he says. This reluctance has led to what manmonthly.com.au
has been coined ‘conservative manufacturing’. “Technology is the main driver of change; being able to manage processes around change is really important,” Maddison told Manufacturers’ Monthly. To effectively execute a ‘good’ change management program, Maddison says that identifying and aligning with stakeholder groups, as well as working with influential industry leaders, is needed to ensure that everyone in the company and on the floor will be on-board with the new processes. This, he explains, will prepare a more positive result – from floor staff through to management personnel – as they are not kept in the dark about changes and developments. More importantly, it eases people into the change process, and removes the shock and fear change would bring – especially for those who may have been with the company in a particular role for a while. Maddison says the best approach for such a program is having a well-considered and thought-out approach. “When having an effective change management program, the key challenge is communication, ensuring when communicating change it’s about having a clear vision and a clear structure around that,” Maddison said. Breaking through barriers One company proving that change can lead to more efficient production processes is Australian paint manufacturer, The DuluxGroup, which has recently installed an automatic solution. The company’s previous system, which has been in operation for 25 years, involved staff handling decant loose, heavy bags of powders, which caused a hazardous work environment. However, due to changing market demands, and the need for a safer environment, the company decided a change was in order. Working together with the engineering team at Robotic Automation, Dulux developed a
Manufacturers need to change the way they do business: Maddison.
Centralised Make-up Facility, which consisted of three new robotic systems. These systems ensured the products were moved safely and more efficiently. Dulux production manager, Gavan Dowal, said the decision to make the technology change was initially tough, because of the scale of the project, and also the logistics involved. However careful planning and a wellstructured process made the transition to new technology smooth for both staff and management. Dowal says taking a controlled risk management approach is one way of ensuring a successful
MILLIONS
OF
transition to new systems. “It comes down to the fact that when you integrate something a little bit technological, a little bit ‘out there’ into a process, you have got to make sure that stakeholders need to be educated. They need to be on board with the journey, because it is a journey when you make a significant change,” he said. An essential part of the process is clarifying the key objectives from the start, before the project is underway, much like completing a training course, Dowal explains. “When you do a training course you set an objective, you put little tests in towards the end of the training to see if they have an understanding of what you have set out to achieve,” he said. “I don’t think that exist for projects similar to ours, this is where they fall over.” Canon Australia 02 9805 2210, www.canon.com.au DuluxGroup 132 525, www.dulux.com.au
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AnalysisNEWS Automotive, TCF biggest losers in 2020 outlook BY SARAH FALSON
T
REASURY modelling has painted a pretty bleak picture for certain Australian manufacturing sectors in 2020, with car manufacturing and component-making expected to decline 39%. However, the steel industry has been pitched to grow 10%, which is a positive result after so much bad news in the sector. Of great concern is the expectation that our hard-fighting textiles, clothing and footwear sector (TCF) is likely to be down 34% by 2020, however this forecast won’t come as a surprise to those involved in the sector. The Aussie manufacturing industry all up is still expected to grow though, by 5% on 2011 levels, which is good news for an industry that’s been told it might not be around in 10 years. The steel sector is the biggest dark horse in the modelling report, expected to grow 10% by 2020. This suggests last month’s
The steel manufacturing sector is expected to grow 10% by 2020.
The Aussie manufacturing industry is expected to grow by 5% on 2011 levels, which is good news for the industry’s future. 1,400 redundancies in the steel sector could allow the sector to stop, reassess the situation, and reboot for growth.
It also suggests the pressures of the carbon tax and electricity prices, cheap overseas imports, and the high Australian dollar,
won’t be such unsurmountable obstacles in the future. Not surprisingly, the mining sector will flourish, with modelling on the government’s carbon pricing package predicting the resources sector to grow a whopping 77% by 2020. That includes rises in coal mining (45%), gas (100%), iron ore (104%), and non-ferrous ore (92%). Manufacturing and agricultural skills are expected to migrate to the resources, services and construction sectors, which all show positive growth in the Treasury modelling. All up, things are looking up for the Aussie economy, regardless of speculation that we’re heading into another recession. "The economy continues to grow strongly under a carbon price, with real gross national income per person growing at an average rate of 1.1% to 2050," said Treasurer Wayne Swan. Comment at manmonthly.com.au
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AnalysisMANAGEMENT Pathways to sustainable manufacturing Manufacturing business models look set for a major upheaval with calls for more collaboration and new ways of thinking about sustainable design and manufacturing processes. Hartley Henderson writes.
I
N THE prevailing climate of economic and political uncertainty around the world, there is increasing questioning of the strong historical focus on growth, and recognition of the need to find pathways to sustainable manufacturing. Professor Richard Hames, director of the Asian Foresight Institute in Bangkok is an Australian futurist who believes that there is an urgent need to transform industry and that today’s system is unsustainable. “We need to develop a system that enables us to prosper without growth and the prevailing addiction to consumerism. With 7 billion people on the planet, a world over-population crisis is fast approaching,” he told a recent conference in Melbourne. “Some 15-20% of the world’s population is obese, while on the other hand 15-20% is starving. Food, water, climate, and social and economic systems are all in a state of tremor, if not collapse, and we can see the start of a breakdown of social order and the possible failure of nation states. “Tomorrow’s businesses will need to harness new technologies to improve productivity, and we must quickly move from a fossil fuel based system to renewable energy. “There is a need for new business models including networked intelligence, collaborative codesign, and the development of niche manufacturing of new products. Australia can punch above its weight and become a design laboratory for the rest of the world. We must move from intense competition to collaboration, because the future is about design, not machine thinking,” Hames said. Leading carpet tile manufacturer, InterfaceFLOR, is actively pursuing a Mission Zero objective to eliminate any negative 16 NOVEMBER 2011 Manufacturers’ Monthly
Tomorrow’s businesses will need to collaborate and harness new technologies to improve productivity.
impact by the company on the environment by 2020. Central to this is a strong focus on Life Cycle Assessment (LCA) to identify the environmental impacts in product life cycles, including both downstream and upstream influences on the company’s footprint. InterfaceFLOR’s CEO and president of the AsiaPac region, Rob Coombs, says it is important to look at the whole of life impact of the company’s products. For example, only about 15% of its CO2 emissions relate to its own manufacturing activities. “We work closely with upstream suppliers of materials as well as downstream providers of services such as transport to reduce our LCA footprint,” he told Manufacturers’ Monthly. “Our sustainability drive start-
ed by introducing a war on waste at our factory in Picton, NSW, which calls for a reduction in waste of 10% year after year. “Other achievements include reduced emissions from process energy by 41 percent, reduced water consumption by 60 percent, and reduced non-renewable energy by 72 percent. In addition, our use of recycled and biobased materials has increased to 39 percent,” Coombs said. “To date we have diverted more than 250,000m2 of carpet tiles from landfill through our ReEntry recycling program, InterfaceFLOR packaging is now made from 100 percent post-consumer recycled content, and new innovative sustainable products have been designed. “Such results are having a significant beneficial effect on the company’s bottom line. Better
products are being produced at lower costs, and this is helping us to compete effectively with Asian-based textile companies. InterfaceFLOR is now one of the most profitable companies in the global carpet manufacturing industry.” Coombs points out that people increasingly want to work for sustainable companies, which is especially important in a highly competitive labour market. “At the end of the day there must still be a strong profit motive, but there are ethical ways to make money and a key is to replace old ways of thinking with sustainable design and manufacturing processes,” Coombs said. Asian Foresight Institute www.asianforesightinstitute.org InterfaceFLOR 02 8332 2400, www.interfaceflor.com.au manmonthly.com.au
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TechnologyIT@MM change it can be a nightmare. “People spend a lot of intelligence and mental bandwidth on that thing. It’s not modelling it’s programming. “It’s more about thinking about how you need to design it so the end design won’t break rather than the actual design of the product to please customers,” Newbury said.
Free offers Siemens PLM’s Kirsten Newbury believes SolidEdge has the superior technology to knock SolidWorks off the number one spot in the 3D CAD market.
CAD battle gets serious The ongoing war between 3D CAD heavy weights, Siemens PLM’s SolidEdge and Dassault’s SolidWorks, has reached a new level, with SolidEdge claiming second spot in the highly-competitive market. Alan Johnson reports from Boston.
