Manufacturers' Monthly October 2011

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CELEBRATING 50 YEARS Years

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manmonthly.com.au

Est. 1961

October 2011

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Envision a world that doesn’t just turn It flies

INSIDE Automotive Sustainability >> Compressor Savings >> Cutting Tools & Consumables >> Obtaining Finance >> Latest Products >> Industry News >> Industry Opinion >> Training & Events

SAFETY IN NUMBERS >> New products to help you safeguard your plant

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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

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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 Head Office Tower 2, 475 Victoria Avenue, Chatswood NSW 2067 Locked Bag 2999 Chatswood DC Chatswood 2067 Ph: (02) 9422 2999 Fax: (02) 9422 2966 Published 11 times a year Subscriptions $140.00 per annum. (inc GST) Overseas prices applyPh: 1300 360 126 Printed by Geon Impact Printing 69 – 79 Fallon Street, Brunswick VIC 3056 Ph: (03) 9387 7477

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Inside OCTOBER 2011

For daily news visit manmonthly.com.au

4 Editorial ■

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Is your business killing you?

6 Comment ■

Heather Ridout: “Fair Work needs more work.”

8 Analysis News ■ ■ ■ ■

Moody month for manufacturing. Endeavour Awards 2012 sponsor supports safety. Process error causes welder recall. ABB, GM collaborate on car batteries as energy storage.

34 44 Flood Control: How to cope when your customers are waiting and your new Mori Seiki’s three metres under.

14 Energy & Carbon ■

Achieving sustainability in the automotive industry.

22 New Products

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15 Management ■

What’s new in manufacturing machinery and equipment.

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18 IT Your Factory

30 The Safety Show Sydney

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Supply chain traceability. Lean: beyond the shop floor.

Proudly made in Australia. Oil-free air compressors.

40 Fasteners & Adhesives

Obtaining finance today.

Products you can’t afford to miss at The Show.

Meeting new bonding demands. Reclosable fastener.

44 Cutting Tools 20 Materials Handling

34 Compressors

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Labelling, marking & coding.

CELEBRATING 50 YEARS Years

manmonthly.com.au

Est. 1961

October 2011

Print Post Approved PP255003/00324

Envision a world that doesn’t just turn It flies

ABN 80 132 719 861 Average Net Distribution Period ending March 11 15,300 ISSN 0025-2530

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INSIDE Automotive Sustainability >> Compressor Savings >> Cutting Tools & Consumables >> Obtaining Finance >> Latest Products >> Industry News >> Industry Opinion >> Training & Events

An airy issue.

Recycling used cutting tools. 24-station drilling centre.

Behind the cover WHETHER you build, produce, manufacture, run or generate, one fact is clear: better lubricants and better lubricant suppliers correlate to productivity. This is just one reason why more than 5,000 equipment builders worldwide recognise Mobil Industrial Lubricants. With a standard-setting product

range, and unmatched industry expertise, Mobil Industrial Lubricants don’t just elevate productivity. We unleash it. Contact your authorised Mobil Lubricants Distributor to find out more. Mobil 1800 033 863, www.mobilindustrial.com

SAFETY IN NUMBERS >> New products to help you safeguard your plant

sales

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Manufacturers’ Monthly OCTOBER 2011 3

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Editorial

SARAH FALSON – Editor

editor@manmonthly.com.au

Is your business killing you? Manufacturing’s a risky business, but mitigating risks faced by factory workers – at home and abroad – is the responsibility of every manufacturer in Australia.

I

DON’T want to be the bearer of bad news. But in case you aren’t up-to-speed, I’ll put it bluntly. Manufacturing can kill you. Yes indeed folks; your every day job could be sending you to the proverbial process plant in the sky sooner than you know. And no, I don’t mean all you business-owners having a coronary every time you receive a power bill. Nor am I referring to traumatic stress arising every time you check the stocks for the strength of the Aussie dollar. I’m referring to two big ticket news items we reported online this month, both about deadly manufacturing processes. The first relates to our textiles, clothing and footwear (TCF) companies, taking the initiative to cut supply agreements with companies that treat their jeans using the dangerous – not to mention horribly outdated – texturing process, ‘sandblasting’. Number one, we wouldn’t be caught dead in it. And number two, individuals without the appropriate OHS permit were banned from sandblasting some 20-odd years ago – around the time when it stopped being OK to wear it (think acid wash jeans, legwarmers and – the hell with it – a matching acid wash jacket).

Not-for-profit organisation Oxfam is targeting Just Group – which owns denim brands Just Jeans, Jay Jays and Dotti – for selling the jeans after global brands Levi’s, Espirit and Gucci banned the process. Sandblasting gives denim that faded, ‘worn’ look, that so many of us coveted back in the 1980s. The technique however, has since gone out of fashion the same way the jeans did after being linked to a deadly lung disease in manufacturing workers in China, India and Turkey. Sandblasting is still performed in Australia, but not for jeans. Companies that use it must install various safety measures, not least protective clothing, and a medical-style ‘booth’ within which the process in performed. The term ‘sandblasting’ is still used extensively however, to refer to newer forms of abrasive blasting that are less risky, yet create the same textured ‘look’ (but probably not by anyone as fashion-conscious as our Denim Elite). Abrasive blasting is used to smooth, roughen, shape or remove contaminants and buildup from surfaces. For example, ‘glass bead blasting’ is used to remove paint in auto body works before powdercoating.

A device used for adding sand to an air compressor for sandblasting. [Image: Stan Zurek.]

Not only are these new techniques safer for the worker, but the abrasive materials they use can be reused again and again, making them more sustainable. Sand on the other hand must be disposed of after a single use, and replaced with clean sand for the process to start again. One manufacturer we spoke to said only “clowns” use sandblasting. "If I was told I could use sandblasting again today I wouldn't. The risks are too high," he said. Too right. Oxfam is doing us all a service by pushing Just Group to ban sandblasting across

its businesses. Just because it’s not happening underneath our noses doesn’t mean we should turn a blind eye to our supply chains. The silica dust is still as harmful, and the lung disease is just as real. The second death-by-manufacturing story came as local company Fuchs Lubricants guaranteed the safety of its metalworking fluids, following reports from the US that some brands contain biocides which contain a cancercausing carcinogen. The issue of carcinogens in metalworking fluids is not new, with the U.S. Department of Health and Human Services listing formaldehyde – a key ingredient in metalworking biocides – as a known cancer-causer, back in June. Kudos to those companies making a stance against the ingredient, which is often included to kill the bacteria and fungi growing in the water miscible cutting fluid baths. A number of biocide-free products are now on the market, and readily available to manufacturers. Yes, the Aussie dollar is excruciatingly high, and yes, we’re cutting costs where we can. But Australian manufacturers should be making it their business to mitigate workplace risk – not feeding it for a cheap gig. We are a highly-evolved industry, and we know better. It’s time us Aussies lived up to our name and remained True Blue (not that marbly, worn, dated blue we don’t want to see, or hear of, ever again).

NEW 3 PHASE PORTABLE APPLIANCE TESTER TRIO Smartcal has extended the capability of it’s well known Portable Appliance Tester (PAT), the SafeTcheck Pro Logger II, with the introduction of an ALL NEW 3 PHASE Run Test Option. This new option tests 3 Phase Appliances in accordance with the Australian Standard (AS/NZS 3760). The new Pro Logger II’s 3 Phase Test Option features: 1. 20A & 32A plugs and sockets; 2. Monitoring of the combined leakage current from all phases and the resistance in the earth conductor; 3. The ability to sense if the Appliance Under Test is running; 4. The reporting of excessive leakage current as a FAIL; and 5. The ability to record the test result (PASS or FAIL) with the measured value of Leakage Current and Earth Resistance. ADELAIDE BRISBANE MELBOURNE SYDNEY SALES: PH 1300 852 402 FAX 1300 853 409 sales@triosmartcal.com.au SERVICE & CALIBRATION: PH 1300 852 402 safety@triosmartcal.com.au

4 OCTOBER 2011 Manufacturers’ Monthly

www.triosmartcal.com.au manmonthly.com.au

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Comment

HEATHER RIDOUT – CEO Australian Industry Group

editor@manmonthly.com.au

Still no ‘Fair’ for manufacturers Australian Industry Group will argue the case to ensure the Fair Work Act is amended to reduce barriers to productivity growth. Heather Ridout writes.

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HE arguments in support of amending the Fair Work Act to address Australia’s dismal productivity performance are getting louder, and they are coming from widening quarters. Of course, changes to the Act alone cannot deliver the productivity growth that Australia needs – this will require action in a number of areas, including training and education, infrastructure, taxation systems and regulatory systems. However, provisions in the Act also need to to be amended in ways that preserve fairness for employees, employers and others in the community. Recently, we conducted a comprehensive survey involving 250 of our members to obtain their views on the Act.

Survey respondents painted a bleak picture of productivity and flexibility outcomes under the Fair Work Act, with large employers (more than 500 employees) in particular reporting that the Fair Work bargaining laws had made it more difficult to achieve flexibility or productivity improvements. Further, 69% of respondents stated that they would like to see some form of statutory individual agreement option introduced into the Fair Work Act, rising to 80% among large employers. In this regard, the Government's Individual Flexibility Arrangements (IFAs) have promised much, but delivered little. Ai Group believes that legislative change is needed to ensure a workable structure

for IFAs. Another issue our members have illustrated is the increase in union power under the Fair Work Act. Of the respondents to oursurvey, 64% expressed the view that union power had increased in the enterprise bargaining process, with only 13% having the opposite view. Ai Group’s survey also highlights problems being experienced with the Act’s ‘transfer of business’ provisions, which require employers who take over outsourced work to adhere to enterprise agreements and other instruments that applied to the old employer. Unfortunately, the Fair Work Act provides many reasons in this regard for a company not to outsource work, even if it would

be more efficient to do so. Finally, the General Protections in the Fair Work Act are extremely broad and are routinely being used by unions and lawyers to threaten employers and to drag them into conciliation proceedings in FWA. For example, 83 respondents to Ai Group’s survey stated that the Fair Work Act had made it more difficult for their organisation to make employees redundant, with 41% of those citing the risk of a General Protections claim. There will be a review of the Act from January next year, and Ai Group intends to play a major role to inform the Government about the experiences of our member companies, such as those revealed in our survey, and to argue the case for constructive changes that will reduce barriers to productivity growth and labour flexibility. www.aigroup.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 6 OCTOBER 2011 Manufacturers’ Monthly

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AnalysisNEWS Manufacturing moody after rough month BY SARAH FALSON

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ANUFACTURING activity contracted only slightly during August, down 0.1 points to 43.3, remaining below the 50-point mark separating expansion from contraction, according to the Australian Industry Group (Ai Group) - PwC Australian Performance of Manufacturing Index (Australian PMI) report. Though the 0.1-point decline was more positive than the 9.5point drop recorded in July, August’s figures represent the second manufacturing drop in as many months. This decline comes off the back of positive news in June, during which manufacturing levels rose 5.2 points to 52.9, representing growth. The strong Australian dollar, sluggish domestic demand and increased competition from overseas are all being blamed for

8 OCTOBER 2011 Manufacturers’ Monthly

August’s contraction. Ai Group chief executive, Heather Ridout, said the continued weakness is evidence of the “extremely challenging” business environment faced by our manufacturers. However, she says the industry has a bright future in Australia – regardless of the time tough time it is experiencing of late. "The industry has a very positive future in Australia. However, we need decisive government action and a long-term forwardlooking strategy for manufacturing that would contribute to creating the most competitive environment for the sector to flourish and survive through the resources boom. We also need immediate measures to support and improve incentives to invest and innovate. All of this action should be developed in consultation with industry,” she said. Government has played its part in the low ‘manufacturing mood’

these past months. News of the forthcoming carbon tax is still raw, and businesses are lobbying for fairer wages and more jobs. Prime Minister Julia Gillard will hold a one-day manufacturing jobs forum in Canberra this month, where business-owners, government officials, unions and academics will gather in an attempt to come up with a ‘fix’ for the flailing industry. According to the shadow innovation minister, Sophie Mirabella, the government is entirely to blame for this year’s falling manufacturing activity, as it continually overlooks manufacturing sectors traditionally classed as the ‘backbone’ of the industry. Mirabella points out that since the labor government was elected in 2007, there have been 26 monthly contractions in manufacturing activity in Australia – with labor in office during 44 of these months.

“Manufacturing has been drifting for months under this aimless and paralysed Government – and there continues to be no serious response to the deepest crisis in the sector since the Great Depression,” said Mirabella. “They show supreme indifference to groups such as steel makers and fabricators: their Steel Industry Advocate position has been left vacant for nine months and the Steel Industry Innovation Council hasn’t even met for six months to discuss problems at businesses such as BlueScope and OneSteel,” said Mirabella. “The Government is now refusing to even hold an inquiry into the crisis and possible ways out of its mess, and is rejecting deafening calls to dump its jobdestroying and confidencecrushing carbon tax.” www.aigroup.com.au

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AnalysisNEWS

Safety top priority at 2012 Awards BY SARAH FALSON

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ANUFACTURERS have got it tough. Not only are they struggling with the high Australian dollar, but rising electricity prices, a looming carbon tax, intense international competition and a skills crisis are all doing their bit to make the sector work that much harder to stay in shape. “Manufacturing is suffering incredible competition from many areas and manufacturers have to differentiate themselves from these competing sectors to attract investment, skilled people and to show reliability and quality of their products and their production,” SICK manag-

ing director, David Duncan, told Manufacturers’ Monthly. The 2012 Manufacturers’ Monthly Endeavour Awards – to be held on Wednesday 9 May during National Manufacturing Week in Sydney – will reward those companies and individuals that stand out from the crowd. The Safety Scheme of the Year Award, sponsored by SICK*, will showcase Australian manufacturers that have used safety in the workplace and supply chain, for workers and equipment, to gain that competitive edge. “Best Practice Safety Schemes enhance and increase productivity, provide a safe and secure working environment for people and demonstrate reliable quality

Top Tweets in September What you missed last month on Twitter! • Another casualty in Australia’s steel manufacturing decline http://bit.ly/p1SkM4 • $70m for manufacturers lightweighting automotive components http://bit.ly/pA96wu • No escape for Australian manufacturing with BlueScope closures; 1,400 jobs axed http://bit.ly/pjvBII • New QLD smallgoods facility to create 600 jobs http://bit.ly/pHHK62 • 3,200 workers to strike at Toyota plant http://tinyurl.com/6z5yp22 Never miss out again! Follow us @manmonthly for all the latest news, product information and comment pieces from the industry.

