Manufacturers' Monthly April 2013 by Prime Creative Media

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MELBOURNE CONVENTION & EXHIBITION CENTRE

INSIDE National Manufacturing Week – What’s on show >> Endeavour Awards – Innovation in Manufacturing >> Enterprise Resource Planning >> Welding >> Manufacturing for Mining >> Production Line Safety

ENDEAVOUR AWARDS FINALISTS >> Shortlisted nominations for our 2013 manufacturing awards announced!

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Publisher: Martin Sinclair martin.sinclair@cirrusmedia.com.au Managing Editor: Cole Latimer Ph: (02) 9422 2352 Fax: (02) 9422 2722 cole.latimer@cirrusmedia.com.au Journalists: Brent Balinski Ph: (02) 9422 2480 Fax: (02) 9422 2722 brent.balinski@cirrusmedia.com.au Alex Heber Ph: (02) 9422 2884 Fax: (02) 9422 2722 alex.heber@cirrusmedia.com.au Vicky Validakis Ph: (02) 9422 2480 Fax: (02) 9422 2722 vicky.validakis@cirrusmedia.com.au Editor-at-Large: Alan Johnson Ph: (02) 9422 2325 alan.johnson@cirrusmedia.com.au Graphic Designer: Dave Ashley david.ashley@cirrusmedia.com.au Creative Director: Julie Coughlan Production Co-ordinator: Mary Copland Ph: (02) 9422 2738 mary.copland@cirrusmedia.com.au VIC/Overseas Sales: Michael Northcott PO Box 3069, Eltham, VIC 3095 Ph: 0448 077 247 michael.northcott@cirrusmedia.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@cirrusmedia.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@cirrusmedia.com.au NSW, SA/NT & WA Sales: Cirrus Media Ph: (02) 9422 2368 anthony.head@cirrusmedia.com.au Published 11 times a year Subscriptions $140.00 per annum (inc GST) Overseas prices apply Ph: 1300 360 126 ISSN 0025-2530

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Inside

For daily news visit manmonthly.com.au

APRIL 2013

4 Editorial ■ Counting down the days

6 Comment ■ Offshore Manufacturing

8 Analysis News ■ What’s happening

14 IT@MM ■ Proper planning platforms ■ Controlling document storage costs

18 Welding & Profile Cutting ■ Understanding welding fumes

20 National Manufacturing Week Preview ■ Australia’s manufacturing

What can Pirtek’s new ERP system do?

34 The Endeavour Awards

52 Manufacturing Technology

26 Austech Preview

■ Environmental Solution ■ Australian Steel Innovation

■ Design and Innovation

■ What’s on show

■ Significant Achievement

exhibition

28 AUSPACK Preview

■

■ The packaging exhibition

■ ■

30 What’s New ■ Heavy duty cleaning ■ Tough boots and much more

AM M D0 _ 4 M1 A3 N_ M0 R0 E1 A .A p PR d_ f 1 3 P a -g e 1 1 2 0 1 1 3 3 / -0 0 3 3 / -1 1 3 1 , T1 8 1 : 1 3 7 9 : 2 A1 M+ 1 1 : 0 0

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961 APRIL 2013

Making Manufacturing

Print Post Approved PP255003/00324

A D _ M A N M L O C J U N _ 1 2 . p d fINSIDE P a g e National Manufacturing Week – What’s on show >> Endeavour Awards – Innovation in Manufacturing >> Enterprise Resource Planning >> Welding >> Manufacturing for Mining >> Production Line Safety

■ ■

55 Products and Services

Award Australian Industrial Product Exporter of the Year Lifetime Achievement Award Global Integration Safety Scheme of the Year

■ The directory

56 Production Line Safety ■ Safeguarding your workers

58 Manufacturing for Mining ■ Protective electrical enclosures

Behind the cover

RETURNING to Melbourne from 7-10 May, National Manufacturing Week 2013 (NMW) will focus on helping Australian manufacturers boost productivity in dayto-day operations and leverage both the challenges and opportunities ahead. Co-located with Austech, NMW 2013 will feature over 300 local and international suppliers across 12 7–10 MAY 2013 1 4 / 0 5 / 1 2 , dedicated 4 : 5 0Product P M Zones – including new sections for Sustainable Manufacturing

and Metals & Composites – making it even easier for buyers and sellers to come together to do business. NMW will also feature valuable interactive seminars and information sessions. For more information visit nationalmanufacturingweek.com.au for details.

MELBOURNE CONVENTION & EXHIBITION CENTRE

ENDEAVOUR AWARDS FINALISTS >> Shortlisted nominations for our 2013 manufacturing awards announced!

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Manufacturers’ Monthly APRIL 2013 3

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Editorial

COLE LATIMER – Managing Editor

editor@manmonthly.com.au

Counting down the days With less than a month to go until the Endeavours and NMW, tension is building.

don’t say this often, but I am excited. And it is understandable to see why. Next month will not only see us highlight Australia’s manufacturing industry as National Manufacturing Week’s official publication during the exhibition, but we will also be holding our 10th ever Endeavour Awards. For ten years now we have been showcasing innovation and excellence within the manufacturing industry, and to reach such a milestone is not only an achievement for us, but also for all of you. Daily the mainstream media barrages all of us with the news that the industry is in decline, that Australia’s manufacturing industry is practically dead already. Yet National Manufacturing Week is once again huge and covering a massive floor space in Melbourne in May, while the Endeavour Awards has been one of the most successful with close to 100 nominations coming in. The industry, despite the constant predictions of it slowly dying, is coming back and we are proud to highlight the innovation A D _ M A N M of AB BA PR_ 1 3 and developments not only the technology being created by

4 APRIL 2013 Manufacturers’ Monthly

Manufacturing is on show. Australians but also those amazing mention our upcoming Leaders’ people who are creating it as well. Summit as well. This closed forum And I haven’t even started on brings together some of the movers National Manufacturing Week. and shakers in the manufacturing This year is seeing it held in industry, and is a place where we conjunction with Austech and can openly discuss what is happening AUSPACK. in the industry, the challenges it These two exhibitions will be faces, and ways in which it can move showcasing the newest technology forward in this new century. in the industry as well as the latest In fact we will be discussing how -packaging 1 2 0equipment. 1 3 - 0 3 - 1 1 T 1 8 : 4 1 Australian : 3 8 + 1 1manufacturers : 0 0 will not I also want to take a minute to simply just survive the current

‘Asian Century’, but will actually thrive and grow. It will be an immensely interesting discussion, the outcomes of which we will be bringing to you in our upcoming editions. With all of this coming in the next few months you can see why I am so excited. And I hope you are too, and that we see you in May at NMW, and at the Endeavour Awards.

manmonthly.com.au

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Industrial COMMENT

editor@manmonthly.com.au

Offshore manufacturing – Quality Matters While manufacturing offshore saves money, quality can be at stake if you are not careful. Brian Le Mon writes.

he manufacturing industry has an uneasy history with outsourcing to Low Cost Countries for cost reduction purposes. Too many times we see the case where a domestic manufacturer has made the decision to move offshore to reduce costs and finds that quality is down, yield is abominable and the product and company name emerges from the outsourcing venture with a seriously tarnished reputation. The blame is usually laid on the offshore manufacturer. Belief is common that these “emerging country” manufacturers are incapable of reproducing our design with the same specifications and quality of the domestic option or materials and processes are within these countries are substandard. Anyone who has actually visited or worked with manufacturers in these countries and is knowledgeable enough to know the difference can readily dispel these myths. While there may be a few facilities that could be described as incapable or incompetent with shoddy work practices, these are facilities that would be immediately removed from the vendor selection on first pass if minimal due diligence practices are applied by the domestic company. The majority of manufacturers in these countries can no longer be described as “emerging” or startups. The facilities of today have regular, compulsory Lean and TQC training sessions conducted for staff on-site and have extensive continuous improvement initiatives in place from 5S work practices to multiple trained and experienced 6S practitioners as permanent staff. In short most offshore manufacturers now have extensive experience working with multiple customers, high volumes and products with a level of complexity and precision that is virtually unfathomable to the domestic competitor. Taking the above into consideration the

6 APRIL 2013 Manufacturers’ Monthly

alternative suppliers, following this path will typically result in every other supplier (domestic or offshore) delivering non-conforming product because they do not have realistic parameters to reference. Manufacturers will try to match the drawing and often will not question the validity of the specification.

Offshoring presents risks for the unprepared. inevitable question arises, “Why do we see so many attempts at outsourcing manufacturing to an offshore vendor end bitterly with a detrimental effect on the company and brand reputation when there are so many offshore manufacturers that are clearly capable of at least matching the domestic capability?”

trading company and rebranding the products from another company with you own name. As a designer, only you know how you want your product to manifest when it reaches the customer. Taking the attitude that you want to distance yourself completely from your own product is doomed to failure.

1. Outsourcing manufacturing is not the domain of the purchasing/ procurement officer. There is a section of the manufacturing community looking to manufacture offshore with the following philosophy: “I just want to be able to place a purchase order and get my product, I want to hand everything over to the offshore manufacturer and not have to worry about it”. These are those with a foolish idea that they can cull their domestic workforce from senior management to floor staff in one hit, retain their purchasing / procurement department and the offshore manufacturer will “fill in the blanks”. If you fall into this group then you should really abort the idea of manufacturing your own product designs and look at working as a

2. Tolerances. There is a lot to be said for keeping check on the work done by your R&D engineers. have critical areas of the product design been given tolerance levels for the manufacturer to work within? Or have you received a first item from a local manufacturer and then tweaked the design around the standard offering from this company without verifying how this fits into your original design. For a short lived project the latter may be sensible, if you can safely assume the supplier will not become insolvent during the life of your product and you will never need to consider changing supplier. however if you have a longer lifecycle for your products and at some stage believe that you may be looking for cost reductions through

3. Know your products in every aspect. Those looking to outsource manufacture need to know every detail about their product: material types for eVeRYThING, packaging, print, testing, pass/fail criteria, how it all fits together and what the customer expects when they receive your product. We pass control of these items onto a third party and then standardise on the delivered item without having an understanding of how we would replicate the product should we need to change supplier. Knowledge of these specifics are more critical when looking towards offshore suppliers. Asking and offshore supplier to make a recommendation based on the local standard does not result in the same products in look, feel or quality compared to the local supplier. Product material for the local market may be of a lower quality to attract a wider audience in a country with a lower socioeconomic standard. In summary you need to tell your supplier eXACTLY what you require and verify they both understand and adhere to your requirements. If you are considering offshoring, one of your first actions should be to engage a professional who has done it before. Whether it is via employed, contract or consulting professionals, exploring the mysteries and rewards of outsource manufacturing is best undertaken with an experienced guide. manmonthly.com.au