L
OOK out SolidWorks; we are coming to get you. This was the key message from Siemens PLM’s recent analyst conference in Boston – with some impressive growth figures to back up those claims. Kirsten Newbury, Senior VP of Siemens PLM’s Velocity Series, believes he has the product (SolidEdge) and the technology (synchronous technology) to knock SolidWorks off the number-one spot in the CAD market. “We see many reasons for growth, and for taking business away from SolidWorks. “A key element is that SolidEdge, with synchronous technology, is very easy to use," Newbury told Manufacturers’ Monthly. He said users moving from 2D CAD to 3D CAD was just one example. “We have found that synchronous technology has played a key role there. SolidEdge is much more intuitive for a 2D user to go 18 NOVEMBER 2011 Manufacturers’ Monthly
to 3D with synchronous technology than going into the whole parametric modelling with a big learning experience. “SolidEdge has a lot of functionality; you can take 2D sketches and extrude them quickly into 3D.” Newbury said the concern among SolidWork’s users regarding the change of kernel was also boosting sales of SolidEdge. “This is an added opportunity for us,” he said. Describing history-free SolidEdge as a new generation of design, Newbury said synchronous technology was a key element. “Mainstream designer are very passionate about design and spend a lot of time working at it. SolidEdge helps them design better products more efficiently; that’s the key. “There’s the creation part where synchronous technology can show them how quickly they can create things, and test them.
“However designers spend a lot of time just editing. If you look at all the difficulties that people have importing other CAD files and getting them ready to make changes, or making changes; users of 3D CAD understand the issues they are facing with the current history based approach. “That’s why we want people to attend our Edge events and show them how much quicker they can do things; minutes instead of hours, sometime days. “Time spent on a particular task is one major area of benefit, the other which is equally compelling is the mental bandwidth required with a history tree. A lot of thought needs to go into that,” Newbury said. “With history-based systems, you have to think ahead. If you build a model, what changes can happen, there is a whole discipline art around doing it right, because if you don’t , the moment you try and make a
To further attract new users to SolidEdge, Siemens PLM has announced a student edition of the software available free of charge to all full or part time students throughout the world at any academic level. This no-charge 12-month license is available only to students through an easy, instant download. According to Newbury, it contains the latest Solid Edge functionality necessary to create detailed product designs. To register for and download the Student Edition of Solid Edge, students can visit www.siemens.com/plm/solidedge-student. The license can be renewed each year provided the user remains a qualified student. Since the Boston conference, Siemens PLM has now launched a free 45-day trial version of SolidEdge online for all potential users. Newbury described it as, “a full blown version with no strings attached”. “The whole idea is to get this great technology out there and make it easily accessible. “Regarding training we are offering a forum where we can answer questions, plus there are training videos and training slides. That’s what we are starting out with; we think there is a lot more we can do around that. We fully believe in the power of Synchronous Technology as the future of design and modelling. “We don’t believe 2D will ever go away, people still like to look at paper, so we support both, but the move from 2D to 3D is a big opportunity for us, especially in Asia,” Newbury said. manmonthly.com.au
Sustainability With consumers and various regulations forcing manufacturers to understand and improve the environmental footprint of their products, Siemens PLM has developed, through a third party, a sustainable product design software package; Solid Edge EcoDesigner. “In many ways, sustainable product design is about lean engineering and taking waste out of your product’s lifecycle,” Newbury said. “Life Cycle Assessments (LCA) is the science of environmental assessment defined by ISO 14040:2006 and ISO 14044:2006. It specifies rigorous and standardised steps and protocol for an environmental impact assessment over the entire lifecycle of the product. Performing a full LCA can require significant expertise and effort. “EcoDesigner software allows users to perform a screening or light LCA analysis earlier in the design cycle to evaluate part and
assembly designs quickly.” The software is said to be easy to use, with users able to perform sustainability analysis directly in the designers work space. Users can choose from a range of well-known and accepted impact assessment methods and indicators that are most relevant to their industry, geography and product. Solid Edge EcoDesigner is available in two versions: A standard standalone version which uses pre-calculated datasets from Eco Invent, USLCI and ELCD (leading providers of lifecycle inventory data), and an enterprise version which connects with and performs real-time analysis with SimaPro the world’s leading LCA Software from PRe’ Consultants (www.pre-sustainability.com). This version is designed for extensive collaboration amongst fellow product designers and sustainability experts.
Laser tracker measurement software FARO’s CAM2 Measure 10 is a new measuring software for the FaroArm, ScanArm and FARO Laser Tracker, designed to make tactile and scanning measurements easier. CAM2 Measure 10 reportedly builds on the foundation of the previous CAM2 Q, while also introducing new features like Live Color Scan for point cloud inspection, Shortcuts and the Easy Move Wizard. These functionalities are designed to improve measurement processes, whether tactile or scanning. The Live Color Scan feature adds point cloud inspection support to the geometry measurement functionality. CAM2 Measure 10 users can quickly scan freeform parts using the FARO ScanArm – reportedly just as easily as they are measuring geometry with a tactile probe. In a few steps they can complete a scanning inspection, viewing live colour information on their parts as they scan. Another time-saving feature of the new release is Shortcuts, allowing users to create new commands to measure features that are only available through combining measurements and constructions. Shortcuts enable users to record all steps of a complex measurement into a single command that can be easily accessed later. The Easy Move Wizard assists measuring large parts when the need to reposition the device is necessary to complete a measurement. The complexity of finding the correct target correspondence is taken away from the operator, cutting down on the time required for the repositioning and, at the same time, removing the risk of human error, claims FARO.
Siemens PLM 137 222, http://aunz.siemens.com.au
FARO, www.faroasia.com/CAM2Measure
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Manufacturers’ Monthly NOVEMBER 2011 19
Technology IT@MM “By sustainability I mean a holistic view, from cradle to grave. It’s not only how you produce the product and the material you are using, but also how you decommission a product and its impact on the planet.”
the same time look at the four parameters for sustainable design. “We loop the loop. Today we have included solutions which allow you to design a cost effective product while at the same time looking at the product’s impact on the planet,” Sicot said. Calls for a product’s environmental impact to be measured at the beginning of the design process.
Innovative design now the clincher BY ALAN JOHNSON
M
ANUFACTURERS should forget worrying about the possible effects of the Federal Government’s carbon tax and make more of an effort to design their products in a sustainable way. Bertrand Sicot, US-based Chief Executive of SolidWorks, believes Australian manufacturers should make more of an effort to design their products in a sustainable way. “By a sustainable way, I mean taking a holistic view of the impact of design decisions – considering material efficiency, production waste, disassembly and re-manufacturability of the product or project. “Companies who fail to realise this will be at a significant competitive disadvantage,” Sicot told Manufacturers’ Monthly on his recent visit to Australia. “It’s all about innovation. If you want to stay ahead in whatever industry you are in, you need to innovate. There is now a
20 NOVEMBER 2011 Manufacturers’ Monthly
growing trend in industry to sustainable design. It’s no longer just a buzz word. “And it’s not only about green products, it’s also about making sure that over time it can become a competitive advantage. “We believe at Dassault, we have the technology in the design process to help companies to achieve that.” Sicot says it’s important for manufacturers to work on the sustainability of the product early in the design process. “For example, when you design a product, 85% of the product is often set in stone by the engineering department, so if you don’t think about innovation, specifically sustainability, ahead of time then you cannot change anything.” “Whether we like it or not, the next generation, our kids, will be sensitive to sustainability issues, because we have no other choice,” he said.