10 OCTOBER 2011 Manufacturers’ Monthly

Entrants in the Safety Scheme of the Year category at the 2012 Endeavour Awards will show how the latest new factory safety technology can boost your business.

process throughout production and the supply of goods and services. Having effective efficient safety schemes send a clear message to staff and customers about the quality of the manufacturing company,” said Duncan. Duncan and SICK have been supporting the Safety Scheme of the Year Award at the Endeavour Awards for nine years. For Duncan, industry awards programs are a crucial means to showcase Australian ingenuity and encourage companies to collaborate. “Award programs recognise industry and best practice innovations by companies that strive to be the best. Additionally they contribute an overall bench mark and show the leaders in innovative thinking and can shape the future of an industry sector,” he said. Companies that enter the 2012 Endeavour Awards will be able to show that they have reduced complexity, while increasing

safety and productivity – which is always a driver for innovation. Duncan says flexible safety technology and also complete safety solutions are in demand from suppliers at the moment. Safety scanners are also becoming popular. “The ability to provide noncontact safety zones that enable flexible entry and exit areas for production equipment but identify entry into the hazardous areas by personnel is demonstrating the clear benefits of this innovative technology,” Duncan said. To enter the 9th Annual Manufacturers’ Monthly Endeavour Awards, download an entry kit from our website below. [*If you want to sponsor an Endeavour Awards category in 2012, contact Michael Northcott on 0448 077 247 or email michael.northcott@reedbusiness. com.au] Entries & Info: Margaret Tra 02 9422 2759, margaret.tra@reedbusiness.com.au, www.manmonthly.com.au/awards

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AnalysisNEWS EVENTS OCTOBER 10: Certificate in Hazardous Areas for Engineers & Technicians This course provides a comprehensive technical approach to hazardous areas, and explains the subject of explosion protection applied to electrical equipment in such areas. Visit www.eit.edu.au 25-27: The Safety Show, Sydney Materials Handling and Bulkex The Safety Show is New South Wales' only dedicated workplace health and safety trade show. It is co-located with Sydney Materials Handling, showcasing materials handling solutions and new products for Australian industry. Bulkex is also part of this year's show, providing solutions for the bulk materials and powder handling industries. Go to www.thesafetyshow.com.au, www.materialshandling.net.au and www.bulkex.com.au 24 Oct to 25 Nov: Certified Profibus Training The Certified Profibus Training courses to be held in October to November 2011 will include: a oneday Certified Profibus Installer Course; a one-day Profibus Commissioning & Maintenance Course; and a three-day Certified Profibus Engineer Course. To register, for any of these courses, go to www.profibusaustralia.com.au

NOVEMBER 5 & 12: ProEdge Manufacturing Excellence Program ProEdge is a five-day manufacturing excellence program that provides the tools to improve your manufacturing efficiency. The program will be hosted in Bundaberg and Mackay, Queensland. Register at www.qmisolutions.com.au/events 25: HIMA Australia facilitated TÜV Functional Safety Program The HIMA facilitated TÜV Functional Safety Program provides valuable skills and knowledge for professionals working in fields requiring safety protection systems. The course also offers TÜV-approved certification on the successful completion of a final exam. Register by visiting www.hima.com.au/tuv

12 OCTOBER 2011 Manufacturers’ Monthly

Process error causes recall BY SARAH FALSON

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ELDING Industries of Australia (WIA) is recalling all units of its WIA 190 Weldmatic due to a manufacturing assembly error which could cause the metal case to become electrically alive and dispense an electric shock to the operator. The company, based in South Australia, has asked users to stop operating the system immediately and contact the manufacturer to arrange a machine inspection and repair, if necessary. The WIA 190 Weldmatic is a portable welding system for welding steel, aluminium and stainless steel, which features a gas-shielded wire or flux-cored gasless wire. “We discovered the method of routing the wires from the transformer to the voltage selectionswitches had resulted in insufficient distance being left between the wires and ventilation louvers,” WIA general manager, Alan Hamilton, told Manufacturers’ Monthly. WIA hasn’t revealed the number of units affected around Australia, however these are sold through 184 distributors. WIA instigated the recall voluntarily, to ensure the complete safety of its customers.

WIA has been able to adapt its manufacturing process to ensure the defect does not occur again.

“WIA is committed to producing products of the highest quality. The safety of our customers is our primary concern. As such, the decision to recall this product was made voluntarily after a defect was discovered during the routine quality assurance testing process which all WIA machines are subjected to,” said Hamilton. “Under normal circumstances, the consumer’s switch board, a circuit breaker or electrical safety switch should operate and the product would remain safe. There is a small risk of a consumer receiving an electric shock, which would require a number of conditions to be present simultaneously, including:

the louvre piercing the wiring insulation; and the welding torch trigger is operated; and the consumer’s installation earth system is faulty (no circuit breaker operates); and the consumer touches the exposed metal fixing screws whilst in contact with an earthed object.” WIA has worked with the ACCC to ensure the necessary action is taken to alert our customers and remove the possibility of this defect posing any risk. The manufacturing process has also been adapted to ensure the defect does not occur again, with additional inspection points inserted into the process. Units with serial numbers from C1312A1110XXX to C1312A0411XXX, along with some of C1312A0611XXX models and some of C1312A0711XXX are included in the recall. “Customers with a machine in the affected serial number range are advised to stop using this product and contact our Customer Service team on 1300 300 884 to locate their local service agent to have their product rectified,” said Hamilton. “No other Weldmatic MIG machines are affected. We aim to have this matter resolved with minimal inconvenience for our customers.” WIA 1300 300 884, www.welding.com.au

Cochlear recalls faulty bionic implants BY ISAAC LEUNG

COCHLEAR has recalled all the units of its Nucleus CI500 hearing implants after a growing number of them shut down and stopped working. Sydney-based Cochlear says there has been a rise in the number of faults reported against the CI512 model in recent weeks. While these faults are unlikely to cause health problems to customers with the defective implants, they are offering replacement models for reimplantation. The replacements are Nucleus Freedom models, a

previous generation of implants. Cochlear was unable to explain the fault with the titanium-based implants, and is currently evaluating the situation. It has halted

manufacturing of the CI500's until the cause has been determined. However, the firm will likely need to go through the process of regulatory approvals. The company has encouraged people with functional units to continue using them, but has undertaken a voluntary recall of the CI512, CI513, CI551 double array implant and ABI 541 auditory brainstem implant. Cochlear designs, manufactures and sells the Nucleus Cochlear implant and the BAHA osseointegrated bone conduction implant. Cochlear www.cochlear.com/au manmonthly.com.au

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Collaboration on car batteries as back-up BY SARAH FALSON

GENERAL MOTORS (GM) and ABB have jointly-developed an energy storage system from endof-life electric vehicle batteries that could store renewable wind and solar energy and feed it back to the grid. The system forms part of a joint research and development (R&D) project to find ways to reuse Chevrolet Volt battery systems, which are currently being dumped into landfill after their automotive use is exhausted, despite having up to 70% life remaining. GM claims end-of-life 33-volt Chevrolet batteries could offer enough storage capacity to power up to 50 homes for approximately four hours. The R&D team has constructed a prototype energy storage system using an electric vehicle battery teamed with a grid-tied electric power converter. Axel Kuhr, ABB Australia CEO, said the system could be used by

End-of-life electric car batteries could store renewable energy and feed it back to the grid.

power providers to feed energy to homes affected by outages. “This [technology would be] primarily considered for utilities that are employing renewable energy sources as a way of dealing with power generation intermittency,” Kuhr told Manufacturers’ Monthly. The electricity storage system

could also be used during periods of peak demand to supplement traditional forms of energy, saving residential, retail and industrial customers money on their power bills. The system could store renewable energy during quiet periods, and feed it back to the grid during peak times.

ABB and GM originally embarked on the R&D assignment to counteract the number of electric car batteries expected to be dumped as rubbish in the coming decades. With electric cars becoming more popular – for example Nissan’s all-electric LEAF car – there could soon be millions of batteries being used. “It is well accepted that batteries will need to be recycled. The magnitude of this issue will be determined by population growth and the rate of EV adoption,” said Kuhr. “Current projections are that by 2020, there will be approximately 5.2 million electric and hybrid vehicles sold in a global market of just under 71 million vehicles. The number is debated quite a bit, but regardless, there will be a lot of used batteries to deal with in the future.” ABB advises that the system could be used in industrial motors to save energy. ABB 1300 782 527, www.abbaustralia.com.au

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manmonthly.com.au

Manufacturers’ Monthly OCTOBER 2011 13

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CarbonFOOTPRINT of Australian vehicles, while funding for Hirotec is aimed at producing lighter components including aluminium hoods.

Selecting materials

The latest hybridised transmissions offer up to 25% reduction in fuel consumption.

Sustainable automotives A recent conference of Australian automotive delegates highlights how fast our car industry is driving towards a sustainable future. Hartley Henderson reports.

I

N today’s global marketplace, Australia’s automotive manufacturing industry is confronted with a number of major challenges, not least being the proposed carbon tax. At the recent Federation of Automotive Products Manufacturers (FAPM) conference in Melbourne (which had the theme ‘Sustainability in a Global Market’), Deloitte Access Economics’ Professor Ian Harper said the tax could add up to $1,000 to the retail price of a locally-manufactured vehicle. “However, there are also opportunities, particularly in relation to our capabilities in R&D and design. We are world class in these areas and there are opportunities to export these capabilities,” he said. President and CEO of Ford Australia, Robert Graziano, emphasised the need for vehicle manufacturers and suppliers to work together to reduce energy consumption and CO2 levels. “Corporate responses to climate change need to be prepared in the industry, including how to reduce energy or commodity use by streamlining processes,” Graziano said. “In Ford’s case, this means taking advantage of our globally developed Lean Supplier 14 OCTOBER 2011 Manufacturers’ Monthly

Optimisation Program in addition to Supplier Technical Assistance and ASEA (Automotive Supplier Excellence Australia) initiatives. “We are working around the world on a broad range of new and exciting sustainable technologies. Under the One Ford strategy, Ford Australia will have direct access to each of those technologies when they come to market.” The ASEA program helps companies become globally competitive. ASEA director Linsey Siede says the program helps companies undertake a variety of projects including environmental sustainability. “We are currently working with 64 companies and have identified opportunities to save over $1m per company across a three year timeframe. There are a lot of opportunities for improvement in the industry, especially the development of business plans, management and leadership, and quality,” he said.

Less weight Gary Stewart, MD of Lean Design Australia, believes there are substantial opportunities to use lean design to reduce vehicle weight and improve sustainabili-

ty of the automotive industry. “There is a need to go to the root cause of cost, which is design. We need to design for whole of life and increase simplicity rather than adding more complexity,” he said. “We need completely different up-front thinking to replace multiple parts with a single part, and ensure robust designs are created before the steel is cut. It is possible to achieve 10 to 30% reductions in weight quite easily, as evidenced in the big improvements and savings at Boeing.” Four grants totalling over $6.2m from the Green Car Innovation Fund were recently provided to CFusion, Toyoda Gosei Australia, Composite Materials Engineering (CME) and Hirotec to assist in the creation of lighter cars. CFusion is using the funding to commercialise the world’s first one-piece carbon fibre automotive wheel, at about half the weight of aluminium wheels, and Toyoda Gosei will introduce and refine technologies for manufacturing lighter components such as body sealing and safety system products. CME is using the funding to develop a high strength lightweight sandwich panel to be used in the load floor

Senior business advisor sustainability at BlueScope Steel, Ross Davies, believes that a holistic lifecycle approach is required to selecting the best materials. “There is a need to use comprehensive lifecycle assessment to make the best choices and consequently the best material selection and in-use comparisons. There should also be a focus on the sustainability of supply chains from raw materials to the finished product,” he said. “At BlueScope Steel a number of sustainability improvement initiatives are underway including in slag processing. In partnership with OneSteel and the CSIRO, a dry slag granulation experimental plant is being constructed at a cost of $5.4m with a view to capturing and reusing the heat from the slag process, reducing water use, improving air quality, and producing a better quality by-product for the cement industry. “General plant innovation has resulted in a material efficiency measure of over 96% for the last five years. This is a measure of how efficiently a company uses raw materials, which in turn means a significant reduction in waste to landfill.” Also, a $4.4m project looking at replacing a proportion of the coal used in the iron and steel industry with sustainably sourced biomass is underway. Glenn Paine, OEM business manager at ZF Group, said the company’s projects, looking at the size, weight and cost of transmissions, have resulted in fuel and emission reductions. “The new ZF 8 speed transmission provides 6% fuel reduction, and this can be boosted by a further 5% by adding the Hydraulic Impulse System (HIS) to support engine stop/start functionality. Up to 25% fuel reduction can be achieved by converting to a hybridised unit,” he said. ASEA 03 9673 5922, www.asea.net.au manmonthly.com.au

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AnalysisMANAGEMENT How to obtain finance today Today, banks are not the only option for manufacturers when it comes to raising finance. Alan Johnson reports.