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EndeavourAWARDS Be a part of the 10th Manufacturers’ Monthly Endeavour awards With less than a month until the Endeavour awards are held, the manufacturers are gearing up for the 10th Endeavour awards, celebrating a decade in the industry.

haT time of year is upon us once more – Manufacturers’ Monthly’s Endeavour awards. The time of year when the manufacturing industry not only gathers together to recognise and celebrate innovation and excellence within the industry, but also to see the latest developments in technology and practices. and the industry is in need of something to celebrate as it sees a slowdown in operations, not only in australia but also globally as even more manufacturing leaves the first world and moves to emerging regions and South East asia. It has also seen a lack of support from on high, with many government policies seemingly aimed against the industry growing; such as the carbon tax, as well as the rising cost of electricity and doing business, coupled with the slump. This year Manufacturers’ Monthly is not only celebrating the industry and its achievements, but also the fact that these awards have been recognising australian manufacturing for a decade now – rewarding its innovative and forward thinking spirit.

as always, the awards are held in conjunction with National Manufacturing Week – the industry’s exhibition. These two events bring together the nation’s manufacturers, suppliers, and logistics companies in the industry to highlight and showcase the achievements it is making. Despite the fact that industry is daily barraged with reports of its slow demise in the mainstream media, no one has told many of australia’s manufacturers lately, as Manufacturers’ Monthly received even more nominations than last year – highlighting companies that were not only ‘surviving’ the downturn, but practically thriving. Running across 13 categories, the awards received close to 100 nominations, one of the best results in the decade that the awards have been running. In 2013 we

Celebrating innovation. 8 APRIL 2013 Manufacturers’ Monthly

focusing on how well australians are operating overseas, with the Exporter of the Year award and the Global Integration award. Individuals have been highlighted in the Lifetime achievement award and the Young Manufacturer award. This year is set to be one of our most exciting yet, and coming as it does just months ahead of the election, our guest speakers are likely to have more than a little about the future of the industry in this country. With less than a month to go there is still time to book your ticket and see our industry recognised, and rewarded. Be a part of it.

A decade of recognition. will again look at how australian manufacturers have excelled, with the Technology application of the Year award, the australian Industrial Product and Consumer Product of the Year awards, the Safety Scheme award, and the Most Innovative Company award. Manufacturers’ Monthly is also

With so many finalists in this year’s Endeavour Awards we have had to split the shortlisted finalists across two editions of the magazine. To find out who made the cut for the Environmental Solution, Australian Steel Innovation, Significant Achievement, Australian Industrial Product, Exporter, Lifetime Achievement, Global Integration, and Safety Scheme awards turn to page 34, where you can find out who is making a difference in our industry.

The industry’s night of nights. manmonthly.com.au

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Analysis NEWS US factory hours longest since WWII

S Labor Department figures for February show that American factory workers are now working for longer hours than at any other time since 1944. On average manufacturing workers are now working 41.9 hours a week. This figure, which was matched during the economically robust years of 1997 and 1998, is the highest since World War II. Back in 1944, as their brothers fought in the Pacific and in Europe, U.S. factory workers put in a record 45.4 hour working week. The increase has been matched by higher weekly earnings. Even though there has been movement away from higher paid union jobs to non-union jobs, the extra hours worked has translated to a 17 per cent salary advantage over workers from other industries. Since 2009, factories have added 500,000 jobs and the manufacturing sector has consistently delivered productivity improvements. When compared to the figure for 2012, productivity in the sector is up 2.2 per cent. In comparison, productivity for the rest of the U.S. has economy rose by only 0.7 per cent in the same period.

Hours, earnings up in USA.

Governments should buy more locally made cars: AMWU ThE AMWU is calling on governments around Australia to buy more locally made cars in order to support the manufacturing sector. Australian Manufacturing Workers’ Union national secretary Paul Bastian said that the total number of local cars in government fleets had dropped significantly over the last decade. Bastian said ten years ago 66 per cent of the cars in government fleets were Australian made, but now the number levelled at close to 33 per cent.

“Governments need to take the lead and support the local car industry,” he said. At a union delegate meeting, Bastian also called on Canberra to ensure the next phase of defence products, including ships and submarines, were built in Australia. The Federal Government has previously flagged building 12 new submarines, but its plans to attempt to rebuild the existing Collinsclass fleet with Japanese technology are also being considered.

Steel boss sounds dire warning for Chinese mills A senior figure in the Chinese steel industry says the market is oversupplied and a wave of small and large steel mills in the Asian powerhouse will close down over the next few years. Zhang Wuzong, chairman of the privately-owned Shandong Shiheng Steel Group, said decades of ‘blind’ expansion would soon take its toll on Chinese steelmakers. “The Chinese market is now oversupplied,” he said. “It will take time but I believe a lot of the backward private enterprises will be closed. I also believe there will be some state-owned enterprises that will be eliminated too, including some of the big ones.” Wuzong said it was a “certainty” that a number of steel makers would shut down, and ‘survival of the fittest’ was the only way to move forward. Profits in China’s steel sector fell by 98 per cent last year, and the country’s current capacity of 900 million tonnes of crude steel is far higher than the official output of 716million tonnes. Earlier this year the Chinese Government said it would implement new policies to encourage consolidation in the sector, with the aim of bringing 60 per cent of capacity under control of the top 10 mills by 2015. Despite Wuzong’s dire predictions, the spot price for iron ore has soared to new highs over the last few months, but analysts predict demand to soften as the year progresses.

Buy local vehicles, says AMWU. 10 APRIL 2013 Manufacturers’ Monthly

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Analysis NEWS Union sets up 457 abuse hotline ThE ACTU has set up a confidential hotline after hearing more complaints about â&#x20AC;&#x153;unacceptable abuseâ&#x20AC;? of the 457 visa system. In a statement Australian Council of Trade Unions secretary Dave Oliver said the union had seen one example of an engineer made to work, without training, on tube bender machinery that was old and unfamiliar. Along with being placed in difficult situations Oliver said the worker had been on the receiving end of â&#x20AC;&#x153;lifethreateningâ&#x20AC;? pranks by his foreman. â&#x20AC;&#x153;457 visa-holders rely on their employer for their visa, and for any future move to permanent residency. â&#x20AC;&#x153;This means they will not speak up if they are being underpaid or working in unsafe conditions,â&#x20AC;? he said. â&#x20AC;&#x153;Thatâ&#x20AC;&#x2122;s why we are reaching out to these communities. â&#x20AC;&#x153;This Confidential hotline for 457 visa-holders will put them in contact with union officers and government resources who can help them find out about their rights.â&#x20AC;? The CTU said it had also heard reports of a worker employed for painting and sandblasting being made to clean office toilets, his employerâ&#x20AC;&#x2122;s other A D _ Mhouse, A N Mand E C perform I F EB_ 1 3 . pdf Pa ge 1 1 0 / 0 1 / 1 3 , menial tasks.

9 : 5 9 AM ACTU urges reporting of abuse.

Queensland company signs $60m Boeing contract QUEEnSLAnD Company Ferra Engineering has signed a $60 million deal with multinational aerospace and defence giant Boeing. Ferra Engineering specialises in the design, manufacture, assembly and testing of aerospace structures and sub-systems. Speaking at Ferraâ&#x20AC;&#x2122;s manufacturing headquarters at Tingalpa, Queensland Premier Campbell newman praised the high-technology manufacturer for its continued international success. â&#x20AC;&#x153;This Queensland aerospace company began as a two-man operation in 1992 and has grown to become a great Australian success story with more than 130 employees,â&#x20AC;? newman said. he said that the Company had been awarded the contract to manufacture its Joint Direct Attack Munitions Systems (JDAM) for Boeing and pointed out that the contract is expected to generate in excess of $60 million in export sales.

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Cowra cannery closes, jobs cut In the wake of Cowra’s Windsor Farm Food factory going into voluntary administration, more than 70 workers have been sacked and local growers left shortchanged. More than 70 workers have been sacked without pay this week and it’s possible they won’t receive worker entitlements as the business tries to avoid liquidation. Grant Pogroske from the administrator, Grant Thorton Australia Limited, said the business can’t afford to pay the farmers contracted to grow vegies for the plant.

“Unfortunately, unless they have actually delivered the goods, even though there is a contract in place at the moment, they are not going to be reimbursed unless whoever is going to take over is going to keep to those orders,” Pogroske said. Pogroske said the administrator had been appointed to look at not just the Cowra

WA manufacturing employment growing

Windsor cans 70 positions. cannery but also the head office and warehouse in Arndell Park.

Ex-Pacific Brands boss new chair of Manufacturing Australia Sue Morphet, the former CeO of Pacific Brands, has been appointed chairman of the lobby group Manufacturing Australia. Morphet, who led Pacific during its 2009 decision to cut 1,850 jobs and outsource manufacturing to China, was chosen to head up to lobby group due to her “her credentials as a CeO of a manufacturing A D _ M A N M K Ecompany L A P R which _ 1 3 endured _ P . pextreme df Ppressures a ge 1 2 0 The new AM boss. from cheap imports, the GFC and the rapid

manmonthly.com.au

commoditisation of consumer goods”. Morphet replaces Dick Warburton, who announced his retirement in November of last year. The Textile, Clothing and Footwear union’s national Secretary Michele O’Neil was critical: “To say I’m surprised is an understatement … I’d expect an organisation like Manufacturing Australia / to3have / 1 a3strong , 8 and : 0passionate 0 A M advocate for local manufacturing as their leader.”

WA Treasurer Troy Buswell says employment in the state’s manufacturing sector has increased, and the sector is coping with the pressures of the mining boom. Fresh off the back of an election win over the weekend, Buswell said the WA economy was not over reliant on the mining sector. “WA is one of the few jurisdictions in the nation where there’s been an increase in employment in manufacturing, in high end precision-style manufacturing,” he said. “That’s a good thing for the state and that’s the sort of flow on impacts that we need to nurture.” While Buswell talked up employment in the manufacturing sector, businesses around the state continue to struggle, and unions claim the industry has not received its fair share from the mining boom.

Manufacturers’ Monthly APRIL 2013 13

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TechnologyIT@MM Proper planning platforms From a growing global reach to field data from its “man in a van” service, there were a number of things to be considered when Pirtek decided that it might’ve outgrown its old ERP system.