Price not the only issue Sicot says many manufacturers make the mistake of thinking
their customers are just interested in price, “the lower the better”. “The idea that sustainability in a product makes it more expensive is not true. “By sustainability I mean a holistic view, from cradle to grave. It’s not only how you produce the product and the material you are using, but also how you decommission a product and its impact on the planet. “When you design a product you can define the geometry, you can do some FEA (finite element analysis) with our simulation product on how it’s going to behave, and then there is another form of simulation you can do, the sustainability simulation of the product. “That’s what we can deliver to our customers, to understand better what the environmental impact is of their design.” Sicot explained that SolidWorks’s Sustainability product now has a costing module, where the engineering department can create the product, plus look at the cost of it and at
Kernel change When questioned on Solidwork’s proposed kernel change, Sicot bristled at the suggestion that users will be disadvantaged. “There is no kernel change, we are working on the next generation of CAD and the next generation of SolidWorks will be based on version 6 platform of Dassault Systems,” Sicot said. He was adamant this move will have no impact at all on SolidWorks customers. “It’s all a game; we know our competitors speak a lot about us. I like that, it’s free advertising.” Sicot scoffed at the idea that Siemens PLM’s history-free synchronous technology feature is an advantage, describing it as a “marketing ploy”. “The reality comes from our users, who say having a history tree alongside their design has a lot of advantages. “It’s not a question of having a good marketing word, it’s making sure the users have what they need, and that’s all that matters for us at SolidWorks,” Sicot said. SolidWorks is represented in Australia by Intercad and SolidTech. Intercad 1300CAD CAM, www.intercad.com.au SolidTech 1800 824 883, www.solidtech.com.au
Comment at manmonthly.com.au manmonthly.com.au
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Portable diesel compressors THE new series of air compressors from Sullair Australia offers a range of operating specifications that are designed for the harsh conditions in manufacturing and construction industries. Available in four capacities – 550, 600, 700 and 750 acfm – the compressors deliver a range of working pressures from 80–250 psig. Several key features have been incorporated into the design of the new series, including robust highway running gear with a new single axle configuration. The engine is available as a Caterpillar C7, Tier 3 emissions compliant unit, delivering 250hp. The combination of these features has reduced the overall weight of the com-
pressor by 1.2 tonne, providing increased manoeuvrability and portability, says Sullair Australia. A new design for the canopy and service doors is another feature of the portable diesel compressors. The modular design of the canopy allows for sectional replacement or removal as one piece. The large service doors provide access to the fuel tank, engine, compressor and air filter, with a rear service panel to provide access to compressor cooling components.
2,500kg capacity pneumatic tyre forklift THE H50CT pneumatic tyre forklift from Adaptalift Hyster is designed as a cost-effective option for moderate materials handling applications. The forklift offers sealed electrical connectors to O-ring face seal fittings on the truck chassis, durable transmissions, good fuel economy, operator comfort and ergonomic design, says the company. With a lift capacity of 2,500kg, the H50CT is said to strike a balance between the number of loads it moves and the amount of fuel it uses, which is 12% per cent less fuel than similar
22 NOVEMBER 2011 Manufacturers’ Monthly
forklifts use on average. The optional integral sideshifter allows loads to be optimally positioned, and the responsive electronically-controlled inching adjustments are designed to give the operator better control of load positioning. The H50CT is suitable for applications in agricultural, general warehousing and distribution, beverage distribution and bottling, light manufacturing, or retail. An optional 2.6L diesel engine is also available. Adaptalift Hyster 1300 880 335, www.aalhysterforklifts.com.au
Efficiency of the new series has been enhanced by adopting a three-stage filtration process, says Sullair Australia. Additional improvements include the SSAM shutdown system with an annunciator module to warn the operator of high temperatures, low fuel or pressure. The control systems have
been fully revised to provide real time information presented in a user friendly control panel. The new series will be available for shipment from December 2011. Sullair Australia 1300 266 773, www.sullair.com.au
Free downloadable CAD, CAE trials SIEMENS PLM Software is now offering free downloads of its Solid Edge and Femap software that include NX NASTRAN software. The software can be downloaded and used at no-charge for 45 days. This offer from Siemens PLM provides free trial licenses for the full production versions of Solid Edge ST4 and Femap 10.2, and includes access to extensive learning resources, the company says. Solid Edge ST4 offers 3D computeraided design (CAD) with synchronous technology, which Siemens PLM says
is a unique capability combining the speed and flexibility of direct modelling with the precise control of dimension driven design. Femap is a computer-aided engineering analysis (CAE) software, reportedly delivered in an easy-to-use application. The software is available in multiple languages. A description of the programs with a link to the free download sites for Solid Edge and Femap can be found at the websites below. Siemens PLM, www.siemens.com/plm
manmonthly.com.au
Non-corrosive, modular piping system ATLAS Copco Compressors has introduced a modular piping system called the AIRnet. The system is made from a robust lightweight aluminium tube and has been designed to ensure minimum pressure drop for maximum energy savings, says Atlas Copco. With a large selection of fittings, the AIRnet can be used to extend existing pipe work systems or to supply complete installation solutions. Pipe identification is made easy with a blue coloured pipe for compressed air and a green pipe for nitrogen. The non-corrosive properties of AIRnet maintain a constant air quality
from the compressor room to the production equipment. The AIRnet system offers a range of powder-coated aluminium pipe, engineered polymer and aluminium fittings, with associated assembly tools to cover the nominal pipe sizes from 20 to 80 mm or the equivalent inch to 3 inch nominal pipe sizes. AIRnet is compatible with most types of compressor oils and can be submitted to a working temperature from -20°C up to +70°C, and pressures up to 13 bar. Atlas Copco 02 9621 9999, www.atlascopco.com.au
The tubing ensures minimum pressure drop.
HMIs enhance machine visibility THE Allen-Bradley PanelView Plus 6 range of human-machine interfaces (HMIs) are designed for applications that require monitoring, controlling and displaying information in dynamic ways, where operators must quickly understand machine status in order to make better decisions. The terminals range in screen size from 7 to 15 inches, and come in models offering touchscreen only, keypad only, or a combination of the two, along with including conformal coating and Marine-certified models. The units incorporate a memory increase from 64MB to 512MB over the previous models from Rockwell, and support graphics enhancements
along with larger application runtime files, expanding the terminalsâ&#x20AC;&#x2122; capacity to handle demanding applications, the company claims. The power has been increased from 650MHz to 1GHz processing speed, designed to enable operators to get to the screens and data they need faster, avoiding errors and improving their ability to respond. The units also offer remote monitoring utilising built-in VNC and FactoryTalk ViewPoint server; built-in PDF viewer for user manual and troubleshooting guides; and remote recipe and data management. Designed for applications that require monitoring, controlling and displaying information in dynamic ways.
Rockwell Automation 03 9896 0300, www.rockwellautomation.com.au
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What’sNEW Forklifts with mast controller TOYOTA’S new 7-Series forklift range comes standard with the company’s System of Active Stability (SAS), which incorporates an active mast function controller and tilt levelling features. Models in the new series of forklifts offer three-way closed loop catalytic muffler systems, double-action handoperated park brakes, neutral start safety switches, and memory tilt steering columns. The vehicles also have low, wide-
entry steps with dual operator assist grips. Toyota says the 7-Series also benefit from low noise emissions and high visibility overhead guards. Three models are included in the range: 7FGU60, 7FGU70 and 7FGU80 in 6,000kg, 7,000kg and 8,000kg capacities, replacing Toyota’s current 5-Series models. Toyota Material Handling 1800 425 438, www.toyotamaterialhandling.com.au
Asset management iPad application MEX has released an asset management application for the Apple iPad, designed to enhance operational efficiency for businesses by allowing mobile workers to access the MEX platform on-the-go. The new iPad ‘app’ provides a convenient, on-the-go asset management tool that cuts downtime and streamlines the resource management process to allow for instant updates to the client’s MEX platform, says MEX. The iPad tool links in with a client’s
existing MEX system allowing for paperless work to be done. Any updates to the iPad app will inform tradesmen or field workers of all new work immediately, says MEX. The application is designed to give workers greater control over maintenance operations, including assets, work orders, purchasing and reporting. It also helps minimise risk by ensuring task details are recorded immediately. MEX Maintenance Software 07 3392 4777, www.mex.com.au
Three models are available, in 6,000, 7,000 and 8,000kg capacities.
Chemical-resistant, plastic floor matting FLEXIBLE Drive Agencies (FDA) has released two new plastic floor mats in yellow and black colours: Vers-A-Tile Flooring and Link-Mat Flooring. Both mats are designed for industrial and domestic applications, especially where OH&S is a concern. The products are designed for use in potentially wet and slippery areas such as workshops, factory floors, trucks, utes, boat decks, pool areas and a range of other areas. The Vers-A-Tile is chemical resistant,
offering protection against the effects of high temperature exposure. It is also resistant to water and water vapour, and is reportedly easy to install and clean, and comfortable on the feet. The Link-Mat Flooring version is corrosion proof on concrete and hard floors, and cool in summer and warm in winter, the company claims. It is resistant to salt, oil, beer, wine and spirits. Flexible Drive Agencies (FDA) 1300 363 735, www.fdrive.com.au
macnaught flow measurement
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Macnaught has now introduced 4 new product lines that are optimised for dispensing and batching of Fuels and Lubricating Oils, Corrosive Chemicals, Solvents, and Industrial Process Fluids. The product lines include a broad selection of flow ranges, optimised materials of construction, and a full range of accessories that make Macnaught Flow Measurement products easy to select, easy to install, and easy to maintain.