A

S AN Australian manufacturer you will no doubt recognise this scenario: you are an SME and you have just negotiated a long-term, multi-million-dollar contract to manufacture thousands of widgets a month for the next five years, at a very good rate (for you). The only problem is, you don’t have all the necessary equipment and will need a special piece of machinery costing, say, $1.3m. So it’s off to your friendly (see TV ads) bank manager, only to be offered a loan at some exorbitant rate which requires you to put your house, car and all your possessions up as guarantee. Well today, there are a number of other options worth exploring that are not connected to a bank.

Leasing Though leasing has been around for decades, with most companies leasing their cars and trucks, some manufacturers may not be aware that they can benefit from financing their equipment needs through leasing, and not just the financing of largescale production equipment. Nick Aronson, GM at The Leasing Centre, explains that the outright purchase of equipment can be problematic. “Not only does it involve a large outlay of funds, it also equates to paying for the future use and benefits of the machinery. Plus the upfront purchase of equipment through cash or a bank facility is not tax effective and restricts businesses from updating or changing equipment as new innovations hit the market,” he said. “Having a flexible finance facility option (leasing) in place for equipment has many advantages. Firstly, it allows businesses to spread payments over the useful life of the equipment. “This is a bonus when managing cash flow and leaves the business with capital to invest manmonthly.com.au

into other areas. Additionally, finance facilities are often tax friendly with monthly payments 100% tax deductable if used for business purposes – making them a cost efficient way to finance new equipment. “Just as important is what happens when the machinery comes to the end of its useful life. Manufacturing organisations need the flexibility to upgrade or replace equipment at any time, ensuring that they are not left with an out dated machine. “This way, they can invest for growth – ensuring that they have the option to access market leading equipment that will enable them to develop and grow their businesses.” Daniel Moses, director with the Leasing Centre, advises manufacturers to work closely with their accountant and take their advice, rather than the banks’. “When it comes to putting in place a flexible finance facility, manufacturing businesses should look to work with organisations like ourselves, who specialise in financing manufacturing equipment,” Moses told Manufacturers’ Monthly. “Unlike banking institutions, these organisations are able to offer specific tailored solutions designed to secure the machinery and equipment required for growth, while making it tax effective, cash flow friendly and flexible. “We believe every equipment finance strategy should be specifically designed to help bridge the gap between growth objectives and budget limitations, to ensure that organisations in the manufacturing sector get the best investment for their business. Companies like ourselves can add a lot of value; often we know better ways of financing equipment. “Firstly, we don’t charge for advice or for structuring. Plus from a tax perspective, if we structure it in the correct way, >>

With obtaining finance from banks today like pulling teeth, manufacturers are advised to look at other available options.

Manufacturers’ Monthly OCTOBER 2011 15

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AnalysisMANAGEMENT we can reduce the costs. A lot of it is understanding the after tax costs. You might spend $100 on a one type of equipment finance contract and get no tax reduction, but if you spend $120 you might only cost $70 after tax. That’s a very crude example of what we can do.” Moses says forward financial planning is also very important. “We like to work with our customers and understanding what their next 12 months requirements will be. Then we can put a master facility in place with an approval limit of $x, which doesn’t cost anything to put in place and no obligation to use it. It just means they can start planning to secure the contracts or do their capital acquisition planning and know there is finance behind them,” Moses said.

Banks and finance companies are not big fans of industrial equipment; they claim it is expensive with a limited useful life.

Factoring and discounting While not quite as well known as leasing, factoring and discounting (receivable financing) is steadily growing in popularity for Australian manufacturers. According to Tony Della Maddalena, IFD’s chairman, the industry’s turnover is around $60bn with his member companies assisting over 5,000 companies, 20% being manufacturers. “Maybe 30 years ago, factoring was regarded as a last resort option, but today we are following US trends where it has become more mainstream. Business owners who want to improve and secure their business finances, but who don’t want to give up their real estate security, they would prefer to have it secured by their own business assets,” he said. “Australia is following the US and European trends where factoring is a more mainstream finance tool.” Della Maddalena explained that factoring and discounting involve the assignment of debts by a business (the assignor of the debts, usually referred to as the client) for consideration, generally on a continuing basis. “There are various ways the purchase transactions are structured. For example, the debt can be sold to the factor/discounter for a price that is less than the face value of the debt,” he said. 16 OCTOBER 2011 Manufacturers’ Monthly

“In this case the factor/discounter pays the business up to 90% of the invoice value in cash and the balance, less fees, is paid to the business after a set period, or after the debt has been collected. “Sometimes the debt is purchased for its full face value and then a prepayment of the amount owed is made based upon an agreed prepayment rate. “Under both facilities, the client sells the unpaid invoices for immediate access to cash, but under the factoring arrangement the factor additionally manages the client's sales ledger and collection of accounts. “Therefore, under a factoring arrangement the debtor makes payments to the factor. Under discounting, the debtor nominally makes payments to the supplier; but as the debt is owned by the discounter, the supplier is collecting these debts on behalf of the discounter.” Della Maddalena says it’s probably the bigger players using discounting, with the smaller companies using factoring. “They might be given a contract from a larger company. Maybe the company is a small food manufacturer who wins a

contract to supply product to a whole load of stores such as Coles, IGA or Woollies for example, Della Maddalena told Manufacturers’ Monthly. “They can’t fund it themselves, so they go a receivable finance company that basically funds those invoices which some big debtors of theirs won’t pay them until 60-65 days. “According to the latest Dun & Bradstreet figures, average payment days are now about 54 days. Now if you are a small manufacturer turning over $300,000 to $400,000 that’s a ledger of $500,000.” Della Maddalena admits most companies go to their banks first, “But the banks simply look at the company’s asset pool and assess the directors, then demand a mortgage over the directors’ homes. A receivable financing company is a better option.”

Exporting finance If you're an Australian exporter and having difficulty obtaining finance or insurance your first step should be to contact the Australian Government’s export credit agency, Export Finance and Insurance Corporation

(EFIC). EFIC provides finance and insurance to help Australian exporters overcome the financial barriers they face when growing their business overseas. Just recently, EFIC provided a performance bond to support the participation of Australian company Bothar Boring & Tunnelling in a $8.2m subcontract to provide tunnelling services in Kuwait. The main contractor, Kuwait company Process Plant Construction & Contracting KSC (KCPC), required Bothar to provide a performance bond in the form of a demand guarantee. To facilitate Bothar’s participation in this contract, EFIC provided a $900,000, 36-month performance bond. Mark Dart, MD of Bothar said without EFIC’s support, the full cash collateral the company needed to secure the bond would have meant diverting working capital from other opportunities and therefore potentially hindering the company’s ability to further develop opportunities. “The performance bond has enabled us to participate in this major contract and keep growing our business,” Dart said. In another example, Sydneybased Park Assist, a global leader in parking guidance, bay sensing and parking enforcement, secured a US$780,000 contract with the City of Seattle to provide an electronic parking guidance system for the city’s downtown parking lots. Under the contract, the company needed to lodge a performance bond worth 100% of the contract value, with scope for the bond value to increase by 25% in line with possible increases in the contract value. In this example, EFIC underwrote the performance bond to help Park Assist fulfil its contract – the company’s first with a US government authority. Daniel Cohen, Park Assist’s MD, said: “EFIC’s support with the US surety bond freed up a significant amount of our working capital, helping us to fund our strong export growth.” The Leasing Centre 02 9744 7099, www.theleasingcentre.com.au IFD 02 9233 8205, www.factorsanddiscounters.com EFIC 1800 093 724, www.efic.gov.au manmonthly.com.au

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TechnologyIT@MM As well as data about temperatures and pressures from pallets and boxes, there is a need to capture relationships across the manufacturing process.

A variety of uses Automated traceability tech-

AspenTech 02 9572 5544, www.aspentech.com

Traceability is more than just a process of tracking events in the supply chain; it is a method manufacturers take to become customer-centric. Steven Kratsis writes.

T

18 OCTOBER 2011 Manufacturers’ Monthly

inventory management and logistics. The second, product tracing, is identifying the origin of a particular unit and/or batch of product located within the supply chain by reference to records held upstream. Products are traced for purposes, such as recall and complaints. Traceability enables organisations to ‘guarantee’ the origin of a product or raw material. It also allows them to reduce the risks they face where an incident has occurred by more quickly searching impacted products and removing from the marketplace as/when required. In many firms, opportunities for process quality enhancements are lost because genealogical data is so hard to attain.

Scoping out the challenge Many organisations across the process industries, particularly those in the batch industries like consumer products and pharmaceuticals, are still using manual approaches to traceability. This presents a variety of problems as

An effective solution To fully support traceability, sophisticated tools are needed to deal with a range of issues. In the product development process, this includes manual data from pallets, raw materials scans and process automation data. This will incorporate batch data, details of product quantities, sources, destinations and times of despatch and arrival, and supply chain data. When all disparate information has been collected and captured, the information needs to be stored into a database and a user interface provided in order to navigate it quickly and easily. Detailed analysis software is also needed to analyse the data, evaluate issues, find their source and the underlining cause. In this context, a software solution for traceability will address the core manufacturing function and the broader supply chain can be deployed across many process industries and easily integrated with many other systems. Traceability should not been seen merely as a process of tracking events in the supply chain, it’s a method of being customer centric, enhancing service excellence and achieving commercial success by developing a genuine value chain. [Steven Kratsis is country director, AspenTech Australia.]

Supply chain traceability HE need for manufacturers to focus on compliance and traceability initiatives is increasingly significant as commercial pressures grow to meet regulatory mandates. By mitigating the risk of product recalls, reducing manufacturing costs and quality controlling endto-end process traceability, organisations will be able to reduce inefficiencies. Technology can be used to track system status, analyse performance and support decisionmaking. Software systems, for example, are designed to support the levels of strategy, planning, design and operations. All of these forms of traceability are needed in manufacturing to provide a structured, holistic way of managing operations to meet commercial targets. Traceability takes two forms. The first, product tracking, is following the path of a specified unit of a product through the supply chain as it moves between organisations. Products are routinely tracked for obsolesce,

niques are used across a range of applications. First, the approach can be employed to identify lots impacted by an incident, by navigating ascendant and descendant links between raw material lots, intermediates and finished products. Second, it can help identify in which specific lots a particular product has been used. Third, automation can be used to find which equipment items have been impacted by a given lot. Fourth, it enables organisations to use records to find the history of a manufactured lot. Finally, it enables users to compare manufacturing and quality parameters at different steps of the same lot, and between the same steps of different lots.

organisations need to keep a history of transactions, stretching back as many as ten years to comply with regulations. Most businesses keep a paperbased standard operating procedure document and mark comments on it. There are many disadvantages to this approach. First, it is extremely expensive. Second, it introduces errors into the system both in the process and in the documents used to support it. Third, it brings little value to the organisation. Unlike electronic data, it cannot easily be used to support continuous process improvement, carry out ‘what if’ analysis and drive product efficiencies. Some organisations are now looking to digitise the process but the sheer weight of paper that will need to be moved before this can happen makes this a challenging task indeed. It is important that data is collected and analysed electronically.

manmonthly.com.au

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Lean manufacturing: beyond the shop floor BY ROB STUMMER

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T WOULD be hard to find a successful manufacturer anywhere in the world that is not using some elements of lean manufacturing to streamline their operation. However, even among those companies with formal lean programs, the degree to which lean principles extend beyond the shop floor to the office is still very limited. This is surprising, since to a large extent, an organisation that is extremely lean on the shop floor may still be losing time and energy to non-value-added work in the front office. While inventory and product is the focus of shop-floor lean, front-office lean deals, more substantively, with information. Whether the information comes in the form of pieces of paper, verbal and written communications between the company and its customers, complex electronic documents and specifications or simple internal correspondence, a lean front-office must streamline the handling and development of these information objects, as well as the decisions that are made on the basis of the information. Virtually any manufacturing or contracting operation can benefit from bringing lean disciplines to the front office.

Steps to achieve ‘lean’ When implementing a lean front office, manufacturers need to take the following steps. Analyse what people are doing in their respective departments. How do they bring value to the company and its customers? Determine which people touch which documents and processes. How much of this activity is needless and can be removed from the process flow? Go through value stream mapping by determining how much each step in the process costs and what it contributes to revenue. Optimise the physical environment. In some cases it will make manmonthly.com.au

The first step to achieve ‘lean’ is to determine which people touch/open which documents and processes.

sense to move objects and people around in the office to facilitate more direct and efficient communication.. Optimise processes through automation with an enterprise application. As inventory levels dip to a certain point, an application can send up an alarm to notify the correct people. The right application can automate process flows, even when those working on a project are separated by great distances. Monitor your results. Fluctuations in metrics can indicate that processes are not being followed, or that new processes need to be implemented to accommodate changes in your business. Enterprise applications can help manufacturers achieve a ‘lean front office’ enabling them to map processes and route information to the right people. Documents can be made accessible to the right people in or out of house and changes and alterations to specifications can be tracked in a central repository, eliminating enormous amounts of non-value added work.

and where to deploy the application in order to address your specific company’s needs. A built-in workflow to automate your processes. Once you decide the optimal flow of information through your front office, the application must be configurable to match your needs.