HREE-plus decades-old fluid technology franchise Pirtek announced at the end of February that it would be implementing a new Enterprise Resource Planning (ERP) system, working with provider Infor to do so. “I think it got to a point where we had to review the current systems,” explained Pirtek chief information officer Jason Dormor. “Growth has been significant, particularly over the last five years. I think we got to a point where head office were looking to better analyse our data. A D _ItMprobably A N M P Igoes E Aback P R _about 1 3 12 months now but it really started

14 APRIL 2013 Manufacturers’ Monthly

with a look at our current ERP system and what some of the key drivers were to either modify that or move forward with our current system [provided by Australian company Micronet Systems],” Dormor told Manufacturers’ Monthly of the ERP review. The year-long examination of how things were working focused on the way a handful of franchisees took care of business. “We engaged about five or six of our key franchisees - I guess ‘key’ isn’t a great term but they’d been in -our 1system 2 0 for 1 3a-long 0 3 time. - 1 1So T we 1 8got : 1 5 at : what 3 2 +were 1 1 :some 0 0 of the drivers them together a group and looked that they were looking for being

able to run or manage their business electronically.”

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The franchisees’ key issues quickly became apparent. “I think the key outcomes of that initial review were that we really needed to look at our field service automation part, being more electronic with our mobile vehicle part,” Dormor said. “We needed to better analyse our data, so we were looking at business intelligence type things, looking at our data in different kinds of ways. We have an a growing area of our business, which is the manufacturing side, so looking at something that could better handle project work and how we could better handle work in progress, that kind of thing.” Pirtek operates in 13 countries, and the different reporting requirements across these were one set of problems forcing the company, which manufactures a variety of industrial fluid transfer technologies and provides related services, to reconsider the way it ran things. The increasing global spread of the company A D _ M Ahad N Mmeant B A Ccertain APR_ 1 1 . issues had come up which the old

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ERP wasn’t naturally suited to dealing with. The company hastened to add that the ultimate decision to replace Micronet as their provider of ERP system wasn’t due to any failures by Micronet, but due to Pirtek’s changing needs, a kind of “it’s not you, it’s me” explanation. “While they have customers in other regions, internationally, that is not their core focus,” explained Dormer. “When we’ve implemented our current system into other regions we’ve had a lot of issues. “We’ve had Canadian tax laws and South African VAT [value-added tax] and Chinese regulations and obviously that Micronet being an Australian-based company, we’ve had to work out a lot of requirements and then sort of push our software to deal with that. “And that was very much a driver to say we needed a platform that already had a presence in the weg were pcountries df Pa e 1looking 9 / 0at.3 That / 1 1 , was a key driver of making sure that

we deliver a platform that we can build a Pirtek model, but that still be localised in each of the various countries.” Infor’s SyteLine solution, which Pirtek plans to have completely rolled out by end of the year, is pitched as a system suited to discrete manufacturers across various industries, a “tight integration” tool covering sales and customer relationship management, inventory, supply chain and various other business functions, with a high level of adaptability to new business requirements as they come along. Pirtek said that the change to SyteLine isn’t just tinkering at the edges of its operations, and not a “sideways move” to a similar product. It is a new ERP platform used to consider manufacturing, control, project work and service, according to Pirtek. “Our current traditional platform is mainly based on traditional invoicing 2 : 3 3 and P Mdeveloping and it’s definitely individual invoicing,” said

Dormor. “And we wanted something that could handle those four areas.” The fourth area and the company’s emphasis on its mobile operations played a strong part in the decision. “We are a 24 by 7 breakdown service,” noted Dormor. “And we send out a little man on site if your hose blows. We stock vans to manufacture that hose on site. Field service and having automation in the field is key, at its current point everything is quite manual. Work orders are written, paperwork comes back to the office in dribs and drabs, and is very much a post-invoice environment. “Having our vans and our field servers automated is very much a direction we needed to adopt. Again, Syteline have what we consider a great servicing module. “I think the key components of that are having good visibility in entering the jobs in the actual workshops themselves, as a controller for our mobile fleet. And then the capturing of the data by the device out in the field.”

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TechnologyIT@MM

Controlling document storage costs WA manufacturer discovers workflow is the differentiator when it comes to document management of eRP systems. David Bass reports.

ne of the problems of working in the information age is that documentation seems to accumulate at an alarming rate with eRP systems. In 2009, Remote Control Technologies (RCT), an Australian manufacturer specialising in safety and productivity products for industrial users, found the quantity of filed supplier invoices, quotes and customer orders project documents, technical drawings, contracts, and other documents had become so great that physical storage capacity was a real concern. According to RCT’s Financial Controller, Marcus Bundesen, the cost of storage for hard copy files was growing, as was the time required to manage archived documents. “At that point, we decided we needed to store documents electronically and eliminate physical files.” Bundesen began looking at document and content management software, and soon realised that much of the value of such solutions was in their workflow capabilities. “Our eRP system is a transactional system with limited transactional workflows and no document workflows. A lot of document management systems included workflow and we could see the potential, how it could be applied in many areas of our business,” Bundesen said. After lengthy research RCT chose OnBase, a content management solution developed by Hyland Software. Supported locally by Caylx, the software included workflow capabilities that could integrate with RCT’s eRP system.

Start with a high-impact project Within a month and a half of committing to the document system, it was up and running, and the first workflow, which was designed to support the company’s use of customer service job or project cards, was released. 16 APRIL 2013 Manufacturers’ Monthly

Taking the cost out of managing ERP documents. “We started with job cards because it involved a department that was very supportive of the document management system. “We thought it would have the highest return straight away and was a fairly manageable project to implement,” Bundesen explained. The project involved developing workflows for the job cards that encompassed all the possible requirements from initiation of a job to invoicing and completion. He said the RCT team developed queues for jobs awaiting management approval or invoicing. “We also instituted automated calls from OnBase to other databases, easing the task of collating project costings. “The workflow cut down administrative time and made it much easier for project teams to find the information they needed. It also brought consistency and greater control to customer service projects. “We used to have physical cards that were kept according to a tray system. There would be a tray for jobs waiting for parts; another for waiting for labour, or when waiting for a customer to go and install the product. “Others would be used when waiting for the customer order, or when waiting to be invoiced. “The difference now is we can search on a customer or a customer

service department and see where all the orders are up to,” Bundesen said. Data is now shared across different departments, providing each department with its own tailored view. For example, a sales person can see which customers have work in progress while managers may seek to identify who’s working on which projects.

Bringing consistency to quotes RCT’s next workflow was designed to support the quoting system. Given the technical nature of its products and the range of options available, a typical RCT quote can take up to eight or more pages. In the past, there was little consistency from one quote to the next. Sales staff would prepare their own quotes in Word documents, often using different layouts. Using the document management system, a standard quote template and workflow were produced. The workflow allows sales and management to track what stage a quote is up to – whether it is still being worked on, with a customer, or whether it needs to be followed up. When the quote is accepted and a customer order comes in, the system automatically pulls the information

from the quote and creates a new job or project card. The system streamlines administrative effort and has removed the need to re-key existing data into the system. Over the next three years more workflows followed. The processing of supplier invoices, for example, has been completely revamped. When an invoice is received by RCT, it is scanned, indexed and filed in the document management system. It then checks with the eRP system to see if the invoice matches an existing purchase order number or creditor number. The system also checks other details such as the goods amount received, GST code, GST amount and whether the purchase order has been received. If problems or discrepancies are noted, the invoice is shunted to the appropriate purchasing departments for investigation. Bundesen says it all happens automatically behind the scenes. “The accounts payable officer can see all the problem invoices, who’s holding them up and where they are up to. “It stops the problems of emailing or sending invoices around the organisation. All the information is in the system,” he said.

In-house developed The structure of each workflow is initially developed by Bundesen. He then hands the information to an in-house software engineer who creates the forms and any scripts required to enable the document management system to query the eRP database. Bundesen explained that he is an accountant with no IT background, “but having completed the one week OnBase workflow course, I’ve found that I can still do a lot of workflows. The only thing you really need is a qualified programmer for some behind-the-scenes scripting,” he said. Recently RCT employed a systems accountant to focus on more workflows within the company. manmonthly.com.au

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PM A D _ MA N MB E S A P R _ 1 3 . p d f

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The use of military connectors for I/O are designed to enhance reliability. Backplane systems technology has released the mOBl-D2, a mobile platform for long-term reliability in rugged environments. the circuit design, component selection, testing and heat dissipation of the platform are designed to maximise reliability and minimise downtime. the use of military connectors

for I/O are designed to further enhance reliability where cable stress would damage pc style connectors. according to the company, the shock suppression system is designed for 24/7 abuse, not just passing a brief mIl test. Backplane Systems Technology 02 9457 6400 www.backplane.com.au

Industrial PCs AJ Distributors has released a range of rugged PCs with 3rd generation Intel Core i7 and Intel Celeron processor. The PIP30 family (PIP31, PIP38) is a range of low power, highly integrated rugged industrial PCs featuring a specially designed aluminium housing that allows them to be operated in a moderate or harsh environment without fan or ventilation holes. With the design integrating standard connectors for easy connection, the PIP can be used for any PC application where a complete solution is required. The 100% PC/AT compatible PIP30 range can be mounted on a 35mm DIN rail or a wall with flanges. AJ Distributors 08 8285 4889, www.ajdistributors.com.au

mobile computers with integrated rFID

Mobile computers with RFID reader but no external antenna. manmonthly.com.au

Intermec’s 70 series family of mobile computers now offer a fully-integrated UHF rFID reader with no external antenna . Designed specifically for customers seeking a mobile rFID solution in-premise environments, the 70 series rFID reader platform supports medium to long-range read distances. the reader is optimised to read one or many tags in support of inventory and asset tracking applications in retail, healthcare, industrial and government market segments. Intermec 02 9330 4400, www.intermec.com.au.

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Welding & PROFILE CUTTING understanding welding fumes most fabricators and co-workers know that breathing in welding fumes is not good for them, but how many realise that some of those innocuous looking fumes can be deadly. Alan Johnson reports.