For more information call (02) 9567 0401 or visit macnaught.com.au 24 NOVEMBER 2011 Manufacturers’ Monthly
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Idler pulleys for timing belts THE new Type P Idler Pulleys from PIES Australia are designed specifically for timing belts, and come in 11 standard sizes to suit most models. The pulleys are made from aluminium and come fitted with two deep groove ball bearings. Guide flanges to help keep the timing belt on track come as a standard on all 11 sizes. The Type P Idler Pulleys are an easy, cost effective solution for any timing belt drive design whether you have a fixed shaft centre distance or an exist-
manmonthly.com.au
ing drive that requires an Idler, PIES claims. The units can be run on the teeth or outside of a timing belt. The pulleys suit all types of timing belts such as polyurethane, rubber, metric and imperial timing belts. Sizes range from 20mm up to 120mm OD and suit everything from 6mm wide 2mm pitch timing belts up to 50mm wide 20mm pitch timing belts. PIES Australia 03 9303 2063, www.piesau.com.au
BOGE’s new BC series converters are designed to cost-effectively assist the production of oil free compressed air to Class 0 (ISO 8573-0) quality. The converters are being marketed as the ideal way to generate oil free compressed air, when price is of the essence. The unit is suitable for industries such as PET, food and drinks and pharmaceuticals, where generating absolutely oil-free compressed air is paramount, says Boge. The BC series converters are installed directly downstream from the compressor, making downstream oil penetration impossible, the company says. The BC converters are reportedly
Cost effectively produce oil free compressed air to Class 0 (ISO 8573-0) quality.
very energy efficient, operating with a low energy consumption level between 0.01 to 0.005 kWh/Nm3. Additionally, with no filter pressure loss either, operating pressure can be optimised, the company says. BOGE Compressors (Australia) 08 9528 2157, www.boge.net.au
Contactor select iPhone application A NEW Contactor Select iPhone app from NHP is designed for selecting contactors and overloads for three phase electric motors. Users select the motor voltage and kW, and the app will display the motor FLC (amps) and suggest which con-
tactor and overload to use. The Contactor Select App can select from either of NHP’s Sprecher + Schuh or Allen-Bradley brands, providing users with the exact product number. NHP Electrical Engineering 03 9429 2999, www.nhp.com.au
Manufacturers’ Monthly NOVEMBER 2011 25
What’sNEW - Pumps & Valves Sand filter nozzles for water treatment TECPRO Australia is now distributing ILMAP high precision Sand Filter Nozzles for water treatment applications. Models in the ILMAP range are available in a variety of special plastic formulations to provide increased strength, durability and chemical resistance, says Tecpro. This includes glass-filled polypropylene (30% fibre glass) for increased strength and temperature resistance, with a permitted maximum operating temperature of 110°C. The units also come in mineral-filled polypropylene (40% mineral talc) for increased dimensional stability and
compression strength under higher temperatures. PVDF (polyvinylideneflouride) is also available for optimal mechanical strength, abrasion resistance, thermal stability, purity and chemical resistance. The PVDF models are reportedly suitable for contact with drinking water and drinking liquids; this material can be used up to a maximum operating temperature of 135°C. ILMAP is an Italian manufacturer specialising in designing, sizing and supplying filtering solutions for water treatment systems. Tecpro Australia 02 9634 3370, www.tecpro.com.au
Water sorption analysis instrument THE DVS Intrinsic is an economical research-grade water sorption instrument, providing high quality isotherms with minimal operator training, according to manufacturer ATA Scientific. Water sorption behaviour is accurately determined on very small samples (1-20 mg) thus providing savings in the time required to reach water sorption equilibrium. The system can perform isoactivity measurements in which materials are kept under constant RH conditions while linearly or stepwise varying the temperature. Traditionally, the water sorption properties of solid materials have been evaluated by storing samples in sealed jars containing saturated salt solutions and then periodically weighing these until equilibrium is reached.
26 NOVEMBER 2011 Manufacturers’ Monthly
Submersible level transmitters
Apart from being highly time and labour intensive, this manual method has several other disadvantages including: larger sample sizes needed (10-100g); inability to measure the kinetics of water sorption/desorption; risk of mould formation and high weight loss/gain errors, says ATA. In contrast, the DVS Intrinsic reportedly offers an extremely rapid, highly sensitive and accurate means for the determination of moisture sorption properties of solids. ATA Scientific 02 9541 3500, www.atascientific.com.au
Water sorption is determined on small samples of 1 to 20 mg.
The nozzles come in various plastic formulations for increased strength.
DWYER Instruments has released the new Series Miniature Submersible Level Transmitter (MBLT). The transmitter is designed for level monitoring in well and borehole applications, but can also be used for environmental monitoring applications, such as ground water monitoring, surface water monitoring and dewatering, and various other manufacturing applications. The MBLT has a welded 316 SS body and 316 SS nose cap. The body top is 316 SS and tapered to prevent damage or snares when pulling the unit out of the installation, according to Dwyer Instruments. It has full scale accuracy output precision ±0.25%, which is reportedly better than BFSL or BSL rated outputs used by most competitors. In addition, lightning and surge protection is included standard, ensuring the instrument stands up in harsh applications. MBLT is available in polyether polyurethane or ETFE cable materials. All transmitters are vented for barometric pressure compensation, says the manufacturer. The vent is covered with a maintenance-free filter, which reportedly prevents particulate or water droplets from entering the transmitter. The series is available in standard pressure ranges from 15 to 690 feet of water column. Dwyer Instruments 02 4272 2055, www.dwyer-inst.com.au
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Custom shut-off valves for gas, water RUB is an Italian manufacturer of shutoff brass valves with a focus on ball valves for gas, water, air and oil installations. The company develops products for many different applications as well as OEM products tailored to customer's needs. RuB’s offerings meet ISO 9001 and PED. The company’s engineers reportedly work closely with customers at every stage of special product development, from design, to prototype, testing and final production.
Special OEM products include: gas/water valves combining various features into one product; brackets with several valves and fittings assembled and ready for use; oil drain valves for trucks; special pumps valves; refrigeration valves; T- connectors with integrated mini ball valves for water dispensers and coffee machines; and more. RuB’s solutions use several brass alloys, aluminium and steel.
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Broad seals range available online SEALNET, a division of Oz Seals Australia, now has a wide range of ‘standard’ hydraulic and pneumatic seals, packings, mechanical seals, seal kits and customised special seals available from its new online store. The company is supplying seals from brand-names all over the world, from its new Sealnet OzStore; models are available for various manufacturing applications. Oz Seals’s own range of seals and sealing systems are also available on
the website, for hydraulic and heavy duty hydraulic applications, as well as fork lift trucks, injection moulding machines, presses, diesel engines, and valves and pumps. The company can also manufacture products to suit special orders, and will hold these specifications in-store for repeat orders. Oz Seal also makes its own seal manufacturing systems. Sealnet (Oz Seals Australia) 1300 792 600, www.sealnet.com.au
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Automation&ROBOTICS Productivity gains put Streets ahead Quick implementation of Siemens SIMATIC PCS7 and SIMATIC Batch technologies deliver increased productivity that allows Unilever Streets Ice Cream to meet unprecedented demand. By Sean Cahill.
M
ANUFACTURING ice cream is a precise and delicate process, requiring tight control to ensure the quality of the final product. The only way to achieve this is through the use of leading technology, like the PCS7 process control solution from Siemens. The ice cream manufacturing process begins by blending milk and sugar, then adding colours and flavours. The ingredients are then blended further and pasteurised to purify the mix undergoing a homogenising process that breaks down the milk fat to provide a creamy, smooth blend. The purpose-built Minto plant comprises two main batching tanks, a pasteuriser, homogeniser and more than 30 storage tanks, all connected by a network of
pipes. The largest of the storage tanks can hold 12,000 litres of liquid ice cream, while overall the mix plant at the heart of operation produces up to 18,000 kg of mix per hour at full production.
A complex mass of plumbing makes up Streets’ processing equipment.