Portals for visibility. Each front office team member should have action items automatically placed on their personal portal. This needs to be configurable to accommodate individual needs, but still ensure best practices are being followed. While an enterprise application like IFS Applications can be a vital part of a lean front office solution, too often a company’s systems come between them and the efficiencies that are necessary to streamline the operation. Once an application has been identified to help facilitate frontoffice lean, it’s time to begin reengineering your process, in essence, determining where value is delivered in front-office processes and what activities do not contribute to value and need to be eliminated. [Rob Stummer is managing director of IFS Australia and NZ.] IFS 1300 791 200, www.ifsworld.com

Choosing an application As you plan to choose and implement an enterprise application to bring lean to front office and shop floor operations, following are a few things to look for. A business process modeller. This will help you discover where potential efficiencies lie Manufacturers’ Monthly OCTOBER 2011 19

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MaterialsHANDLING Barcode scanners

Insignia national sales manager – labelling, Brad Jeavons, accepts the Imported Equipment Award at the 2011 APPMA Awards of Excellence.

High honour for high speeds This high-speed label applicator received top honours for its cost and precision.

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NSIGNIA’S Domino M-Series label applicator has won the Imported Equipment Award at the 2011 APPMA Awards of

National Coding Technologies Pty Ltd

Excellence, due to its ability to print and apply labels to cartons at high speeds. The label applicator is report-

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edly the perfect tool for manufacturers working with high-volume batches, requiring a highspeed labeller to help them save costs in their labelling process. Insignia says the ability of the high-speed system to print and apply labels on the manufacturing line allows users to reduce packaging inventor. The Domino M-Series also reportedly provides users with more real-time information, allowing them to reduce carton loss and line-changeover times. The system also provides a high level of guarding, to protect the operators and prevent injury, while still providing a clean design and good access for cleaning, insignia says. “The Domino M-Series label applicators facilitate print and apply on lines up to 100 cartons per minute. OEE, user friendliness through common user interfaces and simple loading, and most of all limited service requirements coupled with commonality of parts are major considerations leading to market leading up-time performance for all Domino products,” said insignia national sales manager – labelling, Brad Jeavons, while accepting the APPMA award. insignia 07 3179 2168, www.insignia.com.au

20 OCTOBER 2011 Manufacturers’ Monthly

THREE new barcode scanners (CLV63x/64x/65x) with high reading and networking performance are available from SICK. The systems are suitable for use in packaging, food, pharmaceutical, logistics, handling and warehousing, and forklift applications. Each model can be integrated in existing Profibus DP networks with SICK’s new CDF600 connection box. The barcode scanners feature CAN (CSN and CANopen), Ethernet TCP/IP, and Ethernet IP (for connection type Ethernet) connectivity. Integrated function keys for starting auto-setup or evaluating reading quality are included. The units also incorporate Increased SMART code reconstruction for precisely determining and decoding damaged, badly printed or half-covered barcodes. SICK 1800 334 802, www.sick.com.au

Coding, marking laser THE Rea-Jet Laser CL is a CO2 laser marking system suitable for marking cardboard boxes in the pharmaceuticals, cosmetics and food and beverage sectors, along with glass marking, wood and plastics engraving. The laser beam is generated in an enclosed laser tube which is filled with carbon dioxide. Flexibly-mounted mirrors guide the bundled light beam over the product surface, resulting in the marking effect. The system can mark both mobile and immobile products on a production line, and can be integrated with existing production systems. According to distributor Result Packaging, laser systems have the advantage of being free of consumables and virtually maintenance free, running for 6,000 working shifts without hassle. Users can create text, graphics and drawings using the laser marking system. Result Packaging 03 9706 4474, www.resultpackaging.com.au manmonthly.com.au

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It’s the A220’s tried&true performance that sets it apart.

Selling over 100,000 units worldwide, it’s no coincidence that Domino is an inkjet coding industry leader. Their equipment has been developed to tolerate even the harshest production environments while maintaining premium print quality – providing customers with high levels of performance and reliability across a broad range of applications, proven with the market leading up-time performance. And the operation and maintenance of Domino’s machinery couldn’t be simpler, with the full support of insignia’s national service network, made up of more than 20 field technicians and various comprehensive support options.

Contact us to find out more about the Domino range.

Phone: 1300 467 446

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Email: sales@insignia.com.au

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Web: www.insignia.com.au

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What’sNew See more new products at manmonthly.com.au

Small-footprint storage lift SSI SCHAEFER’s LogiMat storage lift is designed to maximise storage capacity while reducing storage and energy costs. The LogiMat storage lift is an automated storage and order picking solution that uses process automation to provide a six- to ten-fold increase in order picking speeds, at the same time minimising picking errors, the company says. The LogiMat features two rows of trays. Between the trays, there is a lift moving up and down along the entire height of the warehouse automation system to remove the individual trays from their positions and move them down to a service opening that follows the goods-to-man principle. The order positions are transferred directly to a PC located on the automated warehouse system, where the relevant article trays are actuated by the system and transferred to the service opening. The warehouse staff remove the picked goods easily and at an ergonomic height with no operator stress. The range of applications includes: storage of small, standard and DIN parts; production store and conveyor system across multiple levels; incoming goods store; storage and provision of equipment and tools; and production buffer and automatic parts provision. The system is available at any height and width, and can be integrated into an existing warehouse management system. SSI Schaefer 02 9824 3844, www.ssi-schaefer.com.au

The storage lift uses process automation to minimise picking speeds and errors.

Racking audit system now multilingual VICTORIAN company Independent Racking Inspections & Audits’ (IRIA) racking audit software is now multilingual to accommodate clients with global bases. IRIA’s Rack Audit Technology (RAT) was developed to collect and store steel racking audit data in a range of industrial and commercial operations, aiding racking safety. Faults are recorded for storage in a centralised database, allowing users to generate damage reports on-site. The technology now offers the facility to operate in various languages,

accommodating global clients with language barriers. According to IRIA, the multilingual capability was added to the company’s RAT software because many companies with steel storage racking in their business failed to realise their responsibilities within the Australian Standard, including annual inspections. The racking audit software reportedly complies with the Australian Standard for Steel Storage Racking (AS4084) and the European FEM standard. (FEM 10.2.04) IRIA 1300 136 649, www.iria.com.au

We re-level buildings! Machinery re-supported Slab movement fixed Factories, warehouses Drives & houses too Fast: most jobs in a day Immediately trafficable Structural resin injection

iPad2 SaaS solution for managers MANUDYN has released a new SaaS solution for the iPad2 and other tablet PCs, called Cloud 9, designed for manufacturing managers who require access to critical operational and financial data about their businesses while on-the-go. Cloud 9 runs on a wireless network or 3G/4G data service in the plant, allowing businesses to save money on computer servers and internal IT staff. The solution can provide quoting, sales orders information, inventory control, data on accounts payable and receivable, and other general reporting.

22 OCTOBER 2011 Manufacturers’ Monthly

tbeck@uretek.com.au www.uretek.com.au

ManuDyn 02 9542 3066, www.manusoft.com.au

SET TING THE WITH STANDARDS AFE INNOVATIVE S TIONS STORAGE SOLU EF CTIVE COMPLIANCE EFFECTIVE EFFECT COMPLIA ANCE FOR F THE INDUSTRY MANUFACTURING INDUST TRY

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Relocatable bulk stores Safety cabinets Gas cylinder stores Lube stations Bunding Safety showers Custom design to suit your situation

DESIGNED AND MANUFACTURED IN AUSTRALIA

1800 623 312

It is designed for operators, supervisors and management, offering realtime operations and accounts data in seconds from anywhere in the world. Cloud 9 takes advantage of the new iPad2’s 10-hour battery life, light weight, and built-in conferencing capabilities. It can also be used with other compatible tablet PCs. According to ManuDyn, the system’s cost of ownership is low, with users paying a monthly fee-per-user charge only.

protecting the

1300 134 223 1300 307 895 sales@storemasta.com.au www.storemasta.com.au manmonthly.com.au

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Quality Fluke Thermal Imagers at Affordable Prices! From entry-level to high-performance, Fluke has you covered! The only thing that precedes Fluke's highest standards of quality is our reputation for making the finest measuerment tools in the world. Fluke thermal imagers are no exception, and the Ti and P3 Series handily delivers on the promise to offer the most tool for the money.

Superior image quality • Delivers clear, crisp images needed to find problems fast with its 320x240 sensors. • Automatic alignment (parallax correction) of visual and infrared images with Fluke patented IR-Fusion®

One-handed easy to use interface • Intuitive, three-button menu is easy to use— simply navigate with the push of a thumb. • Record findings by speaking into the imager. Voice annotations can be recorded and saved with every image you take.

Torture tested™ • Engineered and tested to withstand a 2 metre drop for the ultimate peace of mind. • Withstands dust and water—tested to an IP54 rating. • Manufactured in the U.S.A. For more information on Fluke’s unique IR fusion or PRICE DROP on selected Thermal Imagers contact Fluke today and quote the special MM reference number: FLU44 l

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What’sNEW The lighting systems are simple to install in factories.

LED lighting saves costs HI-SEMICON Australia has released a new range of LED High Bay Lighting systems for industrial applications. Certified to Australian Standards and designed for Australian conditions, Hi-Semicon LED lighting reportedly saves 75% on power consumption and comes complete with a four-year product warranty. Installation is simple, with users needing only to hang and plug in the lighting system, says Hi-Semicon. The LED lights use Hi-Semicon’s Phase Change Liquid Cooling system, which is said to keep the junction point at 65 degrees, while removing more heat than competitor technologies. According to the company, this allows the High Bay LED lights to burn brighter and last longer, with less running costs.

Mechanical control

The systems use Bridgelux multi-chip LEDs and Meanwell power supplies.

Hi-Semicon Australia (division of ACE Gutters) 02 9584 4767, www.hisemiconaustralia.com.au

Magnetic cable-holders protect workers and equipment

FOR LEASE

also protecting pedestrians from slips, trips and spills. Cable-mate is an easily-installable solution, and holds magnetically onto any steel surface.

Each system holds up to 25kg of weight. An adjustable HDPE strap is designed to hold all hoses and cables. Swift Metal Services 02 6969 2333, www.swiftmetal.com.au

ENERPAC’S Uni-Lift mechanical actuators have been designed for linear motion control in precision positioning and control in a mechanical package. With strokes up to 6096mm, the B and M series Uni-Lifts utilise ball screw and machine screw mechanisms. The Uni-lifts complement Enerpac’s range of high pressure (700 bar) compact and powerful hydraulic lifting and manoeuvring technologies. Enerpac says its line of Uni-Lift accessories allow for easy connection and precise synchronised control of multiple actuator systems. Tight tolerance thread forms, heat-treated gear sets, and pre-loaded bearings ensures repeatability and durability of these linear actuators. Enerpac 02 9743 8988, www.enerpac.com.au

HUME HIGHWAY

SWIFT’S new Cable-mate is designed to keep floorspace and work areas safe and tidy. The system protects cables and hoses from pedestrian traffic, while

The Uni-Lifts utilise ball screws and machine screws with strokes up to 6096mm.

Southern Distribution Hub, Goulburn • 263 hectares to be developed over stages • Warehouses from 10,000m² to 100,000m² • Designed to meet tenants requirements • New Hume Highway on/off ramps, B double/B triple access • 1 hour drive to Canberra, 2 hours from Sydney • Major railway sidings, with proximity to Goulburn Airport • Flexible zoning, manufacturing, warehousing, 24 hour use • Sustainable water and solar power • Government incentives and training • High local white and blue collar employment pool www.colliers.com.au/5818525 Adrian Balderston 0407 506 010 02 8797 1611

24 OCTOBER 2011 Manufacturers’ Monthly

Fab Dalfonso 0412 549 766 02 8797 1610

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The screeners are designed for eye-testing in the workplace.

Sight-checking station lowers risk MANUFACTURING workers can ensure their vision is clear with the help of Honeywell Safety Product’s guide to eye testing in the workplace. The Titmus V Series Vision Screeners are ergonomically-designed, stereoscopic instruments which are said to provide precise and prompt measurement of visual performance. The range is designed for employers to quickly ascertain if a worker’s vision is within the normal parameters.

The units are in keeping with a report in Issue 1 of Australian GovLink encouraging employers to introduce a Visual Performance Program in the workplace, Honeywell says. According to the company, the Screeners help manufacturers work towards promoting a safer workplace by managing the risk that current and potential visual challenges pose. Honeywell Safety Products www.honeywellsafety.com

AM

Iron, steel corrosion protection BIRCHWOOD Casey’s new patented MICROLOK AO coating is a non-toxic aluminium oxide conversion coating that is 0.000060 inches (1.5 microns) thick, silver/black in colour and adherent to metal surfaces. When compared with room temperature blackening, the MICROLOK AO coating reportedly exhibits better corrosion resistance and operates at half the cost, without undesirable pollution hazards. Applications include: tooling and machine components; automotive parts including tie-rods and ball joints, and clutch and brake components. Additional benefits include: anti-

The MICROLOCK AO has anti-galling properties to aid in startup.

galling protection to aid in assembly and startup; temperature stability up to 1400°F; and safe 120-140°F operation with no boiling or splattering. Birchwood Casey www.birchwoodcasey.com

Belt-driven axial flow fans AEROVENT has extended its Sapphire series of belt-driven axial flow fans, which are suited to hot and corrosive applications, such as kiln exhaust and recirculation. The fans are available in carbon steel construction as standard or with full stainless steel or high nickel alloy construction, which includes a fully fabri-

cated impeller, fan case, belt and bearing tunnel. The fans are available in sizes ranging from Ø350 to Ø3000mm. They incorporate the company’s bearing cooling system designed for use in tough appplications. Aerovent Australia 03 9720 8088, www.aerovent.com.au

Atlas Copco’s AIRnet™ compressed air piping system is the lifeline your business needs.