ITH the correct PPE, arc welding mild steel in an outside area, or in a well ventilated workshop, is not a problem, but when welding more exotic materials that’s when fabricators and co-workers should take special care. Arc welding fumes contain very small particles from the consumables base metal and base metal coating. The substances in the fumes change depending on what is in the electrode and the base metal including any coatings. The most common compounds in the fumes when welding mild steel, for example, are complex oxides of iron, manganese and silicon. The short term effects of these compounds, if inhaled, are temporary and include burning eyes and skin, dizziness, nausea and fever. However long term exposure to these fumes can lead to silicosis (iron deposits of the lungs), bronchitis, and even lung fibrosis has been reported. And if the compounds found in the welding fumes includes Barium, symptoms may include severe stomach pains, slow pulse rate, convulsions, muscular spasms and even death. Welding equipment manufacturers and industry organisations highlight the need for fabricators, and their co-workers, to be especially careful when working with new metals and materials, particularly when welding heavy metals such as magnesium and chromium. Welding proffesionals should understand that it all depends on the base material and the consumable the welder is using and if the metal is coated. It is not uncommon for welders to be overcome with paint fumes when welding painted metal, Thankfully, most welders are aware of the dangers of welding fumes, and the short term and long 18 APRIL 2013 Manufacturers’ Monthly

Protection from fumes

Be aware, be very aware, welding fumes can kill. term respiratory problems they can cause. For example the vast majority of welding machines and consumables in Australia have warning labels on them regarding welding fumes. However, welders should be especially aware of working with exotic materials such as cadmium, chromium, cobalt, copper, fluorides, manganese, nickel, silica and zinc, even stainless steel. Fumes from the following metals can cause: • CAdmIum requires extra precautions, especially as it is often found on steel and steel fasteners as a plating or in silver solder. Cadmium fumes can be fatal, even after brief over-exposure. • CHROmIum poses a cancer risk. Stainless steel and other hard coatings contains chromium and can cause lung cancer and asthma. • COBALT may cause respiratory diseases and pulmonary sensitising, and in metallic form it has been know to cause lung damage. • COPPER may cause metal fume fever, skin irritation and discolouration of the skin and hair.

• mAgnESIum may affect the central nervous system, difficulty in speaking, and arm and leg tremors, often non-reversible. • nICKEL may cause cancer. • SILICA may cause silicosis. • ZInC, found in galvanising, may cause fume fever. Sasanka Sinha, Technical manager with WTIA (Welding Technology Institute of Australia) says most welders are aware of the need to wear some form of PPE (Personal Protective Equipment) when welding, “but it’s not always obvious how dangerous these fumes actually are when welding different materials. “Problems can arise when welders take on a new job or a new material to be welded. Sometimes they are not aware what the fumes contain, especially with Stainless Steel. “galvanised or coated materials can also cause problems, it depends on the thickness of the zinc used when galvanising. “If the thickness of the galvanising changes from thin to thick, without the welder being aware, that can cause problems,” Sinha told Manufacturers’ Monthly.

Sinha’s advice for welders is to use their common sense. “In Australia, welders are very good, they know their job and are aware of the dangers of welding fumes. They know what PPEs they must use. “It’s the responsibilty of management to make sure they wear the correct PPE. “Some welding helmets, for example, have there own extractor, so the dangerous welding fumes can be extracted right at the welding arc. “And if the welder is operating inside a confined space such as in a tank, boiler, or pressure vessel, it is the responsibility of the supervisor to provide fresh air and extraction. “It is also mandatory the welder has a ‘fire-watcher’ outside to ensure the welder is not overcome by fumes,” Sinha said. However, most welders know that wherever they are they should wear PPEs such as breather masks and use some form of ventilation. The first option is to ventilate the whole environment. This could take the form of open windows and doors in the workshop so they get cross ventilation. Then there are fans and suction devices that manufacturers can use, through to fume extraction arms and hoods, and downdraft tables through to fully engineered systems. The key is to get the point of extraction as close as possible to where the welder is operating. The goal is for the welder not to breathe any welding fumes at all, so manufacturers should remove as many of the fumes from the workplace as possible. There are a wide range of options available, depending on the location and the metals being welded. WTIA 02 9748 4443, www.wtia. com.au manmonthly.com.au

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Portable plasma cutters WIA (Welding Industries of Australia) has released the Miller Spectrum range of portable plasma cutters. The 240V, inverter-based, plasma cutting machines are said to produce “best in class” results and performance for cutting capacity and cutting speed. Suitable for both on-site and workshop-based cutting applications, the range includes the Spectrum 500i, a 30A system, and the Spectrum 700i, a 40A system. Typical applications for the plasma cutters include sheetmetal fabricators, manufacturing industries, general fabrication, engineering and maintenance. According to the company, the Spectrum 500i’s travel speed is rated at a class-leading 467mm/min when cutting 9.5mm (3/8”) mild steel at 30A, while the Spectrum 700i’s travel speed is rated at 330mm/min at 40A cutting A Dwhen _ MA N M S 15.9mm C H 2 A (5/8”) PR_ 1 3 mild steel, with the travel speeds

The machines are suitable for both on-site and workshop-based cutting applications. approximately 80% of maximum. Both machines feature Auto-Refire Technology, which automatically controls the pilot arc when cutting expanded metal or multiple pieces of metal. The pilot arc is designed to switch in and out when cutting expanded metal and maximum power for cutting thicker metal. WIA 1 2 0 1 3 - 0 3 - 11300 300 884 1 T1 8 : 3 www.welding.com.au

Metal-cored welding wire LIncoLn Electric has released Metalshield Mc-80ni a low-alloy, metal-cored wire designed to produce high strength and toughness and H4 diffusible hydrogen weld deposits required in such applications as structural and heavy fabrication or other high-strength welding applications that require a tensile strength of 550 MPa (80ksi). With H4 diffusible hydrogen levels, the wire is said to feature low spatter and arc stability, with deoxidising agents.

The wire is designed for semi- automatic and robotic applications. Lincoln Electric www.lincolnelectric.com.au

Welding safety guide now on-line LincoLn Electric’s interactive welding safety DVD is now in an on-line format that is accessible and viewable on computers, tablets and mobile phones.Designed to educate arc welders about potential arc welding safety hazards and the safe practices they should follow, the guide offers information on a wide variety of topics, including how to avoid electric shock, prevent fire and explosions and choose appropriate personal protection equipment. Lincoln Electric, 1300 728 720 www.lincolnelectric.com.au 7 : 0 3 + 1 1 : 0 0

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NMW Preview 7-10 MAY 2013

National Manufacturing Week: australia’s manufacturing exhibition

atioNal Manufacturing Week (May 7-10, Melbourne) reflects the brightest trends for the manufacturing industry. in particular, event organiser Reed Exhibitions says this year’s exhibition reflects research identifying areas in which industry will be making investments this year. Paul Baker, exhibition director for NMW said “industry leaders – such as those on the Prime Minister’s Manufacturing taskforce – recommend that business growth will come about through increased productivity, innovation and by creating value-added services & solutions”. “in our own research, Reed Exhibitions has found that many in the industry are gearing up to make concrete investments in these areas in 2013.” Reed Exhibitions conducted a survey of 400 manufacturing industry personnel in December 2012. Respondents – drawn from across industry sectors – consistently stated that key growth areas for their businesses in 2013 included value-added solutions and services, technological innovation and cost efficiency and optimisation. “to support their growth strategies, around half – 49.6 per cent of those surveyed – intended to make moderate or larger capital investments this year,” Baker said. Research findings included that companies were planning to make investments in a range of sectors: in engineering products and services, electronics, materials handling, process control, and materials, especially metals and composites. other feedback to NMW includes that vendors are gearing up to target specific vertical markets – mining and the resources sector, as well as automotive components, defence, aerospace, pharmaceutical and biotech for future growth. NMW built A D 2013 _ M Ahas N Mbeen ROB A Paround R _ 1 3these - findings, Pa ge commented Paul Baker.

Despite the industry slowdown, the manufacturing industry is still innovative, and will highlight its latest developments at NMW. “to begin with, NMW will be laid out – for the first time in Melbourne – in 12 Product Zones, to enable buyers and sellers to easily find each other. the event will also include live demonstrations from exhibitors whose products and services help companies automate and/or optimise their processes,” he said. For example, Millsom Materials Handling will be displaying vacuum lifters and new aluminium jib arms that help optimise businesses’ manufacturing, logistics and manual materials handling. 1 2 0 1Millsom’s 3 - 0 3 - General 1 1 T 1Manager, 8 : 0 0 :Kevin 2 6 + 1 1 : Smith, commented: “We look forward to NMW

every year because it gives us an opportunity to showcase working models of our vacuum lifters and materials handling equipment to a large and varied cross section of potential customers”. Similarly, specialist supplier PlC Hardware will be giving visitors hands-on experience of screen tablets the company is now integrating into its industrial automation solutions. “it’s really important to be able to demonstrate to customers how we go about making savings on automation solutions. NMW gives us the chance to sit down with visitors and run through the finer details that set our products and services apart,” said PlC’s Jason Hardie. Many NMW exhibitors will also outline new products that help companies boost their capacity for innovation. For example, EDGE plm software – participating in NMW for the eighth time – will be bringing new solutions that help companies create, analyse, optimise and modify their designs. EDGE plm’s MD Barry Bevis said “EDGE will be demonstrating a new low- cost CaD tool, 3DSync, from Siemens, which allows designers to edit and manipulate imported 3DCaD data”. adding that “the EDGE stand will be offering hands on use of 3DSync and Solid Edge as well as free trial software”.. in all, concluded Paul Baker, NMW – co-located with austech – will bring together more than 300 companies, each with innovative solutions that help companies maximise their existing processes, or open up new sources of commercial advantage. “it’s going to be a great exhibition. Registrations for NMW 2013 are now open at nationalmanufacturingweek.com.au – and i invite industry to register now, to ensure you receive on exhibitors and events in the lead up to 0 updates 0 this event in May,” he said.