A recipe for success Although the Minto plant met the demands of consumers during the 12 years since its opening, the plant’s old control system had become increasingly problematic. According to Street’s mix plant manager, Graham Haigh, the aging control system was causing significant problems to the manufacturing process. “There were issues which the old control system was incapable of helping us to resolve. Also, it
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28 NOVEMBER 2011 Manufacturers’ Monthly
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The switchover went smoothly and the first batch of ice cream was produced within four days.
Having reached breaking point, a decision was made to replace the obsolete control system with a new generation one. Streets embarked on a meticulous evaluation process over many months to clearly identify its plant’s requirements and expectations for the control system platform. Siemens SIMATIC PCS 7 process control system and its recipe management system SIMATIC Batch was eventually selected, being identified as the system most capable of meeting the stringent demands of the mix plant. As the Streets plant must produce a wide variety of ice cream blends to meet the requirements of the company’s portfolio, a flexible recipe system was critical. Siemens SIMATIC Batch met this requirement effectively while ensuring product quality and consistency demands were addressed. However, what really convinced Streets was the positive experiences of its sister plant at North Rocks, NSW, which used the same technology. Unilever North Rocks had installed SIMATIC PCS 7 and SIMATIC Batch on its Health and Beauty and Aerosols plants several years prior. As such, Unilever was in a good position to offer invaluable advice to Streets. Once a platform was selected, the next major challenge was scheduling a suitable window to switch over. It was a crucial decision with peak demand just around the corner, but with the old system continuing to be temperamental it had to be done. manmonthly.com.au
A smooth, productive outcome Without any possibility of delaying the upgrade further, system programming began with the goal of full system switchover within six months. Two engineers worked fulltime on the project with occasional support from North Rocks. By July, they were well advanced and in a position to perform early I/O tests. According to Streets Controls Engineer Ben Pi, a critical part of this success was due to the use of Profibus for the connection of field I/O, which he describes as: “The most flexible and robust network I have ever used.” As peak season and switchover approached, it was still a nervous time for Streets, even though progress so far had been positive. The switchover went smoothly and the first batch of ice cream was produced within four days. As production ramped up to meet the demands of the summer, minor tweaks to improve the system’s performance continued. Issues with the CIP and pasteuriser were easily addressed with the aid of PCS 7 as was the need to keep production at full capacity to meet the unexpected increase in demand. Mr Pi reinforced the benefits of performing changes while the plant was running without any detrimental effects to production. “PCS 7 makes it simple to identify areas where the process can be improved and we are continually benefitting from this,” he said. The productivity reward for adhering to the original project timescales and achieving a swift change-over would be revealed in coming months. Record high temperatures were experienced in
many states and Streets had to increase its output tonnage by nearly 60% to cope with the increased demand, something that the old system would have been incapable of meeting. Haigh said there had been many unexpected benefits associated with the switch to the SIMATIC PCS7 and SIMATIC Batch aside from being able to meet the massive increase in demand. “There has been an increase in yield of over five percent. Also, I now have access to real time data for the first time which means that I am fully informed when attending production meetings. “With such a clear picture of what is happening, it makes it much easier to adapt production to meet new demands or to identify areas for improvement. In fact, the information at hand is now so complete that we are able to use it as the basis for forward planning for the business as a whole.” Looking to the future, Mr Pi has become reinvigorated since using SIMATIC PCS 7 for the first time. Not content with a successful implementation, he is focused on continually adapting the system to make the mix plant as efficient as possible. “We are already noticing dramatic improvements in product quality and traceability. Our next step is to integrate more intelligent devices to provide greater diagnostic information,” he said. “This will allow us to perform predictive maintenance and to monitor equipment efficiency as well as looking to further integrate the system into our ERP systems for greater reporting and scheduling.” [Sean Cahill is Siemens marketing manager – process automation.]
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Siemens 132 777, www.siemens.com/pcs7 Manufacturers’ Monthly NOVEMBER 2011 29
Motors& DRIVES Streamlined processes
WEG Australia’s latest motors are reducing energy loss.
Innovation drives motors Innovative developments in motors and drives are set to deliver significant
SEW-Eurodrive product manager, Darren Klonowski, says that through improved programming and control, processes can be streamlined by overlapping positioning cycles throughout processes to save time. “This results in productivity improvement because, rather than waiting for a point-to-point task to finish, the motion of many axis can be overlapped to complete the entire positioning task in up to half the time through the use of programmable motion controllers,” he said. The company recently-released a Smart Servo Package (SSP) aimed at making a servomotor drive automation task simpler and faster to implement. The SSP is comprised of programmable or purely configurable SEW controllers, flexible servo universal inverters, and highly dynamic servomotors close coupled to optional compact servo gear units.
productivity gains as well as environmental benefits. By Hartley Henderson. Stainless steel solutions
‘E
NERGY efficiency’ is the phrase of the hour for manufacturing operations, and so too for developers of industrial motors and drives technology. ABB Australia senior vice president, discrete automation and motion, Jussi Rautee, told Manufacturers’ Monthly that because motors are the biggest energy users in industrial plants, the company has a strong focus on energy efficiency. It also focusses heavily on power out-
30 NOVEMBER 2011 Manufacturers’ Monthly
put, in the design of its motors and drives. “For example, we recently launched a new trailblazing high output synchronous reluctance motor and drive package with a power density up to 40 percent higher than a conventional induction motor.,” he said. Power density is coupled with high efficiency, resulting in high output, a compact design and low energy consumption.” “The new motor, which combines innovative rotor technology
and conventional stator technology, is designed without rotor windings, which means rotor loss is practically eliminated. Up to 40 percent higher output at 3,000 rpm is generated compared to conventional motors. “This powerful yet compact motor and drive package is up to two frame sizes smaller than a corresponding induction motor, and is suitable for a wide range of industrial applications, including with compressors, pumps and fans.”
SEW-Eurodrive has released KES37 and RES37 stainless steel gear units that are designed for use where caustic/high-pressure wash downs are required, or where there is potential for product contamination. Klonowski says the new units have casings and shafts made from stainless steel so there is no need to paint the surface. “This overcomes contamination problems from paint flakes and avoids corrosion, ensuring a long service life. >>
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Motors &DRIVES
Quick action saves brewery millions BY JOHN NORRIS
IF Queenslanders knew the real story of the Brisbane floods they would erect a statue to SEWEurodrive in place of that of Wally Lewis. Wally only played a bit of footy, SEW-Eurodrive got XXXX beer back into production, along the way saving Lion Nathan millions of dollars. When Brisbane’s floods peaked on the afternoon of Thursday, January 13, 2.5m of water filled the packaging area, parts of the brewing room and the offices of the XXXX Brewery at Milton. It remained under water for almost three days. That the brewery was able to turn out packaged beer just 18 days later is testament to the foresight and planning of the
continued from page 30
Both models are available with a range of directly mounted stainless steel motors up to 1.5kW,” he said. NORD Drivesystems AU recently announced the introduction of the NORD Severe Duty (NSD) stainless steel corrosion protection coatings as an option for the NORD helical geared motor and electric motor range. Regional sales manager for VIC, TAS and SA, Tony Sculpher, says that compared to an acrylic paint, the NSD coatings have 40 percent higher impact resistance and twice the surface hardness and corrosion resistance. “These coatings are ideal for
engineering management team and the dedication of suppliers. SEW supplied more than 300 replacement geared motors with a two to three day turnaround, in one instance air freighting a pallet or more than 1500kg of equipment.
Damage control With every day of lost production a $0.5m loss to Lion Nathan, no stone was left unturned. As soon as the waters subsided, more than 100 people were turned out for a five-day cleanup and for the following five days another 100 tradesmen and external service providers were called in to strip equipment in the packaging area alone. Jeff Lynn, Castlemaine Perkins’ Engineering Manager,
almost all food manufacturing plants and are also suitable for chemical wash down and corrosive environments. They also offer the protection of stainless steel at a fraction of the cost of a complete stainless steel component,” he said. Other recent releases from NORD Drivesystems AU include the new Screw Conveyor Product (SCP), an innovative range of helical gearbox and geared motors designed especially to fit screw conveyors. “This design eliminates the less efficient and more expensive v-belt drive traditionally used in the screw conveyor industry,” Sculpher said.
The brewery lost $250,000 per day in lost production during the floods.
Packaging at the Milton Brewery headed a team responsible for getting the plant back on line as quickly as possible.