AIRnet™ delivers the best quality air exactly where you need it, at the right pressure and the lowest possible cost. Its lightweight, anti-corrosive aluminium pipes and robust polymer fittings are easy to install and allow ultimate flexibililty to meet your needs. AIRnet™ saves time, energy and increases productivity. Call now and breathe easy. Atlas Copco Compressors Australia 1800 023 469 ausairinfo@au.atlascopco.com www.atlascopco.com.au

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Manufacturers’ Monthly OCTOBER 2011 25

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What’sNEW The system handles totes, cartons and cases.

Eyewash stations

The glove has a remote control fitted for controlling the truck’s movements.

Lending a picking hand CROWN’S QuickPick Remote Advance system is designed to make low-level picking in warehouses and distribution centres simple. Available on the Crown PC 4500 Series centre console rider pallet trucks, QuickPick Remote Advance is designed to allow operators to remotely advance the truck to the next picking point without having to climb back onto the truck, or walk along beside it holding the steering control. The system relies on a special glove that has a remote control fitted for controlling the truck’s movement. Order selectors simply press a button on a wireless transceiver glove to

remotely advance the truck to the next pick location, eliminating the need to return to the operator’s compartment while picking. The technology consists of a wireless transceiver module that snaps into a holder on the back of the operator’s glove. Crown’s QuickPick Remote Advance system is reportedly the first of its kind in the industry. It uses task-automating technologies to simplify workflow and improve the picking process, increasing productivity and reducing operator fatigue. Crown Equipment 02 8788 0000, www.crown.com/au

Barrier warning safety tapes FLOORSAFE International has extended its range of tapes to include barrier warning tapes. The tapes are printed on both sides and are available in 75x100-metre rolls and come in 90 microns thickness.

All safety tapes are always in stock and ready for immediate overnight delivery, the company says. A range of colours and widths are available. Floorsafe International 1300 717 769, www.floorsafe.com.au

The eyewash stations are ideal for decontamination of the eye area where time is of the essence.

Storage, retrieval THE RapidStore Mini-Load is the latest in a series of high-performance storage and retrieval machines (SRMs) from Dematic. The RapidStore ML10 handles totes, cartons and cases in facilities ranging in height from 4m to 20m. Offered in three standard heights (10m, 14m and20m), RapidStore ML10 is said to efficiently handle a host of container types in a multi-deep and flexible-width environment. The RapidStore Mini-Load operates at a travel speed of 6.0 m/s, accelerates at 4.0 m/s2, has lift speeds of 3.0 m/s, and lift acceleration of 3.0m/s2, delivering up to 142 double cycles/hour (based on an 8m crane operating in a 40m aisle), Dematic claims.

SPERIAN Protection has introduced a range of emergency eyewash stations which deliver flushing fluids to decontaminate the eye area. The eyewash stations and products utilise Eyesaline – a preserved, buffered, saline solution, which is said to be superior to tap water. The range includes the Sperian Portastream II(r), the Sperian Fendall Pure Flow 1000(r) and Sperian’s Personal Eyewash Products. According to Sperian, the eyewash stations are ideal in the event of a hazardous eye contamination where time is of the essence. In addition to this range, the company also offers specialised safety eyewear such as the Sperian DuraMaxx Goggle and the Sperian Millennia Sport safety eyewear for worker protection in industrial environments.

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

Sperian Protection 1300 139 166, www.sperianprotection.com.au

KERRICK...the quality is built in for powerful performance

Pressure Cleaners

Hot Water Cleaners

Sydney Melbourne Brisbane Perth Adelaide

Big Vacuum Range

Carpet Cleaners

98 Carnarvon Street, Silverwater, 2128. /@BHjB #QHUD *DXRANQNTFG 1NAHMRNM 1N@C &DDATMF 4MHS +D@BG 'HFGV@X *DVC@KD 2@KDR

www.kerrick.com.au 26 OCTOBER 2011 Manufacturers’ Monthly

Electric Pressure Cleaners

Pumps All Sizes

Material Lifts

(02) 9737 9797

Toll Free: 1300 KERRICK 1300 5 3 7 7 4 2 manmonthly.com.au

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The fan can cut energy use by over 50%.

High-performance terminal blocks ELEMENT14 is distributing FCI’s new range of high-performance signal and power terminal blocks which utilise rising-cage clamp technology to allow for perfect connection, according to the company. Models in the FCI terminal block series are available in various configurations and sizes. The modular system of these components includes from two to 24 positions in various pitch-sizes ranging from 3.50mm to 7.62mm, and wire sizes for signal and power solutions. The robust designs of these terminal blocks ensure durability of up to 200 cycles, which is said to significantly improve the lifespan of end products and minimise the need for repair.

Flexible, portable fans BIG Ass Fans has introduced the new Yellow Jacket; a portable fan designed for flexibility, quiet operation and excellent durability. The system has a heavy-gauge steel carriage engineered to withstand the harshest environments, a Powerfoilinspired blade for maximum efficiency and airflow coverage, and an acoustically-designed fan, motor and carriage for quiet operation. Other features include oversized wheels and ergonomic handle for superior manoeuvrability, multiple speeds and an easy-to-operate locking mechanism for greater airflow control. According to Big Ass Fans, the Yellow Jacket has a high-efficiency design which cuts energy use in the factory by over 50%.

The terminal blocks have been designed for durability of up to 200 cycles.

Said to be versatile, the components also allow for greater flexibility in operating environments. A wide spectrum of demanding applications including industrial, instrumentation, and communication environments are possible. element14 1300 361 005, www.element14.com

BigAssFans 07 5500 0690, www.bigassfans.com.au

Free-standing filtration system LINCOLN Electric Automation has introduced the Circulator, a free-standing filtration system for weld fume control in facilities that have obstructions. The system reportedly offers an economical alternative to a push-pull system and can be used to supplement

an existing source extraction unit. The Circulator was designed to create a cleaner work environment by reducing the amount of dust and dirt in the operator and surrounding areas. Lincoln Electric 02 9772 7222, www.lincolnelectric.com.au

Quick-changeover jaw vises KURT’s HD and HDL Vises and ClusterTowers feature quick-change jaws and fewer components for faster changeovers. Providing 0.0002-inch

repeatable clamping accuracy (from part to part), the HD towers feature a self-adjusting holding block DoAll Australia 02 9671 5011, www.doall.com

Our isolators are so flexible they’ll bend to meet your needs. Mackay has the largest range of rubber vibration isolator and equipment mounts in Australia. We are the first choice for both original equipment and replacement parts. More importantly, our design and manufacturing facility is capable of producing mounts for delicate electronic equipment to very large engine mounts.

We are certain that Mackay can provide a solution to your rubber requirements – it’s amazing just how flexible we are. T (03) 9555 6500 F (03) 9276 8882 E info@mackayrubber.com.au w mackayrubber.com.au

E X C E L L E N C E

I N

R U B B E R

T E C H N O L O G Y

MAC009/B

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Manufacturers’ Monthly OCTOBER 2011 27

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What’sNEW - Sensors & Analysers Easy integration for weighing METTLER TOLEDO has introduced the IND131 and IND331 weighing terminals which deliver precision measurement data in a single, cost effective package for easily backed-up and restoration using SD memory cards. The IND131 and IND331 weighing terminals feature Organic LED weight display which makes the terminals readable in all conditions, ultra-fast A/D conversion rate and patented TraxDSP digital filtering and a choice of AC or 24 VDC power supply. An optional PLC interface allows bidirectional infor-

Thermometer delivers lab-quality accuracy

mation exchange with the terminal. In addition, the weighing terminals do not require the panel to be laser cut in order to panel-mount the unit, therefore reducing the time and cost of installment. The IND131 and IND331 weighing terminals are designed to match the environment enabling multiple mounting possibilities. The weighing terminals are available in four designs: the IND131/DIN rail mount; IND131/JBox; IND331/Panel; and the IND331/Harsh. METTLER TOLEDO 03 9644 5715, www.mt.com

Indoor CO2 monitoring DWYER Instruments’ new series of CDT Carbon Dioxide and Temperature Transmitters monitor the CO2 concentration and temperature in indoor environments. For increased sensor life, a single beam dual-wavelength non-dispersive infrared (NDIR) sensor is used to automatically correct the measurement in both occupied and unoccupied buildings against aging effects. The technology provides high accuracy compared to Automatic Baseline Correction methods which can unintentionally shift the calibration based on CO2 levels and barometric pressure conditions, says the company.

The transmitters monitor CO2 concentration and temperature in indoor Dwyer Instruments 02 4272 2055, www.dwyer-inst.com.au environments.

PACIFIC Sensor Technologies has released Fluke Calibration’s four channel universal bench thermometer, the 1529 Chub-E4 Thermometer. The Chub-E4 has four inputs for reading four different sensors simultaneously which can be configured in any of three different ways according to user preference. Typical accuracies include ±0.004°C at –100°C and ±0.009°C at 100°C. Thermistor readings are converted using the Steinhart-Hart polynomial or standard YSI-400 curve and are as accurate as ±0.0025°C at 25°C with resolution of 0.0001°C. Thermocouple inputs read all the

The 1529 Chub-E4 Thermometer can read four different sensors simultaneously.

common thermocouple types, including B, E, J, K, N, R, S, T, and Au-Pt, and allow users to choose between internal and external reference junction compensation. Pacific Sensor Technologies 1300 662 720, www.pacificsensortech.com.au

Transparent thickness measurement BESTECH Australia has released Micro-Epsilon’s series 2401 confocal distance sensors which are applicable for low range distance and one-sided thickness measurements. They can measure on shiny and transparent objects, and are ideal for precision measurement against diffuse and reflective materials.

According to the company, polychromatic white light is focused onto the target surface by a multi-lens optical system. The lenses are arranged such that the white light is dispersed into a monochromatic light by controlled chromatic deviation. Bestech Australia 03 9540 5100, www.bestech.com.au

Leadership has a class of its own

FLIR E-Series: Picture Perfect A new generation of FLIR hand-held ‘point & shoot’ thermal imagers is here. Packed with class leading features, the E-Series is designed for applications including electrical, industrial, mechanical, HVAC and building. Take your pick of three pixel resolutions – all with 60Hz frame rate and a 3.0 Meg visual camera built in. The new FLIR E-Series. It’s all class. Get Connected! Connect to iPhone or iPad via Wi-Fi to use the FLIR ViewerApp for processing and sharing results.

◊ Mobile Device Wi-Fi Connectivity ◊ Large Bright Touchscreen ◊ Built-in Digital Camera & Laser Pointer ◊ Groundbreaking Performance & Affordability ◊ Superior Point & Shoot Thermal Imagery

FLIR Systems Pty Ltd. 10 Business Park Drive, Notting Hill, VIC 3168, Australia VIC: 03 9550 2800 NSW: 02 8853 7870 WA: 08 6263 4438 QLD: 07 3861 4862 SA: 08 82743747 Tel: 1300 729 987 Email: info@flir.com.au www.flir.com ISO No. FLIR20837

28 OCTOBER 2011 Manufacturers’ Monthly

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Mongrel SP Range Because what you do makes a difference to the boots you wear Our Mongrels SP Series was designed to incorporate the most significant technological, comfort and safety features into one premium range. Now Mongrels have expanded the SP designation to meet the requirements of different work conditions. For example the mining industry and light manufacturing industries have very different needs. Now, along with SP>P Originals we offer SP>R, SP>S, SP>Z, SP>T and SP>N ranges. Take a look on our website or call for a Mongrel salesman for more information.

Features many of the original and popular styles of our SP Premium Range launched in 2006.

The high tech rubber-soled work boot that’s built to take the heat no matter how rugged the conditions – heat resistant soles up to 300˚C

The lightweight, work boot with aluminium toe-cap and advance Sport technology soling.

The revolutionary ZipSider style allows for great ankle support with easy on and off features required by many trades.

Our Trade range featuring high spec features matched with a comfort innersole and value for money rugged leather uppers.

Many workers don’t require a steel toe cap. So Mongrels has provided a number of non-safety styles from riding boots to classic elastic sided boots and a security range.

SP RANGE The Aussie born and bred work boot designed to work best for you

Victor Footwear 15 George Young St. Auburn NSW 2144 p: 02 8667 2555 f: 02 8667 2500 e: sales@mongrelboots.com.au w: www.mongrelboots.com.au SPR 001

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Preview THE SAFETY SHOW SYDNEY: 25-27 October 2011

Safety professionals have a great opportunity to discover the latest products and services, see demonstrations and seek expert advice, all under one roof.