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NMW Preview 7-10 MAY 2013

Screw compressors Welding consumables and metal finishing

Flap discs

SCR Australia through our exclusive Australian agent Westair International Pty Ltd is pleased to announce our new range of Direct Drive and Variable Speed rotary screw air compressors. through an Australia wide network of resellers, Westair can provide the complete solution for your compressed air requirements. Come and see us at NMW 2013 on stand 1210 where we will be displaying our SCR10D-t 10hp receiver mounted direct drive and our SCR30DV 30hp variable speed units. the Variable Speed and Direct Drive range (7.5 to 280KW) offer excellent value for money and can result in significant savings on your power bill. Many of its components are of European design and manufacture, delivering equivalent performance and reliability. All our units are of robust design with low speed , oversized airends and uncomplicated “one to one“ drive, resulting in strong, quiet, reliable, long life machines. Westair International 08 94188008 A Dwww.westaircompressors.com.au _ MA N MQ MI A P R _ 1 3

At NMW this year, Klingspor will be showcasing a unique quick-change Flap disc range on stand 2010. Many manufacturers of steel and stainless steel products use flap discs these days but KLINGSPOR can show you how to reduce the price of your consumables as well as reducing labour costs by using this unique patented product. Klingspor’s CMt quick change flap discs are available in 40 to 120 grits as well as a full range of surface conditioning products so your company can go from weld removal to a fine finish quicker than ever before! Klingspor were the inventors of the flap-disc and have remained ahead of their competition by constantly improving their range. Klingspor also has a full range of industrial abrasives to provide solutions for every application. From cutting and grinding discs to finishing wheels, Klingspor is a one-stop shop for all your abrasive needs. Klingspor 02 9737 0597 www.klingspor.com.au

MIDWAY Metals is a 100% wholly owned Australian company, and is Australia’s largest independent Stainless Steel Stockist. Midway Metals is also the Australian agent for Avesta Welding and Avesta Finishing Chemicals. Stainless steel welding. Avesta Welding specialises in stainless steel welding plate that when cut or folded will retain consumables in GMAW, GtAW, MMAW, flatness. FCW and SAW. the Slitting Line can break-down larger Avesta Finishing Chemicals specialise coils into smaller coils and slits thickness in the surface treatment of stainless steel from 0.55 to 8.0mm and applies PE supplying Pickling pastes, coating. Baths, Sprays, Passivators, Cleaning the Flat Bar Line levels, straightens solutions, accessory items and technical and edges finished Flat bar into lengths support. from 2M to 6M producing in widths Avesta complements the range of 20mm to 200mm. Flat & long products, Angles, Rounds, It will showcases its products on stand Fittings, Pipes, tubes & Valves complete 2021. with a plasma cutting service offering the Midway Metals customer a one stop shop. 02 96708900 services - Other 1 2 0 1 3 include - 0 3 -a Blanking 1 1 T 1 Line 8 : 2 2 : 2 6 + 1 1sydney@midwaymetals.com.au : 0 0 that Produces Laser flat quality sheet and www.midwaymetals.com.au

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NMW Preview 7-10 maY 2013

Plastics and printing

For high temperature applications.

Castors and wheels BacKeD by an experienced team, QhDc australia is certainly serious about its future in wheels, castors and materials handling. It has carefully selected specialist manufacturers from around the world to supply its comprehensive range of quality products which it brings to the australian market and to NmW 2013 on stand 2311. among the products on display will be Premium heavy Duty wheels and castors with capacities up to 11 tons, an industrial range with all of the popular wheel types and high quality institutional and medical castors equal to the best in the world. also on display will be unique products like height adjustable castors, wheels and castors for high temperature and corrosive applications. QHDC 07 5593 4718 www.qhdc.com.au

TechSPaN australia is a supplier of high quality plastics and printing technologies. The company is part of the Techspan Group, a privately owned group of companies specialising in plastics and printing technologies for 34 years. at the NmW 2013 Techspan will be exhibiting it’s range of BaK plastic welding equipment on stand 1725, including hand-held hot air welders for plastics fabrication and repair, automatic welders for seam welding flexible plastic fabrics and membranes, and DohLe extrusion welders for fabrication welding of very thick section plastics. rINco ULTraSoNIcS plastic welding and cutting systems will also be exhibited.

Metal forming

For plastic welding.

The BaK Seon 40 wedge welder is a compact, fully automatic welder for welding thermoplastic tarpaulins, banners, and coated foils, from 0.25mm to 1.0mm thick. Techspan www.techspanonline.com

Automation and safety solutions TreoTham automation provides cables and connectors, machine automation, polymer bearings, precision gearboxes and machine safety and control products for a number of industries. at NmW, Treotham will also display a number of new safety products, including mosaic programmable controller with bus modules; wipos range of power supplies from Wieland; three phase and Single phase surge arrestors for lightning protection ((Type 1, 2 and 3); flare range of multi-function timers, multi-function

monitoring and switching relays; new range of mechanical and non-contact interlocks from Wieland; eoS range (IP 69K) light curtains. Treotham Automation A D _ M A N M S U P A P03 9555 4890 R_ 1 3 www.treotham.com.au

WmS now has one of the most advanced metal forming manufacturing facilities in australia –showcasing new capabilities that represent a ‘first’ for australia. among these is the capacity to accurately form mild Steel up to 8mm and Stainless Steel to 6mm, plus new technologies, including the Leifeld cNc metal Spinning lathe that completes multiple operations in one with unmatched capability in production or precision standards. WmS manufactures a broad range of items – from household appliances to wind generators – including metal spinning, laser cutting, metal fabrication, metal pressing and metal machining. established in 1937, WmS is proudly 100% australian owned and operated by the crawford family and has modern cNc machinery and high calibre in-house tool-making facility, and showcasing its goods on stand 2007. WMS 02 98245677 enquiries@woodland.net.au 1 2 0 1 3 - 0 3www.woodland.net.au - 1 1 T1 8 : 2 7 : 5 3 + 1 1 : 0

Production line welding The obara name is well known throughout the world’s automotive manufacturing industries. recognised as a level 1 preferred supplier to the automotive sector, obara australia provides local support assisting australasian companies with their welding/metal joining and fabrication requirements. While obara is renowned for robust and reliable production line welding equipment, we continue to look at and focus on new ways to improve and support our customers. For many years obara australia has been representing coral s.p.a, a well-recognised european manufacturer of anti-Pollution dust and fume extraction systems, coral s.p.a are a ce marked ISo accredited company. Visit stand 2614 to see some demonstrations of coral products, including Portable fume/dust unit/s, oil mist extraction units, as well as to gather manmonthly.com.au

New stationary spot welders. new ideas on consumable products for Stationary spot welders and mIG welding. obara australia looks forward to assisting manufactures with products and services. Obara Australia 03 8795 0100 obara@obara-aust.com.au www.obara-aust.com.au Manufacturers’ Monthly APRIL 2013 23

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NMW Preview 7-10 MAY 2013

Cleaning technology

Automated finishing.

Dust and fume control oLiveR technologies specialise in project and equipment solutions for dust & Fume Control, Abrasive Blasting, Bonding & Sealing, Spray Painting and Powder Coating. our engineered projects, equipment and services are utilised in a wide range of industries including automotive and component manufacturing, structural steel, wood, defence, mining and other general manufacturing and fabrication industries. our team consisting of technical Sales, drafting, engineering, Manufacturing, Project Management and Preventative Maintenance will assure

you receive the right advice, equipment, service and innovation to compliment your business. Come and see some of our core product range featuring a 2K Paint Mechanical dosing designed for protective coating and finishing applications, the Sames Nano Bell & Powder Bells for Robot operated finishing, Kremlin thor Bonding and Sealing Applicator, Spray Booths, Solvent Recycling and more at the 2013 NMW. Oliver Technologies 1300 538 948 www.olivertechnologies.com.au

Clamps and holdings tables PRoduCtivitY is a key issue for the Australian welding & fabrication industry. the new FixturePoint and BuildPro work holding tables and clamping systems offer an affordable solution to the problem that will be showcased on stand 1821. Nissen Markers uSA has a wide range of specialty markers on display including Low-Chloride pens for safe use on stainless steels. tanjant tool is demonstrating roller guides, circle guides, line cutters, guide kits & accessories for gas or plasma cutting, all proudly Australian made. New this year are alloy work tables from BuildPro, ideal for stainless steel fabrication. A unique engineering feature on the new FixturePoint tables is the patented steel/alloy honeycomb sandwich plate that forms the work surface. it offers superior strength with light weight. these tables come in a 24 APRIL 2013 Manufacturers’ Monthly

Aids in welding and fabrication. convenient 90 x 60cm size which is perfect for individual work stations, while having the same precision assembly systems as the larger BuildPro tables. Tanjant Tool Co 03 9872 6222 www.weldingtablesaustralia.com.au www.tanjant.com

At NMW this year, Centralised Pumping Systems is introducing new, industry specific, surface cleaning technologies from BioRem and HiLite Solutions on stand 2513. Centralised Pumping Systems has been providing bioremediating, speciality cleaners’ products to Pacific and South Asia businesses for 15 years, making it the first real provider of alternatives to harmful, solvent-based products in this part of the world. Centralised Pumping Systems’ mission is to help companies work smarter, cleaner and greener. this philosophy has now become part of its identity and branding through the Smarter. Clean. Green product range. the company’s parts washers and systems provide a cost-effective solution and help customers meet their green mandate. they are specifically catered to the requirements of specialised technical industries and applications including aviation, military and automotive,

An alternative to solvents.

and meet the strict health and safety standards required of industrial cleaners. Centralised Pumping Systems +64 9263 8005 scg@smarterclean.com www.smarterclean.com

Lubricated for life gearboxes APex dynamics launch the P ii series ‘second generation P series’ at NMW 2013 on stand 3513. Following on from the success of the Apex dynamics P-series planetary precision servo gear boxes, Apex have chosen NMW 2013 to launch the ‘second generation’ P_ii series. this completely new product is format compatible with the first generation P series but at the same time great care was taken to produce a gearbox of outstanding smoothness, quietness and low friction, attributes which make the new P_ii series a standout product in the marketplace. Precision is enhanced by utilising laser welding and patented bonding techniques during manufacture. in addition, all P_ii series gearboxes feature revised gear carriers, gear tooth profiles, input oil seals, input clamp and gear casings. these enhancements endow the new P_ii series with class leading smoothness, quietness, efficiency, ultra low moment of inertia, low backlash and reduced weight. the new input clamp ensures perfect alignment and dynamic balance coupled with higher clamping force. State of the art gear profiles give an approximate 50% reduction in noise across the range. Alloy end caps coupled with a new hardened and honed ring gear give maximum accuracy, strength and reliability coupled with low weight. this has all been achieved alongside a major reduction in rotating mass, giving a low moment of inertia suitable for demanding, highly dynamic, drive systems and a reduction in static friction. Like all Apex dynamics products the new range is lubricated for life, maintenance free and carries a comprehensive 2 year warranty. the new P_ii series leverages a cost effective, light weight, performance solution for ultra high precision servo systems and general precision engineering applications which require a step down or step up gear solution. the Apex adaptor system allows fitment to just about any servo motor and using our free online tool, selection is accurate and easy! Apex Dynamics 03 9585 2739 sales@apexdyna.com.au www.apexdyna.com.au

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CALLING ALL

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Austech Preview

7-10 MAY 2013

Precision lathes It is not often that you are given an opportunity to see the processes involved in producing high-precision parts for industries such as the exacting medical sector. At the forthcoming Austech exhibition, Swisstec Australia will be providing visitors a rare insight into how a part such as a bone screw is taken from concept to product to assured tolerances. to show this process, Swisstec Australia has teamed up with Delcam Australia, a specialist in CAD/CAM software, and Renishaw Pty Ltd who will provide the final testing and gauging of the product turned and milled in Swisstec’s recently released tornos St-26 CNC lathe. “Adopting the latest machining technologies is key for shops to accurately and repeatedly create medical components,” says Peter Staebner, of Swisstec. “Swiss-style lathes offer a good combination of precision and repeatability for these applications thanks in part to their guide-bushing design, which provides support for the workpieces very close to the cut.” the tornos St-26 CNC Swiss-style lathe