His own pre-emptive action was very much responsible for the quick recovery. The day before the flood peak he super->>
High efficiency
need for forced cooling, which is achieved by losses minimisation, resulting in a more efficient package,” he said. “Also, following huge demand to meet the requirements of an explosion-proof solution for large motors and machines, the company has launched the EX-p certified range of motors, which means that specific and expensive certification is not required for each individual motor.”
The latest development in motors from WEG Australia is the W22 high efficiency motor which the company says exceeds the requirements of AS 1359.5–2004 High Efficiency Levels, and reduces energy losses by 10-40 percent compared with other typical MEPS motors. Leandro Mattedi, WEG’s product manager – automation, says the CFW11 variable speed drive makes use of WEG’s extensive experience in motors to develop a truly matched package. “When combined with WEG motors, the Optimal Flux feature can be used to produce full torque at low speeds without the
ABB 1300 782 527, www.abbaustralia.com.au Nord Drivesystems 03 9394 0500, www.nord.com.au SEW-Eurodrive 03 9933 1000, www.sew-eurodrive.com.au WEG 03 9765 4600, www.weg.net/au
maxon EC motor
And that's not all by a long shot. When a broad selection of brushless DC motors is called for, maxon EC motor provides the answer: Ø6 – 60 mm, 1.2 – 400 watts. Their wide range of speeds, detent-free operation, dynamic acceleration and unsurpassed service life make these electronically commutated drives stand out. maxon motor is the world’s leading supplier of high-precision drives and systems of up to 500 watts power output. Rely on the quality of the highly specialized solutions which we develop with and for you. Tel. +61 2 9476 4777, info.au@maxonmotor.com, www.maxonmotor.com.au
maxon motor driven by precision 32 NOVEMBER 2011 Manufacturers’ Monthly
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vised removal of critical equipment such as variable speed drives, PLCs and switchboards and as he waited for the waters to subside he was already writing orders for replacement equipment. “We wanted to get in first, to secure our orders well before other factories that would have the same requirements,” Lynn said. He added that he was surprised to learn that at the same time SEW was providing an almost identical volume of geared motors to Amcor Fibre Packaging and smaller quantities to Weston Milling and a number of other companies in the same situation. “They were certainly bending over backwards to help us. Our local guy Jim Gilroy at E and G Automation facilitated the whole thing. He was unbelievable in what he was able to achieve, working out what motors we needed and getting them here either from his own stock or from SEW Melbourne,” he said. “Sometimes your suppliers don’t have the understanding that when we say we want them (parts) soon as, we want them soon as. SEW even steered away from their normal transport methods for us. “I know that SEW’s General Manager of Sales and Operations in Melbourne, Nick Lobianco, personally rang up and got one delivery halted because it was about to go on road. He said ‘go
back and get it and get it on a plane’ and we had it next day,” Lobianco said. “That’s what we needed to happen and he made it happen for us and when you’re looking at a lost production cost of $0.5m a day you need that sort of support.” Five models are available, all suitable for the food and beverage sector.
Superior support When Lynn moved to the XXXX Milton plant 18 months ago he discovered a facility that was almost 100% SEW-Eurodrive equipment, not as a result of a company mandate but because the technical people at Milton had insisted on it over the years. Prior to the flood the selection rationale revolved around product quality and, particularly, SEW’s policy of standardisation. “There aren’t a million different models. It’s all plug n play so you can bolt up one motor to various gearboxes with a transition plate or pinion change. If you want to slow a conveyor you don’t have to replace the whole shooting match,” Lynn said. Subsequent to the flood the brewery has a million more good reasons to stay with SEW, all of them dollars saved as a result of a policy of maintaining extraordinary stock levels backed by two large assembly plants and complete service and technical backup available 24/7. [John Norris is editor at Newsletter House.] SEW-Eurodrive 03 9933 1000, www.sew-eurodrive.com.au
Washdown gear units A NEW line of two-stage helical bevel gear units from NORD offers washdown models in five different sizes with torques between 90 and 660 Nm. All units reportedly feature a high-strength, die-cast aluminium gear-case, which is designed according to the company’s ‘UNICASE principle’. The principle is as follows: since the gear-case doesn’t require an inspection cover or a screw-on input cover, the units are small and light-weight. This is said to facilitate handling, and to help reduce energy consumption in applications where drives are moved. The new units have washdown gearboxes, meaning cleaning liquids can wash off regardless of installation position. For that purpose, all external surfaces
have been designed with wide radii; there are no indentations or dead spaces, according to NORD. The gearboxes are suited for use in conveyor technology and in the food industry. Further applications include hoists, storage facilities and overhead conveyor systems. NORD Gear is one of the world's largest producers of drive technology for mechanical and electronic solutions. NORD Drivesystems AU began trading in Australia early in 2009. The range of products includes geared motors, motors, frequency inverters, motor starters, frequency inverters for decentralised drive control and servo controllers. NORD Drivesystems 03 9394 0500, www2.nord.com
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Motors &DRIVES The 36mm models feature a contraption allowing them to replace larger models.
Motor control centres integrate ethernet
36mm linear actuators MOTION Technologies is distributing Haydon Kerk’s new G4 36mm linear actuator, said to offer 20% higher output force than its predecessor. The actuator measures 36mm, and replaces the larger 42mm and 46mm units; the new model includes a special adaptor plate to allow ‘drop in’ replacement of larger units. When replacing a larger unit, the actuator’s adaptor allows to be mounted using the same bolt pattern, for quick, simple
34 NOVEMBER 2011 Manufacturers’ Monthly
upgraded installation, says the company. Force output for the G4 is from 70N to 260N, and the system is available in three configurations: captive, where the screw is held from rotation by the actuator; non-captive, where the screw drives through the motor; and external linear, where the motor drives the screw with the load nut running externally on the screw. Motion Technologies 02 9524 4782, www.motiontech.com.au
ETHERNET/IP capabilities have been added to the Rockwell Automation CENTERLINE motor control centres (MCCs), allowing users to access more detailed production data. According to Rockwell Automation, leveraging a single, standard network simplifies communication for the entire enterprise and provides users with the flexibility to control, configure and collect data from any point in the system. By taking advantage of the company’s Premier Integration,
users can configure and commission their MCC faster with RSLogix 5000 software, reducing the risk of errors associated with redundant programming, Rockwell Automation claims. The Ethernet connection also allows CENTERLINE MCC users to access information remotely. This allows personnel to monitor, troubleshoot and diagnose the MCC without being exposed to dangerous conditions and power equipment. Rockwell Automation 03 9896 0300, www.rockwellautomation.com.au
Model-based design cuts development THIEN eDrives (formerly ATB Technologies), a developer of electrical drive systems, has used MATLAB and Simulink to model, simulate, and implement an electric motor control system on TI’s C2000 microcontroller unit (MCU). By applying Model-Based Design, Thien eDrives moved rapidly from the first prototype
to the final series, reducing development time by 50%, MathWorks claims. Using models also simplified design reviews with Thien eDrives customers by eliminating the need for code reviewdriven processes, says MathWorks. MathWorks Australia 02 8669 4730, www.mathworks.com.au
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Metalworking& MACHINE TOOLS
The PythonX is compact, but offers a range of features for automated 3D fabrication.
Python delivers killer bite A new automation system delivers a deadly combination of 3D fabrication services to this country-based structural steel fabrication business. Branko Miletic writes.