A safe, efficient workplace With the harmonisation of safety laws rolling out across the country, there has never been a better time to get acquainted with what’s new on the safety beat. TECHNOLOGY can play a key role in improving safety and workplace performance. It can be the difference between being competitive or not – and that applies to manufacturers trading locally as well as exporters. But managers, while dealing with day-to-day issues, must stay abreast of what’s coming on-stream. That is why The Safety Show Sydney, Sydney Materials Handling and Bulkex, to be held on October 25–27, are so important, as these exhibitions offer manufacturers a unique opportu-

30 OCTOBER 2011 Manufacturers’ Monthly

nity to check out what’s new, all under one roof. All three events, at the Sydney Showground, Sydney Olympic Park, will showcase hundreds of new products and services, with experts on the spot to answer questions in detail. The Safety Show Sydney will cover an enormous range including personal protective equipment; health and safety management software; risk management tools; safety signage; security and communication equipment; health and safety consultants; insurance products; medical and

rehabilitation services; first aid; ergonomics and office safety; vehicle safety; and hygiene services and equipment. Opening hours are as follows: Tuesday 25 October 2011, 10am to 5pm; Wednesday 26 October 2011, 9am to 5pm; and Thursday 27 October 2011, 9am to 4pm. Following is our pick of the top products and services on show at this year’s The Safety Show Sydney, Sydney Materials Handling and Bulkex, concurrently running and co-located. The Safety Show Sydney 03 9654 7773, www.thesafetyshow.com.au

Non-flammable, non-explosive cleaning products.

Safe cleaning THERE’S no excuse today to use unsafe cleaning products. CIPL’s Simple Green range is safe to use, both for equipment and employees. The range is non-flammable, non-explosive, readily-biogradable, non-toxic, non-reactive, and has mild alkaline pH ranges, replacing most cleaning and degreasing chemicals and solvents used in industry today. The Drainbo Drain Cleaner will penetrate and digest household waste such as grease, soap film, oil, proteins, fats, detergents and other common blockage material safely. See all these products on stand F49. CIPL 0408 623 035, www.simplegreen.com.au

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Suitable for automotive and food sectors.

Keeping hands clean DEB Australia is to showcase a ‘global range’ of hand hygiene products for the workplace, that builds on 70 years’ experience with industrial, commercial, automotive and food sectors. The firm reportedly designs products that are innovative, fit The company is giving out a free First Aid iPhone application.

iPhone first aid kit NO office or plant should be without a first aid kit, and one of the best examples will be shown at the Survival Emergency Solutions stand. Survival Emergency Solutions, which has sold two million copies of the Emergency First Aid Handbook, will be exhibiting its ‘Handy’ First Aid Kit, an ‘Extras Pack’ for the Traveller Kit and a new ‘Workplace’ First Aid Kit. Visitors should also ask about the free First Aid iPhone application at stand F05. Survival Emergency Solutions 0414 816 496, www.survival.net.au

manmonthly.com.au

An ugly job

for purpose and pleasant, easy to use, cost effective and tested to the highest internationally recognised protocols. See all their offerings on stand F50. Deb Australia 02 9794 7700, www.debgroup.com

Preparing for change ORGANISATIONS must be prepared for the new OHS legislative environment, for the changes to processes and procedures. Visitors to the ComOps stand at G8 will learn how Salvus, a comprehensive safety, risk and claims management system, can help by efficiently managing safety processes, mitigating risk, cutting costs and ensuring compliance with legislation. The system helps by proactively protecting and driving the business. ComOps 02 9923 8000, www.comops.com.au/salvus

Ugly Fish ambassador Angry Anderson will be at the stand on 26 October.

UGLY Fish Safety Eyeware will feature wraparound sunglasses designed to protect the eyes at work or play at its stand at The Sydney Safety Show. All the lenses in the range have anti-fog and anti-scratch coatings and are suitable for use with hard hats and earmuffs. Coverage is maximised to reduce risk of eye injury from dust and other particles and polarised products are available for those exposed to UV. Ugly Fish’s safety ambassador, Angry Anderson, will also be at the Ugly Fish stand, D43, on 26 October. Ugly Fish Eyeware 02 4284 7888, www.uglyfisheyewear.com.au

Manufacturers’ Monthly OCTOBER 2011 31

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Preview Boots made for working LIFESTYLES Industries Group will present new CarbonMax technology in its Wolverine Guardian Work Boot line. The CarbonMax safety toe is resistant to extreme cold and heat, and is 50% lighter than a steel toe, but still offers all the protection needed in harsh work environments, while leaving the wearer less fatigued. Visit the firm on stand F34. Designed for harsh Australian conditions.

Lifestyle Industries Group 03 9540 0777, www.wolverineaustralia.com.au

Braving the elements THE Tanami Hat by Vision Safe, with a 50+ UPF (ultraviolet protection factor) rating, is designed for outdoor work in harsh Australian conditions. In addition to providing excellent solar protection, the Tanami Hat offers a generously sized brim to help cut out sun glare, says Vision Safe. The hat also uses showerproof material in its construction, and has a flexible back panel to shield the neck. Visit Vision Safe’s stand H04 at The Safety Show Sydney. Vision Safe Pty Ltd 08 9295 0624, www.visionsafe.com.au

The safety toe is resistant to extreme cold and heat.

The tester is efficient and fast-acting.

Drug testing saliva instrument A CONCERN at manufacturing plants is an increasing use of recreational drugs and abuse of prescription drugs. When such users are truck drivers, operators of cranes and

forklifts or other machinery, the risk of injury perhaps fatal to themselves or others is high. Pathtech will showcase its Securetec DrugWipe saliva drug detection devices that provide

an efficient, reliable and rapid test with the added benefit of portability on-site and a visible result within 10 minutes. Visit stand B04.

components from the various types of scaffold manufactured are compatible with each other across the range. The system is manufactured in

Australia from materials that were also extruded and moulded in Australia.

Pathtech 03 8480 3500, www.pathtech.com.au

Australian-made integrated scaffolding system QUICK Ally Access Solutions will be showcasing the Quick Ally fully-integrated aluminium scaffold system that includes aluminium modular scaffold, alu-

minium mobile scaffold, bridging units and slab edge protection at stand N05. An inspiration for the system was the need for quality, where

Safety response kit ON show at the Enware stand (F22) at the Safety Show Sydney will be a broad spectrum toxic chemical spill response kit that promises to end potential confusion and delay when hazardous chemical spills and vapour leaks occur in laboratories. Regardless of whether the spill occurs in commercial, industrial, scientific, educational or medical facilities, Enware’s chemical spill 32 OCTOBER 2011 Manufacturers’ Monthly

Quick Ally Access Solutions 07 3877 2771, www.quickally.com.au

Replaces as many as five different treatments.

response kit is said to have the right treatment for your needs. FAST-ACT is designed to help eliminate hesitation and delay when emergencies occur on industrial sites. Users don’t have to think about which treatment to use, as the product replaces as many as five different treatments that would otherwise be required, Enware says. Enware 02 9525 9511, www.enware.com.au manmonthly.com.au

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Online defibrillator

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The safety padlocks can withstand extreme conditions.

SCHILLER Australia will be demonstrating the FRED Easy AED Online defibrillator at stand P08 – a networked public access defibrillator that is under observation at all times and can be directly managed from a central station. Online connectivity means an alert can be programmed and sent (via email or sms).

Online WHS prequalification service.

Manage contractors

Schiller Australia 02 4954 2442, www.schiller.com.au

Sliding furniture EZ MOVES furniture slides from Diplomat Blades allow one person to easily move heavy furniture and more, increasing efficiency and obviating the need to empty drawers or shelves. Simply tilt the object being moved, place a slide under each corner then push or pull the object with ease. See the slides on the EX Moves stand at K16. Diplomat Blades Australia 03 9562 0777, www.diplomatblades.com.auM

Under lock and key MAYO Hardware will present the entire range of its Master Lock Lockout/Tagout Solutions, at The Safety Show Sydney this month. This includes the newlylaunched safety padlocks, hasps and lockout cables for smaller diameter lockout points. The S31 safety padlock has a durable non-conductive Xenoy lock body and a 4.76mm marine grade 316 stainless steel shackle.

Available in nine colours, S31 safety padlocks are reportedly extremely light in weight. The padlocks are said to perform in extreme conditions and can withstand harsh chemicals and corrosion. Visit Mayo Hardware at stand F04 to see these safety padlocks in the flesh. Mayo Hardware 02 8337 7938, www.mayohardware.com.au

WORK health safety (WHS) in contractor management is complex because many variables impact on organisation and contractor obligations. Noel Arnold & Associates developed Cm3, an online system that provides an independent and robust WHS prequalification process. The system enables the selection of a broad range of WHS prequalified contractors. It also offers review and verification of the currency of contractor insurances, along with trade licenses and other relevant documents. Noel Arnold & Associates 02 9889 1800, www.cm3.com.au

THIS MONTH’S PRODUCT FEATURE IS THE VACUUM LIFTER JUMBO FLEX 35

The vacuum lifter that can lift and move a huge range of products weighing up to 35kg and can handle boxes, bags, sacks, rolls of film and many other items as well. Lifting, lowering and releasing of the load are controlled with a single trigger action on the operator control handle, this handle is also suited for both left and right handed operation

Millsom’s also have a great range of vacuum lifters capable of lifting up to 2000kg and jib cranes, bridge cranes and low friction track systems to suit most applications. HANDLING SOLUTIONS

LIFT & MOVE SHEET,

STEEL OR WOOD

EASY LOADING OF YOUR CNC

JIB CRANE

WORKSTATION CRANE

FOR THE WOOD INDUSTRY

The Right Advice, The Right Solution,The Right Choice MELBOURNE, SYDNEY, BRISBANE, PERTH, ADELAIDE & NZ

manmonthly.com.au

FREECALL 1800 99 22 11

www.millsom.com.au email - sales@millsom.com.au Manufacturers’ Monthly OCTOBER 2011 33

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Compressors& PNEUMATICS

A compressor air audit can help save up to 50% on energy costs for the unit.

Compressor waste an airy issue Compressors generate only a portion of factory air pollution, however their high

compressed air systems. He also says they should have a professional indemnity insurance of a minimum limit of $10 million. According to McLean, the International Organisation for Standardisation is currently working on an energy auditing standard for compressed air systems. But, he says, it is unlikely the standard will be introduced before 2013. CAPS Australia’s St. Baker says the energy savings gained from carrying-out an air audit properly can be sizeable. “If you exchange a compressor with a variable speed drive model, you might save 20% of energy. With a more holistic approach, you could save double that. Energy savings of up to 50% aren’t uncommon,” he said. Air audits should be conducted at least annually, according to St. Baker. “For more complex systems, you might want to do it more often than that. But an annual audit will at least allow you to make sure that the measures you’ve put in place are being maintained and to identify any new opportunities for improvement,” he said.

electricity consumption makes them the ideal place to start saving. Rita Mu writes. The carbon issue

W

ITH climate change and energy costs at the forefront of the public and political agenda, the environmental impact of industrial facilities has become a pressing issue, particularly for manufacturers who are already facing the pressures of the strong Australian dollar. Now is the time for manufacturers to look at saving energy in non-traditional areas, such as air compressors, which are often overlooked. National manager of CAPS Australia’s Energy Efficiency Services department, Quentin St. Baker, says though air compressor systems are found in almost all industrial plants – accounting for 10 to 15% of all electricity consumption – they are an inefficient form of energy. “As an energy source, compressed air is about 10% effi-

34 OCTOBER 2011 Manufacturers’ Monthly

cient compared to using electricity directly, and the main reason for this is because when we compress air, about 90% of the electrical energy we put in ends up as waste heat,” said St. Baker. Only 50% of compressed air is typically used for productive purposes. Often, compressed air is used for jobs that could be performed using an alternative energy source, St. Baker said.

Air audits One way to measure the energy efficiency of an air compressor system is to carry out an air audit. These assessments vary depending on the manufacturer and the systems used, but they generally involve measuring the power, pressure and flow of the air compressors, as well as checking for leaks. According to CompAir Australasia key account manag-

er, Gilbert McLean, manufacturers should think carefully about the provider used to conduct the audit. He says air audits conducted in Australia are more like ‘assessments’ because service providers are not required to comply with any standards. “There is currently no Australian standard for auditing the energy efficiency of compressed air systems. The only standard that is valid is the ASME (American Society of Mechanical Engineers) EA-4 – so when a company wishes to have an energy audit on their compressed air systems, they’ve got to be careful about who they are going to have the audit carriedout by and what methodology will be used,” he said. McLean recommends choosing a qualified mechanical, electrical or associate engineer with a minimum of five years experience in

Under the government’s carbon price, which is set to commence from September 2012, around 500 of the biggest polluters in Australiawill be required to pay. Though air compressor systems make up only a portion of all industrial air pollution, St. Baker says carrying out an air audit is a good starting point for companies trying to slash their energy. “Compressed air is a utility, which is only one of many areas a company could investigate in order to save on energy,” he said. “Generally, air compressed projects have fast paybacks, so conducting air audits might get companies to start looking at other areas in the business [where they can reduce their energy use].” CAPS Australia 08 6250 9800, www.capsaust.com.au CompAir Australasia 03 9212 5800, www.compair.com manmonthly.com.au

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Compressor energy savings is more than just hot air Recover your energy with Atlas Copco Compressors

ENERGY RECOVERY SYSTEMS

INTEGRATED DRYERS AND FILTERS

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EFFICIENCY BY DESIGN HERE’S HOW! VARIABLE SPEED DRIVEN COMPRESSORS Energy consumption Installation Maintenance

Contact us today and find out just how easy it is:

Investment

Atlas Copco Compressors Australia 1800 023 469, ausairinfo@au.atlascopco.com www.atlascopco.com.au

Energy savings

LCC of a standard compressor

LCC of a VSD compressor

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Compressors &PNEUMATICS Why we’re proud to be made in Australia BY CLENCY MAHON

MANUFACTURING in Australia is getting tougher and tougher. The challenge is to continually improve, stay on top of the game and always provide your customers with a quality product that is backed with superior customer support. To compete, Australian manufacturers need to provide the best service, advice and assistance to meet the needs of their customers. A national service centre is one way of centralising the service scheduling, technical support, sales, customer satisfaction, parts and engineering enquiries of a company, and deliver the necessary value-add many customers are looking for. In addition to customer service, quality assurance certification is a prerequisite for remaining a step ahead of overseas imports. Customers should look for certificates of excellence provided by a third-party certifier,

Sullair Australia’s manufacturing facility in Victoria, Australia.

meaning the manufacturer meets quality standards, and these standards are applied to improve all aspects of the business. Local manufacture also means customers have the unique opportunity to meet design engineers face-to-face to discuss their application. Suppliers are able to custom-make systems to meet these specifications.