For exacting industries. features 7-axis functionality and a sliding headstock. the machine boasts up to 36 tools, 16 of which can be used at any one time, with or without a guide brush. “It has the capacity to produce anything from a repetition item like a washer to a highly precise item like a bone screw. the 23-mm capacity means the tornos can produce highly specialised parts.” to visualise the complexity of the design capabilities, Delcam will be demonstrating the design composed on the company’s ‘Partmaker’ software via a big screen on the stand. the part will then be manufactured onsite by the tornos lathe and Renishaw will be utilising its expertise in gauging and measurement to show the precision that has been achieved by the machine. Swisstec 03 9769 3988 www.swisstec.com.au

3D printing ONCe considered science fiction, the ability to do 3D printing has long become a reality, especially in the manufacturing world. Here, the trend is going to pick up steam in 2013, and tasman Machinery will use the opportunity of the upcoming Austech exhibition to demonstrate the latest technology advancements. As an alternative to conventional subtractive manufacturing methods such as milling or turning, tasman Machinery will be displaying a full suite of additive manufacturing technologies, including both FDM from Stratasys and Polyjet

Additive manufacturing on show. technologies from Objet.tasman will have a Stratasys Fortus 400mc 3D Production System onsite. s, workholding tools or end-use parts. Tasman Machinery www.tasmanmachinery.com.au

Fasteners FujI Fasteners is an Australian cold forming manufacturer and importer of quality fasteners – screws, bolts, lock nuts, wheel studs, solid rivets, headed pins, sems assemblies and weld studs. Visitors to the Fuji Fasteners stand at Austech 2013, will see an extensive range of fastener examples produced by Fuji Fasteners at its South Dandenong factory. the stand will be manned by the company directors. 26 APRIL 2013 Manufacturers’ Monthly

Screws and bolts. Fuji Fasteners 03 9706 6652 www.fujifasteners.com.au manmonthly.com.au

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Austech Preview 7-10 MAY 2013

Sheetmetal working

CNC lathes

LEADINg Australian sheetmetal equipment supplier, Sheetmetal Machinery, will once again showcase its innovative range of bending, folding, laser cutting and materials handling solutions to the manufacturing industry at Austech 2013 in Melbourne, Stand 582. Suitable for a Sheetmetal Machinery Australia will exhibit the RAS range of sheetmetal XL folding centre which offers technical excellence bending applications. with 3200 mm folding length at 1.5 mm mild steel capacity. The machine is suitable for efficient bending of sheetmetal parts in low to medium high volume jobs and other applications. Sheetmetal Machinery Australia 03 9758 9377 www.sheetmetalmachinery.com.au

HS CNC Machines together with Qumac Engineering Services will showcase for the first time in Australia the Feeler HT-30Y multi-axis CNC lathe, which has become the company’s number one selling multi-axis centre. The machine features C & Y axis milling capabilities combined with a built-in spindle motor and a 12-station BMT-60 turret with a powerful milling function, as well as a Fanuc 31i controller. Mal Durdin, Director of HS CNC Machines, representatives of Qumac Engineering Services and technical experts from the company’s overseas suppliers will be on hand at stand 579 over the four days of Austech 2013, which will run from 7 to 10 May 2013 at LEANER times call for leaner to discuss their lean manufacturing the Melbourne Exhibition Centre. manufacturing processes. Learn how needs with TXM. The company will “The relationship between HS CNC lean manufacturing techniques can help be showcasing the recently launched and the Taiwanese group spans more your business from leading Australian online store that provides many of the than 15 years, providing Australian Lean Manufacturing and Project key visual tools needed to improve the customers with long-term support Management company TXM during lean production systems and assist with and knowledge,” Durdin says. “We Austech 2013 in Melbourne, stand 501 managing routine daily tasks, problem are excited to be able to demonstrate to be held at the Melbourne Exhibition solving and planning production. the Feeler multi-axis lathe and vertical Centre from 7 to 10 May 2013. TXM Lean Solutions machining centre at Austech. It is a great Visitors opportunity people to the A D _ will M Abe N given M P Rthe OF EB_ 1 3 . p d f P a g e 1 www.txm.com.au 2 1 / 0 1 / 1 3 , opportunity 2 : 3 5 to introduce PM HS CNC and Qumac teams, but also to

Lean manufacturing

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Multi-axis milling and machining centres. have the opportunity to speak directly with the technical experts during the exhibition. We will also have at our stand information on the full range of Mori Seiki CNC machine tools.” Included in the display will be the MT range of power rotary tooling accessories from MT Marchetti of Italy, as well as two new four-axis vertical machining centres from the popular Feeler VMP series. The machines’ rugged construction manufactured from high-quality cast iron assures optimum rigidity and stability, making it ideal for precision jobs. The 10,000-rpm spindle produces fine surface finishes required by many industries. HS CNC Machines 03 9763 8207 www.hscnc.com.au

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AUSPACK PLUS 2013 What AUSPACK PLUS 2013 has in store We have a sneak peek at what this year’s AUSPACK PLUS exhibition has on show.

The newest equipment for packaging and processing will be showcased.

HIS year’s AUSPACK PLUS will highlight the latest developments in packaging and processing materials. tna, Emrich Packaging Machinery and Swiss Pack are just three of the companies who will be exhibiting at AUSPACK PLUS 2013 in May at the Sydney Showground. According to Luigi di Palma, general manager of tna Australia: “As an Australian company, we are always delighted to demonstrate our packaging solutions at AUSPACK PLUS, and this year is no exception. “tna will be exhibiting the new tna robagFX 3ci high speed vertical form fill and seal packaging machine, which provides up to a 30 per cent improvement in performance in both output and reduction in rejects and achieves unprecedented throughput rates of up to 150bpm. “Visitors will also experience our seasoning system, the tna intelli-flavOMS 3c. A complete, one-piece solution for both wet and dry seasoning and flavouring, the tna intelli-flavOMS 3c delivers exceptional performance and provides even coverage at

28 APRIL 2013 Manufacturers’ Monthly

throughput rates of 100 – 500 kg per hour for a wide variety of applications. “Technical experts will also be on-stand to demonstrate our tna rofloHM 3 horizontal motion conveyor, which smoothly distributes goods to minimise losses and breakages. We will also be showcasing our controls and integration expertise, demonstrating how our electrical and control system integration solutions can help manufacturers achieve optimum performance in their production lines by reducing inefficiencies and maximising output.” Emrich Packaging Machinery will be exhibiting a wide range of equipment on their stand including the PFM ZC1 integrated multi-head weigher and bagging machine and the Adco 15D105 horizontal hand load cartoner. The PFM ZC1 integrated multihead weigher and bagging machine is designed for mid-speed duties up to 80 bags per minute and targets products such as snacks, confectionery, pet-food, granular products, biscuits, pasta, etc.

The ZCI meets the need for an inexpensive system that nevertheless offers a high degree of flexibility, accuracy and is simple to use. The absence of a gantry reduces cost and machine footprint compared with conventional systems while the compact nature of the unit also allows elevators and other support equipment to be downsized for further savings in capital. The Adco 15D105 horizontal hand load cartoner is designed for easy conversion to a fully automatic barrel cam machine and available to run in either continuous and intermittent mode, the 15D105 delivers class-leading carton erecting performance and flexibility in a compact and economical package. Fast changeover, simple operation and clean design make the 15D105 ideal for the most demanding production environments. All ADCO machines are constructed in stainless steel and available in standard and washdown configurations. Following a very successful AUSPACK PLUS in 2011 Swiss Pack will also be heading to Sydney to showcase their new product

line of machines. In the past Swiss Pack had been concentrating only on packaging materials; however they have now branched out into packaging machines. According to Brendan Yee, general manager – flexible division, Swiss Pack are now able to design, install and service various packaging machinery. “Our packaging machines are suitable for all solids, liquids and powders – such as: VFFS, Mini pouch packing machines, coffee packing machines, flow wrappers, shrink tunnels, rotary pouch packing machines, and carton packaging solutions.” The Swiss Pack range of materials is extensive and covers both flexible and rigid packaging types such as: pre-formed pouches, flat bottom box pouches, printed rewind, shrink sleeves, woven PP bags, printed cardboard boxes, buckets and pails and custom moulding jars and containers. MPI Australia, Esko Australia and Paksmart Machinery have announced details of the equipment set to take the limelight at their manmonthly.com.au

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Pa ge

PACKAGING + PROCESSING + MATERIALS

5 / 0 3 / 1 3 ,

2013

Australia’s Premier International Exhibition of Packaging and Processing Machinery, Materials and Associated Technology

Tuesday 7th - Friday 10th May 9.00 am until 5.00 pm Sydney Showground Sydney Olympic Park

AUSPACK will highlight start of the art solutions. respective stands, with a suite of new offerings ranging from tray sealing machines and high speed friction feeders to carton machines, high speed bagging equipment, x-ray machines and palletisers Paksmart has revealed it will be showing its new PF400 high speed friction feeder for the feeding of flat paper, fibreboard and plastic products and some sachet style packets. The PF400 is designed for high-speed production lines in conjunction with other machinery such as conveyors, glue systems, labellers, inkjet printers and other PF400s. The machine can also be used for other purposes such as tipping, inserting, offline coding and collating. Also on display from Paksmart will be its PC40 carton machine, an intermittent motion carton machine with automatic end loader and using a new generation servo motor drive technology to load at up to 40 cycles per minute. Privately owned local company Esko Australia, meanwhile, plans to showcase a large range of equipment

suitable as part of a processing, filling, retorting, packaging, palletising/de-palletising or packing line for PET or glass bottles and jars, pouches, trays and cans. MPI Australia, for its part, will be exhibiting newly released state-ofthe-art products including the launch of its PA SL4 Eclipse range of tray sealing machines, the launch of APS FAS for high speed bagging and the launch of the Safeline X3310 x-ray machine. It will also be exhibiting a new concept for economical bagging of consumable and industrial products and protective packaging from its Autobag range of equipment, as well as the Automac tray stretch wrapping machine, the Shrinkmaster L bar sealer and shrink tunnel and Cryovac Polyolefin shrink film. Visitors can expect to see over 1100 brands and 270 exhibitors, including 68 internationals, all under one roof. AUSPACK PLUS 2013 is a ‘must-attend’ exhibition on the Australian Packaging and Processing calendar and will be held at the Sydney Showground, Sydney Olympic Park from Tuesday the 7th to Friday the 10th of May 2013.