E
STABLISHED in 1980, Hutchins Bros Engineering (HBE) is a family-owned business based in the Riverina township of Narrandera; their primary field of expertise is in the supply, manufacture and erection of structural steel servicing the defence, health and aged care, education, commercial, industrial and manufacturing sectors. “Our portfolio of projects have included wide span portal frame
industrial buildings, tilt-panel multi-unit retail developments, multi-deck car parks, intricate architectural balustrades and stairs, large and small fabricated trusses, animal feeders, farrowing crates, forestry framing and construction equipment,” said director Bill Hutchins. The company’s structural steel fabrication and beam cutting system has now been improved with the installation of a 6-axis robotic PythonX CNC Plasma Cutting
Fabrication System from Sydneybased Power Machinery. The system brings automated 3D fabrication to processing beams, channels, SHS, angle, plate and bar. “We chose the PythonX for its operational functionality in comparison to other beam line alternatives. It is a one-stop shop which takes up minimal room and the short set-up time was a bonus,” said Bill Hutchins. “Our business utilises the PythonX for processing hot
rolled sections, SHS/RHS sections and flat bars. For cutting, coping, notching, holes, layout and D marks. It services our own fabrication workshop’s processing needs and we take on third party work also.” The PythonX can be used for beam drill line, band sawing angle line work, plate/bar line work, as a coping machine, marking machine or small burning machine. Hutchins says his decision to purchase the unit was influenced by its “ease of operation, flexibility and number of functions”. “It has dramatically improved our processing times, freeing up valuable man hours for other fabrication work. It greatly reduces the risk of man-error,” he said. The PythonX accepts files via direct download from structural design software like Tekla XSTEEL, SDS/2, AutoCAD and more. The machine control reads the file, probes and measures the piece, then goes to work. According to Power Machinery managing director Ken Christensen, the PythonX has an “unprecedented flexibility like an entire fabrication shop in a single machine”. Even a modern, fully automated metal fabrication shop typically requires transfers and conveyors to feed and offload multiple pieces of equipment. This takes up a lot of space and time, and that, says Christensen, offers huge savings in floor space, labour and material handling. “One PythonX plasma cutting
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million in terms of machinery. â&#x20AC;&#x153;The PythonX is 10 machines in one and that doesnâ&#x20AC;&#x2122;t count how much manual labour and double-handling a fabrication shop can save on with one of these units,â&#x20AC;? he said. Accuracy is â&#x20AC;&#x2DC;built inâ&#x20AC;&#x2122; to parts cut by PythonX. Starting with the precision part positioning, PythonXâ&#x20AC;&#x2122;s probe and measure function mean all the guesswork or chance for human error are taken out of the equation. Christensen says the PythonX handles a wide array of structural shapes and part sizes. â&#x20AC;&#x153;It will cut steel up to 32mm thick in shapes up to 1,200mm wide and 400mm high and with conveyor options and can even handle beams up to 26 metres long,â&#x20AC;? he said. â&#x20AC;&#x153;You cannot compare this machine to beam lines. That would be comparing apples and oranges. The PythonX can do so much more than any beam line.â&#x20AC;? Power Machinery 02 9971 1755, www.powermachinery.com.au
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line automates all your shop's structural fabrication tasks into a single machine,â&#x20AC;? he said. The PythonX torch head will probe and measure the piece to be cut, so it places each feature exactly where it needs to be. This compensates for out-of-spec beam geometry to give users finished beams that are in spec and good for the job, with AISCapproved boltholes. The fact that there's no manual programming of the cuts and they're all determined from the part detail drawing files, means that if the drawing is correct, the fabricated piece will also be correct. PythonX not only produces features and holes of high quality, it also places them precisely where they need to be, even if the workpiece has a slight bend or imperfection. According to Christensen, the PythonX can replace so much machinery that for under $700,000, users can get the same amount of functionality that would normally cost nearly $2
Manufacturersâ&#x20AC;&#x2122; Monthly NOVEMBER 2011 37
Metalworking &MACHINETOOLS Swing beam shears A NEW range of Adira E Type GH hydraulic Swing Beam Shears can be provided with an optional SCSC sheet support system. Consisting of a pneumatic pivoting table and retractable pins in the back-gauge bar, the material will be kept flat during the cutting process. The E Type GH Series detects the pressure required to complete each cut, and develops only the required clamping force and cutting force necessary. This reduces damage to the material through the clamping operation, particularly with light or soft material and ensures longer machine life, and reduces energy consumption, according to the company. An automatic retraction of the back gauge during the cut prevents wear on the gauge bar surface. Power Machinery 02 9971 1755, www.powermachinery.com.au
Open-pore metal foam VERISARIEN is launching an open-pore metal foam, reportedly offering high thermal efficiency, mechanical strength and reduced weight. The open pore structure allows coolant fluid to pass through the material, and the surface area produces heat transfer rates which are around 300% greater than is possible with current technology, the company claims. The manufacturing method dis-
tributes the pores evenly through the material, ensuring the mechanical and thermal properties are constant throughout each component, and can be repeated for batches of parts â&#x20AC;&#x201C; which has been a problem with some metal foams. Developed by the University of Liverpool, and initially focusing on porous copper products, the technology will soon be expanded to other materials, including
The foam will soon be available for aluminium.
aluminium. Verisarien sales@versarien.co.uk, www.versarien.com
Sheetmetal software speeds Formula 1 production RED Bull Technology in Europe has manufactured a Formula 1 racing car using JETCAM sheetmetal software. JETCAM was used to produce parts from composite ply rather than mainstream sheetmetal. The system was reportedly very user-friendly, and reduced machine cycle times by up to 42%. Red Bull claims the JETCAM system paid for it self within three months.
The system allowed Red Bull to gain live recording data for immediate visibility of material costs on the shopfloor; staff were reportedly trained to use the system in just one day. JETCAM also returned low levels of scrap and high efficiency rates, with nests at least 16% more efficient than current nests, Red Bull said. Managing director of Maxitec â&#x20AC;&#x201C; JETCAMâ&#x20AC;&#x2122;s local distributor â&#x20AC;&#x201C;
Andrew Bentrup said his company oversaw the installation of JETCAM in a growing number of businesses in Australia and New Zealand. â&#x20AC;&#x153;There is probably no industry in the world better equipped than the Formula 1 world to provide an applied scenario where fabrication software must perform to extreme efficiency,â&#x20AC;? said Bentrup. Maxitec 02 8543 9900, www.maxitec.com.au
Acra Machinery Pty Ltd
20 Fowler Road Dandenong, Victoria, 3175
ph. (03) 9794 6675 www.acra.com.au
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EUROPES NO.1 FABRICATION MACHINERY SUPPLIER AVAILABLE IN AUSTRALIA 38 NOVEMBER 2011 Manufacturersâ&#x20AC;&#x2122; Monthly
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Compact machining centre MORI Seiki has released the MILLTAP 700; a next-generation compact machining centre which reportedly features improved work capacity and chipping performance. This vertical milling and boring center offers high machining speed usual found in tapping centers, and is supported by a high speed tool changer which reportedly achieves chip-to-chip times of 1.5 seconds. The complete drive of the magazine, which takes 15 or optionally 25 tools, is integrated into the spindle head. Key features in this context include dynamic response of up to 1.6G in the linear axes as well as fast axis movements up to 60m/min to significantly increase productivity. The MILLTAP 700 has a triangular bed design as well as the static cover of the X-axis optimse the chip flow and enable parallel disposal of the chips. Users can either position the cooling system on the machine from the front or back.
The MILLTAP 700 has a high-torque 10,000 min-1 spindle.
The centre has a work area of 700mm in the X-axis, 420mm in the Y-axis with a Z-path of 380mm. The machining table and the wide distances between the linear guideways enable the machining of work pieces up to 400kg. A number of clamping options are available for machining flexibility. DMG/MORI SEIKI Australia 03 8540 4600, www.dmgmoriseiki.com/au
Portable intelligent MIG welder ESAB Australia has released the new Caddy MIGC200i; a portable MIG welder which comes in a12kg package that includes torch and cables. The welder can be used for fabrication, repair and maintenance work with materials such as steel, stainless steel and aluminium. It can also be used for MIG/MAG brazing using silicon bronze wire. Electrode polarity can be changed for use with gasless wires. The welder is equipped with QSet, an artificial intelligence feature which automatically sets all of the welding parameters, while maintaining and adjusting the optimum wire/gas combination throughout the welding process for consistent weld arc quality. Inside the Caddy MIG 200i side panel is a wire feeder that fits a standard 200mm wire spool, with an inner diameter of 51mm. The welder comes with the ergonomic, high quality MXL180 torch, with 3m cable. The tough enclosure is rated to
The welder has a maximum welding output of 200A.
class IP23 and operating temperature is up to 40°C. ESAB Australasia 03 9383 7652, www.esabasia.com
Manufacturing your components
SPECIALISTS IN • zinc die casting • machining • powder-coating • chrome plating • packaging & distribution 20 Enterprise Street Caloundra Qld 4551 AUSTRALIA Phone 07 5491 3566 Fax 07 5491 3107 Email emro@emro.com.au www.emro.com.au
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Manufacturers’ Monthly NOVEMBER 2011 39
MaterialsHANDLING
A new 28,600m2, temperaturecontrolled NDC can store 26,000 pallets.