Sullair Australia – a local manufacturer of rotary screw air compressors – makes its entire industrial range in Melbourne. By meeting the criteria for the Australian Made campaign, Sullair Australia ensures its products evolve with the compressed-air needs of industry, but also meet the challenges posed by Australia’s harsh climat.

Further, many successful and lasting supply relationships can be established through manufacturing locally. “When looking for a partner in the compressor industry, having Australian-made products with a local service point was an important factor in choosing Sullair Australia’s Champion and Sullair branded compressors,” said Daniel Castley, sales engineer for Remtron Automation – exclusive servicing distributor for Sullair Australia in Albury-Wodonga. So before you sign a supply contract, think about the benefits of supporting Australianmade. Manufacturing in Australia benefits all Australians by providing employment and a range of flow-on effects that stimulate the Australian economy. Support the industry that supports you. [Clency Mahon is executive manager operations, Sullair Australia.] Sullair Australia 1300 266 773, www.sullair.com.au

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manmonthly.com.au

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www.kaeser.com

WE DON’T PREDICT AIR QUALITY,

WE CREATE IT.

KAESER’s Dry Screw Compressors create oil-free quality air for your manufacturing needs.

KAESDR

To find out more about creating clean air, contact us today. 1800 640 611 or info.australia@kaeser.com

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Compressors &PNEUMATICS

Saving energy is more than just hot air BY JEFF TREBLE

VSD technology can save 35% of energy consumption.

WITH the cost of electricity set to rise even further, there has never been a more critical time for manufacturers to look at solutions that will save energy. A 90kW air compressor that is sized with 20% extra capacity could be costing the user over $140,000* a year to operate. Using an air measurement tool and simulation software, compressor suppliers can measure the electrical consumption of compressors on-site, then accurately simulate the savings against this consumption using modern Variable Speed Drive (VSD) technology. VSD technology can save an average of 35% of energy consumption compared to standard load/unload models. Using the 90kW example, VSD technology is able to provide savings of $49,000 a year, every year, over the life of the compressor. Over a 10-year period, this can add up to $490,000 in savings.

Some integrated VSD solutions incorporate dedicated VSD motors that can handle eddy currents generated by varying the power frequency, plus, as they are designed to work with the VSD control system incorporated in the compressor, they can be slowed as low as 20% of full speed. Added to this, should the compressor actually stop, VSD sepa-

rator vessels don’t need to blow-off and waste valuable air like traditional and other VSD compressors do before they can restart.

Fully integrated Atlas Copco provides a VSD solution with EMC compliance as standard, where the VSD components are fully integrated into the control panel.

“Whether Le Mans, Sebring or Daytona to win here is a question of efficiency; of the team, the cars and the equipment. And for that reason, when it comes to our compressed air supply it has to be BOGE.” Franz Konrad, Konrad Motorsport

To control the VSD, the compressors feature a fully integrated Elektronikon controller that controls the operation of the VSD and the compressor. For fixed speed machines, the Elektronikon control module has the ability to save further energy with several control algorithms built into the operating program. For example, the delayed second stop algorithm provides additional savings by monitoring and predicting future operating variables, stopping the compressor as many times as possible without affecting the longevity of the motor.

Starting current and power For some manufacturing operations, the starting current and power factor can make a significant difference to the current supply required for the site and to the compressor. In some cases, a high starting current and low power factor can result in a required upgrade to

BOGE AIR. THE AIR TO WORK.

www.boge.net.au

Who wins a race is not just decided at the finishing line but also in the preparation stages. No one knows this better than Franz Konrad, owner of Konrad Motorsport. For 35 years he has successfully raced, including winning the team title at the Porsche Mobil 1 Supercup. He now wants to repeat this success with 3 ultra-powerful “Porsche GT 3 Cup”, a feat only possible with absolute precision and perfection in every detail. That’s why a BOGE RM series piston compressor is essential to him.

38 OCTOBER 2011 Manufacturers’ Monthly

manmonthly.com.au

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The set up of the compressor’s dryer system can also make a significant difference in the energy consumed. Unlike traditional systems that utilise a free standing external dryer, Atlas Copco offers Full Feature (FF) machines with the dryer incorporated into the compressor. A less obvious benefit of the design is that FF machines save on pressure drop, with the system’s pressure measured at the outlet of the dryer and not the compressor. Having the dryer integrated to the Elektronikon controller means that the compressor can control the dryer and turn it off when the compressor turns off. This is unlike separate dryers, which will run all day, every day, unless they are manually turned off by an operator. Added to this, the Elekronikon dryer algorithm will monitor ambient temperatures and ensure that a relative humidity of less than 50% is achieved while minimising the dryer use. The FF machines also offer a fully integrated filtration system,

the power supplied to the site, adding cost and time. Add to this the fact that some electricity providers base their billings on the peak current reached, meaning the current peak provided by traditional compressors, utilising star delta start, can increase the overall energy cost per kWhr. With VSD, the current never exceeds the compressor’s full load current. Multi compressor control systems are also an important consideration when there are two or more compressors working together to meet the required plant air demand. With every 1 Bar of pressure drop adding 7% extra energy consumption, the Atlas Copco ES Control system helps reduce the operating pressure band and further save energy. The ES control system is built into the Elektronikon controller and provides a load sharing platform ensuring each compressor operates for equal hours, consolidating service costs and ensuring users get the most out of their compressors equally.

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which can reduce pressure drop even further. The FF compressors are designed to operate in some of the world’s harshest environments; up to 46degC ambient temperature as standard and up to 50degC with the addition of the High Ambient option can be achieved. To further save energy, these compressors are available with an energy recovery system, available as a stand-alone unit or integrated. With around 90% of the energy used to generate compressed air dissipated as heat, the energy recovery system utilises this wasted heat energy for space or hot water heating. * Estimate based on compressor operation at $8,000 hours a year, sized to 80% capacity, $0.25/kWhr. Does not consider losses due to unloaded power consumption and does not consider complete system power. [Jeff Treble is business line manager, Industrial Air Division, Atlas Copco.] Atlas Copco 02 9621 9900, www.atlascopco.com.au

Oil-free compressors BOGE has launched a second generation SO series oil free screw compressor, offering eight models in 16 variations. According to BOGE, the compressors set new standards in the 110 to 255 kW performance class, boasting higher efficiency, reduced sound pressure and a new service-friendly layout. The cooling air flow of the SO-2 models has been optimised, says BOGE, as intake air is drawn from the coolest area to help increase the free air delivery. The SO-2 models are equipped with a combined sound and pulsation absorber. They also include a condensate separator in the intercooler between the first and second stage airends. BOGE’s oil free screw compressors are suitable pharmaceutical, food and semi-conductor applications. BOGE Compressors (Australia) 08 9528 2157, www.boge.net.au

There’s Only One Choice To Save You Money %NERGY %FßCIENCY 3ERVICES IS !USTRALIAlS INDEPENDENT AIR ENERGY AUDIT TEAM 7E GO FAR BEYOND THE INDUSTRY STANDARD FOR COMPRESSED AIR AUDITING GIVING YOU IMPARTIAL SPECIALISED REPORTS ON YOUR COMPRESSED AIR SYSTEM WITH BRAND NEUTRAL RECOMMENDATIONS /UR UNIQUE APPROACH IDENTIßES OPPORTUNITIES WITH FAST PAYBACK THAT COULD SAVE YOU HUNDREDS OF THOUSANDS OF DOLLARS

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1800 800 878 manmonthly.com.au

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Manufacturers’ Monthly OCTOBER 2011 39

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Fasteners&ADHESIVES mental friendly. According to 3M Industrial Adhesives & Tapes product specialist, Gavin McClelland, adhesive offerings have come a long way over the past few years, with some providing the strength of a mechanical fastener, yet offering flexibility. “There is an obvious trend to move away from using mechanical fasteners in the marketplace. For companies wanting to be at the cutting-edge of design and performance, tapes and adhesives offer significant advantages,” McClelland told Manufacturers’ Monthly.

Meeting new bonding demands A tough economy has seen manufacturers push for cheaper, greener alternatives, with global suppliers still getting the lion’s share of the business. By Annie Dang.

F

ASTENERS and adhesives are not always at the forefront of manufacturing news, but current economic conditions, including a high dollar

and the introduction of a carbon tax, has spurred on demand for bonding options which are not only cheaper and more lightweight, but also more environ-

Increase productivity in your manufacturing process by pre-coating all your threaded fasteners. Stop the shake, rattle and roll…. Microencapsulated coatings available for: every type of threaded fastener all applications every assembly process Dry finish, Easy handling No drips, no mess, no fumes, NO WORRIES Extensive range includes: Loctite, 3M, ND …

These advantages include reduction in the product’s physical weight, which is essential in aerospace, shipping and automotives manufacturing. McClelland says low surface energy (LSE) plastics, such as Polypropylene or Polyethylenesutomotive, are becoming more commonly used to decrease weight in automotive, commercial vehicle and aerospace applications, resulting in growing demand by manufacturers for more advanced adhesives technology to bond low surface energy plastics. Other advantages include the development of ‘green’ or environmentally-friendly adhesives. While low emission adhesives have yet to take off, Australians should watch this space; demand is speculated to increase once the carbon tax kicks-in next year.

Market trends

Ask Belmatic to provide the ideal solution for your needs. Belmatic Industries Pty Ltd 12 Kylta Rd, Heidelberg West VIC 3081 P: 03 9459 8097 W: www.belmatic.com.au

APPLIED FASTENER COATINGS • SPECIALISED PRECISION ENGINEERING 40 OCTOBER 2011 Manufacturers’ Monthly

In Australia, adhesives manufacturers and suppliers make up one of the smaller industries of Australia's overall chemical sector. According to IBISWorld’s latest Adhesive, Cleaning Product Manufacturing Market Research Report released in July, our overall chemical sector comprises 391 establishments and 3,050 employees (7% of the general

chemical manufacturing sector). Companies which manufacture or formulate chemical products, such as polishes or cleaners, waxes, dry cleaning preparations, oils and adhesives are considered to be part of this industry. With solid employment figures and forecast economic growth, largely from rising demand in the construction market, the industry has reportedly bucked the trend of poor growth figures over the last five years. The IBISWorld report estimates that revenue for the industry is expected to be $1.97 billion in 2011–12, compared with $1.89 billion five years earlier. The industry displays high market concentration within certain segments, but an overall low level of market concentration due to the varied nature of the products it manufactures. Smart companies in this sector are fast realising the benefits of consolidating, and investing in R&D to develop new, ‘greener’ offerings. One company making the move to consolidate activities and grow in emerging markets is industrial adhesives and sealants manufacturer and supplier Henkel, who records 42% of its total adhesives sales within the emerging markets and 53% of its employees in those markets. Headquartered in Düsseldorf, Germany, the multinational company will grow its consumer and industrial adhesives, sealants and surface treatment business division with the construction of a 150,000 square-metre adhesives factory in China’s Shanghai Chemical Industry Park. Scheduled to begin production at the end of 2012, the new Henkel factory is said to be the largest adhesives factory in the world, employing 600 people and pulling in an estimated annual production of 428,000 tonnes. The new facility will reportedly be more environmentally-compatible to meet demands for higher operational efficiency, and lower energy and water usaeage and carbon emissions. 3M Australia 136 136, www.3M.com Henkel Australia 1300 885 556, www.loctitie.com.au manmonthly.com.au

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Designed to be a part of everything you build & repair.