• Over 1100 brands on display, more than 270 exhibitors including 66 international. • Most advanced technologies for integrating your packaging and processing lines-in action on the show floor. • Solutions for increasing line productivity, versatility and efficiency. • Revolutionary product launches offering new heights in safety, security, automation and cost-savings.

Celebrating 30 Years

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AUSPACK PLUS APP NOW AVAILABLE

Manufacturers’ Monthly APRIL 2013 29

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What’sNew

Brought to you by

See more new products at manmonthly.com.au

Heavy duty cleaning

Cuts transition time from transport to radial positions.

EXAIR’s new 205 Litre Premium Heavy Duty Dry Vac System is a rugged, industrial duty vacuum cleaner that has been engineered to rapidly vacuum high volumes of dry material. Designed for tough industrial environments, the hardened alloy construction resists premature wear. Because this compressed air powered vacuum has no motors or impellors to clog or wear out, it is ideal for the clean-up of abrasive materials like steel shot, garnet, metal chips, and sand, yet can also be used for general purpose applications. It is extremely quiet at 82 dBA (half the

noise of electric vacs), making it suitable for a wide variety of environments. Surrounding air is kept clean by the 0.1 micron filter bag that traps particles when vacuuming dusty materials. It is covered by a five year warranty. The 205 Litre Premium Heavy Duty Dry Vac System comes complete with a 3m (10’) static resistant hose, 6m (20’) compressed air hose, shutoff valve, pressure gauge, heavy duty aluminium tools, tool holder, drum dolly and a 205 Litre drum. Compressed Air Australia Pty Ltd 1300 787 688 info@caasafety.com.au www.caasafety.com.au

Swing axle telestacker conveyors SuPERIoR Industries, North America’s only combination manufacturer of conveyor systems and their related accessories, says its engineers cut major setup time required to transition a Swing Axle TeleStacker Conveyor from transport to radial positions. The new Swing Axle XTP TeleStacker Conveyor shifts from road to radial mode in just five to ten minutes. That is compared to 45 to 60 minutes for the original model, a design still common to competitive swing axle telescopic conveyors. Three key design features characterise the next generation Swing Axle XTP. First, to engage the stacker’s power travel, chains and sprockets are replaced with a pre-installed t-handle mechanism. While the chain and sprocket arrangement takes up to 30 minutes to install, requires maintenance and can

be tricky to guard, the new power travel system takes just seconds to engage and needs no maintenance or guarding. Secondly, the new axle design requires fewer link arms during both transport and operational modes. This modification again helps to reduce setup time. Lastly, the addition of a pivoting walking beam allows for true wheel alignment during radial travel. Poor alignment results in tire scuffing and can even cause a conveyor’s feed point to shift out of position. First generation Swing Axle models can be retrofitted with the new Swing Axle XTP. The company also builds models for highly portable applications, extreme capacities, highly mobile terminals and applications that require tracked travel capabilities. Superior Industries www.superior-ind.com

Built from stainless steel.

Digital pressure transmitters AuTomATED Control and STS have launched the new DTm digital pressure transmitter. The DTm is a reliable and compact unit with robust stainless steel assembly, incorporating a piezo-resistive measuring element. The DTm is suitable for all pressure ranges between 0 and 30 APRIL 2013 Manufacturers’ Monthly

50 mbar and -1 and 1000 bar, with calibration available for all common pressure units. It is available in gauge, absolute or sealed gauge configurations. Automated Control 03 4964 4022 www.automatedcontrol.com.au

250 litre dry vacuum system.

Electric enclosures coolers VoRTEC Enclosure Coolers have released their latest range of electrical cabinet coolers. According to the company the coolers keep electrical and electronic enclosures cool, clean and protected and are a low cost alternative to expensive, high maintenance air conditioners; and avoid contamination with dirty, humid air caused by fans. Today’s small, compact multifunction electronic controls, variable speed drives, servos and programmable logic controllers are extremely sensitive to heat and contamination. Smaller cabinet sizes make temperature control difficult and prone to premature failures. Excessive heat will cause digital displays to misread, controls to drift, and breakers to trip below rated loads.

The result is productivity lost due to machine or line shutdowns. The new enclosure coolers maintain a slight pressurisation in the cabinet to keep electrical and electronic components clean and dry; and most are thermostatically controlled to maintain enclosure temperatures within a specified temperature range. Vortec offers multiple types of enclosure coolers to meet your enclosure cooling needs, all available in a variety of cooling capacities and ratings (NEmA, IP, HazLoc). Vortec Australian Agent is Knight Pneumatics. Knight Pneumatics 03 95030550 sales@knightpneumatics.com.au www.knightpneumatics.com.au

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What’sNEW Digital multimeters

Continuous motion leak tester.

Pharma leak test lPS (Air logic Power Systems), of Wisconsin USA, , have released a new version of their successful Speed glider high speed linear leak tester, called the Speed-glider 4.5s that has been specifically designed for the pharmaceutical bottle market. The 4 station continuous motion leak tester is capable of rates of up to 250 bottles per minute and incorporates a smaller root diameter timing screw to handle container sizes down to approximately 1.9cm in diameter. The Timing Screw provides positive

AgIlenT Technologies introduces the 34450A 51/2 digit benchtop digital multimeters designed to turbocharge electronic test and measurement applications for industrial and educational use. One of the fastest benchtop digital multimeters in its class, the Agilent 34450A is capable of measuring up to 190 readings per second with 0.015% DCV accuracy. Multiple connectivity options, including USB 2.0, serial interface (RS232) and general-purpose interface bus (gPIB) give users greater flexibility when transferring data to a PC for analysis. Key features of Agilent 34450A

benchtop digital multimeters include its ability to delivers up to 50,000 readings of onboard memory; allowing users to log up to 14 hours of data at one sample per second; a built-in histogram performs basic statistical functions and provides simple data analysis; its dual-display device performs 11 measurement functions; a high-contrast OleD display enables users to easily set up measurement functions using the one-page menu; and it has a built-in code compatibility simplifies migration of existing test programs to the 34450A DMM. Agilent Technologies 1300 845 455 www.agilent.com

container handling and control, in order to ensure high efficiencies and quick/ efficient changeovers at the higher rate demands. The system can be easily mounted to existing continuous conveyor systems, eliminating the need for additional conveyors and bottle transfers. The machine is designed to detect “Short Shot”, Seal surface and other types of seal defects that occur. HBM Plastics & Packaging Technologies 02 8814 3103 www.hbm.com.au

Allows for air cylinder replacement without alterations. Turbocharges electronic tests.

Expanded electrical drive range The demand for integration and the search for solutions in terms of mechanics, electronics and pneumatics have led Metal Work to expand its product range. The result is a range of electric drives with the same overall dimensions as ISO 15552 pneumatic cylinders. This allows replacement of a Pneumatic air cylinder without the need for any mechanical alterations, as an added bonus, all the accessories of traditional cylinders can be used. 32 APRIL 2013 Manufacturers’ Monthly

If the application requires controlled ramping of acceleration and deceleration during the stroke of the cylinder; the ability to accurately stop at any point or points of the stroke with high repeatability; or for higher forces and accuracy than normal pneumatics, then an electric cylinder undoubtedly performs this role much better than conventional Pneumatics. Metal Work Pneumatic www.metalwork.com.au

Tough boots hOWleR has released its latest range of work boots. Designed for tradies and workers in the construction environment, the boots are built to be durable. The new range of howler boots have been built with a double-density shock absorbing sole; double stitching for extra toughness; a wide-fit toecap, and are built to all international safety standards. The boots were launched in March. Howler Boots 08 9209 3322 www.howlerboots.com

manmonthly.com.au

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Brought to you by

Planetary gears

Stops buckling and distortion.

Precise heat control CIGwEld has released its latest family of welders, the Transtig 170Ti and 170pi. welders that work with specialised stainless steel and precise pipework, or those in fabrication workshops or the food and beverage sectors doing intricate TIG work will appreciate the need to have all the safety, power saving and high performance features of the 170i except with the addition of HF High Frequency Start and pulse. That is where the Transtig 170pi has it all. No more buckling. No more distortion. The Transtig 170pi gives operators a

precise heat control when it is needed most – on those more intricate welds. It’s a pulse TIG type machine, which reduces distortion and improves penetration. So operators get a better mix of metals and a much cleaner finish after welding. And with high frequency you’ll get a more positive arc start at a lower amperage setting – one that starts first time. Cigweld 1300 654 674 www.cigweld.com

ApplIEd Motion products has released its new pG series of inexpensive planetary gears. Custom designed for use with its new line of brushless dC motors, the first model is available in 42 mm diameter with as many as three gear stages and a wide variety of reduction ratios ranging from 3.65:1 to 393:1. For brushless DC motors. See the website for stocked standard ratios. output torques Input and output are co-axial and the ratings range from 3.0 to 15 N-m (425 to shafts turn in the same direction. 2100 oz-in). The new gearheads are suitable planetary gear design offers higher for clockwise and counter clockwise speed, load and efficiency combined with rotation, for alternating, continuous and low backlash in a compact cyclic operation. Unlike other gear types, package when compared with spur their compact design provides ultimate gears. power density and excellent torque our cost effective offering makes these transfer in the smallest space. theAfirst D _choice M A NforMyour R E most C A Pdemanding R_ 1 3 1 2 0 1 3 - 0 3 - 1 1Applied Motion T 1 8 : 3 8 : 4 3 + 1 1 : 0 applications. www.applied-motion.com

SAFETY CORDONS

MADE EASY.