Lion’s share of the supply chain Thanks to a smart new layout and storage systems, this dairy and drinks NDC distributes 100,000 cases a day.
L
ION (formerly Lion Nathan National Foods) is a leading beverage and food company with a portfolio that includes many of Australia and New Zealand’s favourite brands. Last year, Lion engaged Linfox to manage the majority of its Australian distribution requirements. The Dairy & Drinks division (formerly National Foods) produces household name brands of milk and dairy beverages, juice, dairy, cheese and soy products. The Dairy & Drinks footprint includes production facilities and sales offices in all Australian states, as well as New Zealand, Singapore, Malaysia and Indonesia. In addition to consolidating linehaul and transport opera40 NOVEMBER 2011 Manufacturers’ Monthly
tions for Lion, a key feature of the massive 3PL contract was the establishment of two new national distribution centres (DCs) in Sydney and Melbourne. The Sydney NDC was up and running in January 2009, with the new Melbourne NDC at Laverton now fully operational as of June 2011. With a storage capacity of more than 26,000 pallets, the new 28,600m2, temperature-controlled Laverton NDC is a high velocity operation, distributing over 100,000 cases per day.
Meeting demanding project milestones Linfox’s NDC operations manager, Travis Small, said: “Many of the SKUs (stock keeping units) we distribute for Lion have a
limited shelf life. “Stock turns over very quickly. Storing and distributing such SKUs efficiently requires a smart DC layout and storage systems, and that’s exactly what Dematic delivered. “The use of drive-in or double deep storage racks would have improved the site’s total storage capacity. But, given the high turnover of the products we are distributing, Linfox opted for single deep selective racking to provide safer, faster, unrestricted access to every product line,” he said. “It also gives us total storage flexibility, with just about every product capable of being slotted in every location. “Dematic didn’t just meet our demanding project deadlines;
they exceeded expectations at every phase of the project,” added Linfox’s Travis Small. “We basically took possession of a massive empty shed in October 2010 and had to bring the first phase of the NDC with over 20,000 pallet locations online before Christmas. “Fitting out a DC with over 20,000 pallet locations in such a short timeframe is no small task, and installation of the storage system was very much on our critical path. “Dematic’s ability to complete the installation of more than 26,000 pallet storage locations ahead of time across all four implementation phases contributed greatly to our meeting critical project delivery milestones.” manmonthly.com.au
Custom job: Dematic’s Joe Carmody and Linfox’s Travis Small.
Project management the key Dematic’s Project Engineer, Joe Carmody, said implementing the short two-month installation schedule required all of Dematic’s extensive project management experience. “It was essential we had all of the storage equipment in place prior to each phase going live, which meant working around the clock, seven days a week when necessary,” he said. The installation of such a large storage system in under two months was only made possible through Dematic’s ISO9001 Certified Quality Systemaccredited project management and implementation methodology, said Mr Carmody. Initiatives included: • Setting up a steering committee comprising senior Linfox and Dematic managers to facilitate open communications at a high level. • Project planning and scheduling, including a detailed program of works covering all major implementation tasks from site establishment and installation to commissioning and acceptance • Development and implementation of risk management. • Regular site meetings, detailed weekly progress and monthly reporting. The Laverton NDC is currently configured with two separate chambers – one providing storage for over 21,000 pallets, and the other more than 5,000. Splitting the NDC into separate chambers gives Linfox the
flexibility to run different zones at different temperatures if required. The NDC and storage system layout make it easy for walls to be added to create further separate chambers if required.
High order safety About half of the NDC’s orders are despatched as full pallets. Split case orders are picked from Colby Cartonflo carton live storage and packed into shippers and palletised for local direct to store delivery through Linfox’s route trade distribution network.
All order picking is RF-directed, with both Linfox and Lion running SAP IT. Through its Vision Zero program, Linfox is totally committed to ensuring occupational health and safety (OH&S). To that end, the NDC’s storage systems incorporate a number of safety initiatives including Dematic’s ColbyRACK Protect-a-Rack. Dematic designed the 26,000 pallet capacity storage system to suit Lion’s requirements, which includes not storing products on the ground for hygiene reasons. A first storage beam level
300mm above ground keeps all pallets clear of contamination or pests, and provides sufficient access for regular cleaning. To help prevent rack damage during pallet put-away and retrieval, the storage system incorporates modified Colby Protect-a-Racks to suit the 300mm high first beam level on all rack uprights, together with end-of-aisle protection. The new baseplate protector is mounted to the base of front uprights providing protection at ground level against minor collisions with forklifts and pallets. It features an angled front face, which curves and wraps around the whole upright to eliminate any catch points when pallets are being placed or removed. Colby Protect-a-Rack upright protectors interlock with the Protect-a-Base, forming a highly robust member. Protect-a-Rack upright protectors not only deflect impacts away from the upright, they also absorb them and transfer inertia to the strongest part of the rack – the bracing nodes. They also include a rear flange protector to ensure the entire upright is shielded from direct impact damage from the rear. “Safety is obviously our number one concern. Preventing storage systems from getting damaged in the first place not only provides a much safer workplace, it will also reduce operating costs over the life of the DC,” said Linfox’s Operations Manager Travis Small. Dematic 02 9486 5555, www.dematic.com.au
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Manufacturers’ Monthly NOVEMBER 2011 41
Materials HANDLING Power steering in stackers
The stacker range has units to 2,000kgs.
LENCROW has released the new EP walkie stacker units which come standard with power steering. This feature is available on all stackers above 1,400kg capacity. The new EP stacker range has been built to comply with OH&S and with the steering makes them suitable for all people to handle. The range has units to 2,000kgs and lift heights to 5,000mm making them more suitable to warehouse requirements, the company says. The new series also incorporates AC operation which is said to offer outstanding response as well as provide longer duty cycles from the 280 amp hour battery. According to Lencrow, the new EP units are also easy-touse because it has a wide view masts for better user vision. Lencrow 1300 536 276, www.lencrowgroup.com.au
42 NOVEMBER 2011 Manufacturers’ Monthly
The RG Series has drive speeds to 14.5km/h and lift speeds to 700mm/s.
Warehouse forklift trucks NISSAN Forklifts has launched its new warehouse forklifts truck – the RG Series – which has been designed to offer operator comfort and safety. The new forklift has an operator compartment which is multiadjustable for left-and-right armrests and seat position. Floor height is electrically-adjustable to accommodate to different operator sizes, while the optional ERGO Logic joystick provides up to nine different mast-related functions. It features an AC TECH controller which is said to provide productive, reliable and costeffective truck operation, including automatic horizontal fork levelling, sideshift centering, load-weight indication and double-deep storage, while the
Level Assistance System allows operators go to preset lifting heights in the racking. The RG Series has drive speeds to 14.5km/h and lift speeds to 700mm/s. Uptime is reportedly maximised by 1,000 hour service intervals, long-life hydraulic fluid with 6% energy reduction and the HSHL drive wheel for reduced wear. Batteries can be exchanged quickly, with three systems to assist: reach-out battery; sideways battery roll-out; and motor powered battery roll-out allowing battery change by just pressing a button. The RG Series features reach trucks from 1.2 to 2.5t load capacity and a wide variety of masts, with lifting heights to 12.1m while keeping optimal
Height adjusting stacker for operator safety ACTISAFE is now distributing automated and manual lifting devices designed for safer work with pallets, skids, bins and stacks. The Actilift range includes the Quikstak Smart Stacker, an automated stacker offering automatic height adjustment during loading and unloading to keep
load capacities. Powerlift Material Handling 1300 550 607, www.powerlift.com.au
Height adjustment is automated while loading and unloading.
the work height at an optimised set position for ease-of-use and operator safety. This in-built height adjusting sensor is designed to keep the unit positioned at pre-determined heights whether it is loaded with palletised goods, bottles or large sheet material. Actisafe 1300 852 397, www.actisafe.com.au
High-turnaround order picking system SSI SCHAEFER’S A-Frame fully-automated order picking system is designed for highturnaround products. The A-Frame is said to be the
world’s fastest and most efficient order picking solution for single item picking. With up to 50,000 items per hour, peak loads are easily covered; the system is
designed to increase productivity levels for fast-turnaround items by more than 400%. SSI Schaefer 02 9824 3844, www.ssi-schaefer.com.au
manmonthly.com.au
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