Over 50 years of innovation has put strength and reliability into everything that carries the Loctite速 brand. To take advantage of Loctite速 engineering adhesives call 1300 88 555 6 or visit www.iloctite.com

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Fasteners &ADHESIVES Reclosable fastener 3M Australia’s Dual Lock Reclosable Fastener (SJ3870) features mushroom-shaped stems on one side, which interlock with identically-shaped stems on the other side, for a reported five times greater closure strength and holding power than hook and loop fasteners. They can be opened and closed up to 1,000 times. The SJ3870 incorporates a modified acrylic adhesive which is said to enhance the adhesive capabilities. It offers good temperature performance and bonds well to plastics (acrylic, polycarbonate, ABS), powder-coated paints and medium-to-low surface energy materials. This product was reportedly launched in response to manufacturing market requirements to bond plastics to powdercoated materials, with little or no surface preparation. 3M Australia 136 136, www.3M.com

42 OCTOBER 2011 Manufacturers’ Monthly

Flexible, adhesives-less laminates US PRINTED circuit materials manufacturer, Rogers Corporation, has developed a way to heat laminate Victrex APTIV film directly to metal foils or other materials in both roll-to-roll and flat-panel laminate structures, without the need for adhesives. According to the firm, delamination caused by deteriorating adhesives that traditionally bond the layers of laminate structures can lead to premature product failure, as adhesives often deteriorate when exposed to high temperatures, moisture or chemicals. Eliminating the use of adhesives has numerous benefits, says Rogers Corporation, including the reduction of VOCs (volatile organic compounds) during production, which makes the laminate structures more environmentally-friendly. This also reportedly reduces the amount of raw materials used, compared to adhesive-based systems. Other benefits include increased laminate thermal

The company’s process allows laminate film to be heated directly onto metal, without using adhesives.

conductivity by elimination of the insulating adhesive layers, and the ability to reduce laminate thickness which allows for miniaturisation in smaller, thinner devices. To produce the adhesive-less laminates, Rogers Corporation

installed a new line in its Belgium facility. The proprietary process allows APTIV film to be combined with metal foils like copper, brass, aluminum or other materials including aramid or glass fiber fabrics. Rogers Corporation www.rogerscorp.com

manmonthly.com.au

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THREADLOCKERS Applied as a liquid, threadlockers are superior to conventional lock washers, nylon inserts and other mechanical devices because they secure the entire fastener assembly against loosening from space between threaded metal parts, curing to form a tough, adhesive bond and seal. They also seal the threads against leakage, preventing rust and corrosion. To order contact your local engineering supplier for more details.

Ordering Info Product

Stock Number

Pack Size

Low Strength Threadlocker Purple

P22250A

50ml

Why Pay More for a Red Bottle?

Low Strength Threadlocker Purple

P222102

10ml

High Strength Threadlocker Red

P27150A

50ml

High Strength Threadlocker Red

P271102

10ml

PermatexÂŽ Threadlockers in the BLUE Bottle.

Medium Strength Threadlocker Blue

P24350A

The Reliability You Need. The Price You Deserve. 50ml

Medium Strength Threadlocker Blue

P243102

10ml

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Metalworking& CUTTING TOOLS neers, Takuma Takami, up here who was able to get direct access to the factory and when we powered the machine up, he talked to the right person in Japan who was an expert in that area to get the answers for us. That cut out about two weeks of wandering around in the dark, wondering why the machine isn't doing what it should be doing.”

Superior machine design Chaotech's Mori Seiki NZ 2000 emerged near new after Qumac’s Alan Clinch (left) and Rex Manderson pulled the system apart piece by piece to rescue it from flood damage (inset).

Through troubled waters When floods ripped through Queensland, metalworking firm Chaotech was hit hard – with a brand new Mori Seiki CNC centre three meters under.

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HEN Brisbane and Ipswich were bracing for flooding in January this year, no one expected the worst floods in decades. On 13 January flood levels peaked at around 4.5 metres, submerging scores of suburbs and forcing thousands of residents and businesses from their premises. “By Thursday morning the water level peaked at about 3 metres in our factory and there was nothing you could do but watch the water level rise,” said Rex Manderson, who runs Chaotech, specialising in CNCmachined parts, slit materials and industrial products. “Authorities wouldn’t let us into the area as there was fuel coming out of a petrol station contaminating the water, but I fought to get in there, trying to get more things out.” A tide of helpers from all walks of life – including police workers – turned up at his factory, helping to clean up the mess. This includes various machine tool dealers who helped Manderson clean, overhaul and

44 OCTOBER 2011 Manufacturers’ Monthly

re-install his range of CNC machinery. One of the supporting companies, Engineering Services company Qumac, spent almost four months in Manderson’s factory to get Chaotech’s Mori Seiki NZ 2000 multi-axis turning centre up and running again. The machine was only delivered on the day before the floods – a brand new addition to his business. “The biggest challenge was not only to get the machine running again as quickly as possible, but we wanted to hand over a brand new machine. The machine had never even been connected, and to make things worse, it was Rex’s first Mori Seiki, so we wanted to make it an experience as good as possible,” Qumac’s Alan Clinch said. The team spent every day in Chaotech’s factory, stripping the machine to the casting, getting the water and mud out, and replacing most mechanical parts. “I've been in this business for about 30 years, but I have never experienced anything like this,” he says.

Complete overhaul Qumac decided to concentrate on the mechanical side of things as the electronics came out mostly undamaged. The team carefully removed and cleaned one part after the other. And according to Clinch, Mori Seiki didn’t let them down and provided extensive support. “Mori Seiki provided a rare service level – it was totally unusual. We explained the situation to Mori and they not only provided parts at cost, they even delivered parts which they normally wouldn't provide like the balls in the ball screws,” he said. “They knocked out all their normal rules and everything we wanted or needed was delivered quickly. When we finally got to the stage to fire the machine up, we had a lot of alarms and issues because the machine is waking up. Software designers imagine it is only possible that one thing can break down at a time. “But there were multiple alarms, it was very challenging. DMG/Mori Seiki in Melbourne sent one of their service engi-

While most of the other CNC machines had to be shipped off-site for repair, Qumac was able to overhaul the NZ 2000 in the workshop. “The design of the machine and the way Mori had designed the drives or spindles allowed us to pull the whole machine apart on the ground. It is almost impossible to get the drive system out of alignment, for instance. They designed it very cleverly,” he said. Getting the workshop up and running again was Chaotech’s primary concern. As soon as the NZ 2000 was rebuilt to a stage that some of its functions could be used, Chaotech’s afternoon shift ran the machine for a stand-alone finishing operation on a part that couldn’t be done on any of the other machines usable at that stage, while Qumac continued with the repairs in the mornings. Today, most of Chatotech’s machines are running to full capacity again and everyone involved came up smiling. Manderson and the whole Chaotech team are extremely thankful for all the support they received from all of their machine tool suppliers and service engineering companies, but he admits that Qumac’s support was outstanding. “Qumac set up their own work area and while we were still busy cleaning the factory, I was able to let the Qumac guys to just get on with it. Qumac have clearly distinguished themselves as providing superior support,” he said. DMG Mori Seiki Australia 03 8545 0900, www.dmgmoriseiki.com/au manmonthly.com.au

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24-station drilling centre PROFILE Cutting Systems (PCS)’ PCS Large Drilling Machine is designed for fast drilling of up to 100mm diameter with an accuracy of 0.1mm. The system, which utilises a 60HP Bosch Rexroth servo motor coupled to a high-speed spindle with the option of up to a 24-station tool changer, reportedly combines top quality parts, quality workmanship and an easy-touse drilling interface. The Bosch Rexroth motor is predestined for main spindle applications. Rated at 60HP, the motor and cooling fan are enclosed in an IP65 enclosure, suitable for harsh areas. When the system is being used for six or less tools, a carousel is fixed to one side of the machine. Upon tool change, the main spindle will position itself on top of the carousel and perform a quick and easy tool change. This can be done manually as well as automatically, according to the part program. For more than six tools,

The machine can drill up to 100mm diameters with 0.1mm accuracy.

the system uses a 24-tool carousel that is mounted next to the main spindle. This method facilitates quick and easy tool changes without the spindle travelling to one end of the machine to perform a tool change. This method is primarily designed for jobs that regularly require a large number of different tools. Profile Cutting Systems 03 9305 2555, www.profilecuttingsystems.com

VERICUT interface for SolidCAM SOLIDCAM’S VERICUT CNC program verification software is designed for companies in the aerospace sector that need the power of the software’s 5-axis and mill-turn technology to cut critical components. The new implementation is designed to provide an extension to SolidCAM’s existing internal

manmonthly.com.au

toolpath verification, by proving out the actual G-codes, used to drive the CNC machine. The tools, fixtures and stock material created in SolidCAM are transferred into VERICUT, which is set-up to allow simulation to start immediately. SolidCAM 0400 622 133, www.solidcam.com.au

Manufacturers’ Monthly OCTOBER 2011 45

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Metalworking &CUTTINGTOOLS Recycling used tungsten carbide cutting tools pays off BY PETER ROLLAUER

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ITH increasing pressures and competition from low-cost-countries, Australian manufacturers may find the task to become an environmentally-conscious shop daunting. However, there are many different approaches to improve operations which not only reduce the carbon footprint, but can generate extra cash and reduce production costs. For example, when an operator replaces a carbide insert, about 95% of the carbide is still intact and capable of being recycled. Of this carbide, tungsten comprises 75% of the content. Tungsten is a finite resource with the interesting ability to be recycled infinitely, reducing our reliance upon mining. The tight supply of tungsten has been keeping upward pressure on the price of the metal. Recent rule changes in China’s new ‘Five Year Plan’ might alleviate some of the supply issues this year as the quota for tungsten production has been raised to 87,000t from 80,000t last year. However, in the long run, the rule changes cap new production growth at an average 8% a year. This holds immense power over

With many cutting tool suppliers buying back the used carbide, it is both a wise financial and environmental choice.

the market because approximately 85% of global tungsten output in 2010 came from China. According to the Tungsten Investing News, the price of tungsten APT (ammonium paratungstate) has risen from US$185 per MTU to its January 2011 price of $335 in a year. The effect of rising tungsten prices is causing concern generally across the tooling sector, and recycling is attracting considerable attention from carbide tip producers to dampen down high carbide prices. Internal calculations, based on international standards, have

shown that production of tools from recycled material consumes up to 75% less energy than production from virgin materials. It also reduces CO2 emissions by roughly 40%. No comprehensive studies have been undertaken to determine how cutting tool recycling impacts chemical consumption and water pollution, but it is widely accepted that these areas benefit as well. There is no difference in quality between cutting tools made from recycled or virgin materials. Today there is no excuse for not recycling your carbide as almost every major cutting tool

supplier has a program in place. With many of these suppliers actually buying back the used carbide, it is both a wise financial and environmental choice. One example of a cutting tool recycling program is Sandvik Coromant’s Coromant Recycling Concept (CRC), launched in 1996. The program offers a comprehensive, easy-to-use and free-of-charge service to its customers that also includes solid carbide tools. Using CRC, all used hard metal materials of any brand are collected in boxes placed by the machine tool and returned to the Coromant manufacturing plant for recycling. More and more customers are becoming increasingly aware of the need for recycling of carbide products in the light of increasing consumption of non-renewable materials, and the growing take-up is encouraging. With its initiative “Turn your trash into cash”, Sandvik Coromant Australia is currently offering $18/kg for scrap carbide, allowing participating companies to reduce the environmental impact of manufacturing, plus make some extra money. Sandvik Coromant Australia 03 9238 7163, www.coromant.sandvik.com/au

Sheetmetal fabricator happy to be operating at half capacity BY VAL PAVLOVIC

IF the owner of a sheetmetal fabrication plant is over the moon because work demands dropped from full- to half-capacity overnight, you would normally associate the reaction as a sign of madness. But not at Servgas Sheet Metal. The Sydney-based company couldn’t be any happier. This is because work hasn’t dropped off at all – management just found a smarter way to handle production. “It was all down to a straight out machinery upgrade,” said managing director Adam Veitch. “We replaced our longstanding Finn Power TP 2000 punching machine with a new Finn Power 46 OCTOBER 2011 Manufacturers’ Monthly

New punching machine slashes existing work schedules.

E5x and immediately our existing work schedules began taking just half the time.

“We had always run about 600 small/niche jobs a month through the plant at full capaci-

ty but now, incredibly, we have room for at least another 300 more sheets per month!” The company’s new E5x is a servo electric turret punch press, rather than a hydraulic-powered machine. Servgas Sheet Metal’s E5x provides automated material handling capabilities that arm this SME fabricator with a multipurpose machine. The E5x is said to eliminate the bulk, noise and vibration of hydraulics by arming the user with programmable punch modes, stepless speed and position adjustment, and accurate forming. It also reportedly returns low energy consumption and low maintenance costs. Maxitec 02 8536 5800, www.maxitec.com.au manmonthly.com.au

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± 120°

± 120°

ø 840 mm Height 500 mm

monoBLOCK® NEXT GENERATION – Redefining 5-axis milling with a swivel rotary table ________

Whether for 5-axis simultaneous machining, highly dynamic

high-speed milling, high-torque performance cutting, or for volume parts production on 3 to 5 axes, the DMU 65 monoBLOCK® provides precision, performance and productivity for all applications without compromise. The Displayed: Francis Turbine

DMU 65 monoBLOCK® is the COMPREHENSIVE solution for all industries.

HIGHLIGHTS DMU 65 monoBLOCK ® _ Large work space capable of holding work pieces that are up to ø 840 mm wide, 500 mm high and 1,000 kg in weight with the swivel rotary table. Alternatively, work pieces up to 1,000 × 840 × 560 mm and 1,800 kg can be processed on the rigid table. _ Stainless steel work space retains machine value _ Crane loading from above over the table centre (standard) _ Open door and accessibility: _ Door opening 1,430 mm _ Front tool loading during production _ Fully accessible from the front, even with automation _ Smallest foot print (7.5 m²)

All DMG / MORI SEIKI news is available online at: www.dmgmoriseiki.com DMG / MORI SEIKI Australia: Melbourne Head Office Unit 6, 6 Garden Road, Clayton VIC 3168, Australia, Tel.: +61 3 8545 0900, Fax: +61 3 9561 4999 Sydney Office: Tel.: +61 2 8844 9700, Fax: +61 2 9638 6111 If your mobile phone is equipped with QR code recognition software, you will have direct access to our homepage. Authorized DMG / MORI SEIKI Dealers in Australia: Qumac Engineering Services – Queensland, Tel: +61 7 5547 5066 / HS CNC Machines – Victoria, Tel: +61 3 9763 8207 / Harris Machine Tools – Western Australia, Tel: +61 8 9574 6951

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