Worm gear units Nord drivesystems now offers a new range of worm gear units in a robust, one-piece UNICASE housing in five sizes with a maximum torque of 427 Nm. The new, larger output bearings allow users to choose increased shaft diameters than the previously available series. In addition, the large bearings ensure a much extended service life. An aluminum permanent mould casting process was optimised for the SMI series, resulting in an especially smooth surface that prevents dirt build-up. Closed SMI worm gear versions are washdown-capable, and can therefore be easily cleaned along with other systems during plant cleaning processes. manmonthly.com.au

• Spring retractable • Fitted with 15m of safety barrier chain or webbing • Australian made quality ... and thousands more reels for any workplace hose, cord or cable handling g appliation. pp Max torque of 427Nm. Nord Drivesystems 03 9394 0500 www.nord.com

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Manufacturers’ Monthly APRIL 2013 33

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EndeavourAWARDS Environmental Solution – 2013 Finalists

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Greener manufacturing practices PTRONIK pMC Master Control PTronik has been recognised for its unique factory dust management system with anomination for the Environment Solution of the Year award. Ptronik’s pMC Master Control was the answer for Impact Fertilisers’ manufacturing plant to retrofit upgrade its dust collector to achieve a high level of “Environmental performance standards and safety” and to “employ innovation for the pursuit of excellence”. Ptronik’s pMC Master Control employs innovative engineering principles to automate the cleaning process by continuously monitoring plant performance, collecting and diagnosing the performance data, and automatically triggering ‘pulse’ cleaning to suit pre-defined criteria. The PTronik pMC is a selfcontained process controller for industrial dust collectors that continuously monitors the condition of a dust collector filters and automatically controls and manages the filter cleaning process. The installation of the pMC had significant affect on Impact Fertilisers operations via reductions in energy use, improvement in OH&S outcomes with air quality with trend data logging and diagnosis, savings in operational filter bag consumerable costs, optimised plant operating efficiencies by reducing plant downtime. BALTIMORE AIRCOIL Baltimore Aircoil is a worldwide manufacturer of evaporative heat transfer and ice thermal storage products that conserve resources and respect the environment, and is a now a nominee of the Environmental Solution of the Year award. Within its own Somersby facility it has made a number of changes to become more sustainable. Electricity - Scope 2 carbon emissions. Annual usage was reduced, with a saving of 66,320 kwh which equates to 11 per cent. Key changes included changing lights within factory and office, new compressor, and reducing two brake presses to one brake press. Gas – Scope 1 carbon emissions. Air conditioning adjustments saw a 30.5 per cent reduction in Gigajoule usage when comparing a five month period Aug-Dec 2011 34 APRIL 2013 Manufacturers’ Monthly

Waste Management Program. Employees are encouraged to improve all methods of waste disposal at BAC. Major changes have occurred in the way waste was treated. Recycling for the past 12 months: waste steel: 144.09 tonnes (up 0.41 tonne). Wood 59.91 tonnes: increased 4.86 tonne. PVC Sheeting : started Jan 2013, with an estimated ten tonnes being sent to China. Paper: 1.825 tonnes of A4 ream paper (up 0.31 tonne). Canteen waste - Recycling bin introduced August 2011 to collect all recyclables. This equates to a 240 litre bin full each week. BAC has gone as far as designing a whole new line of heat rejection equipment that doesn’t require chemical water treatment. This equipment, known as the 3C Cooler, can reject heat from a process (similar to a closed circuit cooling tower) while using up to 80 per cent less water and without requiring chemical dosing which would inevitably end up in sewerage. WRIGHTWAY PRODUCTS Wrightway Bin Wrightway is a Lismore, NSW-based family business established in 1996, involved in manufacture of a range of Lid Lifta foot pedals for waste bins, the wrightway2MT bin tipper, and new related products such as the Wrightway Bin. The bin maintains the integrity of the bin (no holes), eliminates the health risks and damage from dragging, and lessens the likelihood of strain or back injuries caused by the use of standard wheelie-bins within industrial situations. The Wrightway Bin facilitates the operator being able to slide the bin forward when it is located with its rear wheels against a wall rather than dragging the bin and

its contents forward by fingertips. The underside of the bin lip is host to insects and bacteria and dragging damages the base of the bin, especially on non-slip flooring, resulting in the recurring expense of replacement bins. The Wrightway Bin allows the bin to be manoeuvred without effort (even in tight spaces), allows smaller stature operators to complete tasks without risking their wellbeing, and eliminates damage (and replacement expense) caused by dragging bins over non-slip flooring, without compromising the integrity of the bin itself. The bin is raised above ground level and as it never has to be dragged at any stage of relocation, worn-through bases are prevented. CST WASTEWATER SOLUTIONS Bathurst Council water recycling system CST Wastewater Solutions formed more than 20 years ago to supply the industrial and municipal wastewater markets. Bathurst Regional Council has introduced a supernatant recycling system into the filtration plant in the town water supply, helping to conserve potable water and providing substantial water savings over the long term. A Berson UV disinfection system, supplied by CST Wastewater Solutions, was fitted between the pumping station and the rapid mix tank to disinfect the recycled water from the sludge lagoons before returning it to the rapid mix tank. The system fully disinfects up to a flow rate of 60 L/s and has a variable power control to enable the UV dosage to be adjustable to suit operating conditions. Bathurst council’s recycling system, installed by Ted Wilson & Sons using equipment supplied by CST Wastewater Solutions, recovers and disinfects the filter backwash water at the plant. Disinfection of backwash supernatant – clear liquid that collects above sediment – is not widely used in Australia, but can recover up to 10 per cent of raw water supply while avoiding the need for discharge flows into river systems. CST’s technology has a huge environmental benefit and the technology is available nationally. The filter backwash water is discharged into the system’s three sludge lagoons, along with sludge from the sedimentation tank. The overall water to be saved is estimated to be 13,000 ML over 50 years. manmonthly.com.au

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0413 - FP - MM - Atlas Copco.pdf 1 13/03/2013 3:25:05 PM

Atlas Copco Compressors - 140 years old and still your number one environmental partner

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For six years, Atlas Copco has been named one of the world’s most sustainable companies. In addition to social indicators, companies were measured against an objective ‘sustainable path’ standard for energy, carbon, water and waste ratios. We are proud to be the major sponsor for the Environmental Solution of the Year award and wish all the finalists the best of luck! Atlas Copco Compressors Australia 1800 023 469 ausairinfo@au.atlascopco.com www.atlascopco.com.au

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EndeavourAWARDS Australian Steel Innovation – 2013 Finalists

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Australian made, Australian innovation Profile Cutting SyStemS Profile Cutting Systems has been nominated for the Australian Steel Innovation award for the development of an Australian first profile cutter made entirely from Australian steel. The company’s 7500 BHP is essentially a very large profile cutting machine with a large drill on it. Profile Cutting Systems explained that on traditional plasma cutters such as X-Y CNC machines are able to cut steel plates, this latest development is the next level in cutting as it is basically an entire machining centre on ensconced on a single machine “so instead of only being able to cut a hole you can actually now cut and drill a hole for a perfect hole”. This overcomes many of the problems facing large end fabricators such as BHP, where they are specifying that whatever holes they need made have to drilled not cut, as cutting causes a slight taper which can causes shearing on bolt holes down the line. On top of this you can drill a hole faster than you can cut it, so you aren’t losing any production time. PCS added that the plasma can also bevel as well, “so you can cut on angle to provide 3d cutting”. While machines there are several manufacturers of these types of equipment, and profile cutting machines being imported, it is first time that it has been fabricated and manufactured in Australia. PCS added that “other makes and models been made in oz, but not in same league as this, as it is more powerful”. The machining centre has 60 hp main spindle on it, can provide oxy fuel cuts, drill, and also has a 24 tool carousel on it, as well as a large range of drill sizes. modular Wall SyStemS Australian security, boundary, and acoustic wall manufacturer Modular Wall Systems has been nominated for Australian Steel Innovation for the development of Quikwall, the world’s first moveable, height extendable temporary walling solution. Modular Wall Systems purchases all steel required for manufacture from OneSteel and BlueScope Australia. QuikWall’s’ innovative integration of a winch system with the wall design allows for the extension in height that characterises QuikWall. QuikWall components are manufactured out of Australian steel. They are designed, laser cut and tested to precise 36 APRIL 2013 Manufacturers’ Monthly

designs and far exceed typical warranties. The design enhances costefficiencies in the production of coal, of which Australia produces more than 500 million tons a year and is the world’s largest exporter by proportion of production. Exports alone earn more than $50 billion a year. The company’s low-height transfer chute features a conical head developed by mining specialist designers to maintain high volume high flow rates when The machine is the first of its conveyors change direction either kind to be built in Australia. underground or on the surface. “The design more than covers standards. Used by Australia’s leading mining what we do. It’s a robust simple design that’s and construction companies, QuikWall pretty wear resistant and easy to adjust for represents Modular Wall System’s innovative our operations, which involve about 1200 tons and creative spirit and ability to respond and hour with throughput containing lumps to an identified customer need. Through up to 300-400mm,” the company said. extensive research and development and in T.W. Woods’ tough hardened steel design – consultation with major mining companies, built to easily outlast conventional types and Modular Wall Systems developed the first incorporating large quantities of Australian free standing, relocatable, lightweight and steel – is based on the group’s experience of height adjustable temporary noise wall more than 40 years in constructing plant for in the world: QuikWall. The wall’s height mining, energy, construction and materials can be extended and lowered, offering the handling plant throughout Australia. ultimate flexible solution to deal with all climatic conditions (a fixed height, 4 meter metSo high wall for example, might get damaged or Metso has been nominated for the Australian blown over in high wind regions. Using the Steel Innovation Award for the creation of innovative winch assembly, QuikWall can massive train unloaders using Australian easily be extended from a resting height of steel. The unloaders, which are used by 2.6 meter to its maximum 4.4 meter height in Fotescue Metals Group and Rio Tinto less than a minute. subsidiary Hammersely Iron to unload its ore trains at Cape Lambert and Port Hedland, t.W. WoodS were initially installed in 2010. T.W. Woods innovative Australian made Already recognised by the Australian Steel coal chutes have been recognised for the Institute, winning the Engineering Projects Australian Steel Innovation award. Steel Design Award, the single tandem car The chutes are smooth flowing low-height dumpers were built in conjunction with transfer chute are built to overcome space, CIMVEC, in Henderson Western Australia. spillage and conveyor bulking problems The cars weigh in excess of 350 tonnes and common in coal mining and coal handling are designed to off-load two train wagons per facilities. All of the material used in operation. The project involves around 400 production of the chutes is Australian. tonnes of Australian AS/NZS 3678/9 Grade The chromium carbide material used in 250-300 steel plate ranging from 8mm through construction is either a Bradken Product to 250mm thickness.Due to the high fatigue (Duaplate) or the Arcoplate is made by cycle of the structure Metso specified welding Alloysteels. to the Australia standard code AS1554 part 5 Both are manufactured in Western code for high fatigue structures. Australia. The design has already been Special welding techniques were developed proven service with some of Australia’s to cater for the design’s specifications, and leading coal producers. A bonus of the design a large purpose built gas fired furnace was also is that it has been quality engineered in erected on site by CIMVEC to carry out T.W. Woods’ own extensive metal working post-weld heat treatment of the completed facilities to easily outlast conventional structure prior to machining. manmonthly.com.au

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EndeavourAWARDS Significant Achievement – 2013 Finalists

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Better business planning AW Bell In 2009, AW Bell undertook a thorough business review with their Enterprise Connect business advisor, Steven Lakotij. This resulted in a new strategic direction for the business: expanding into the aerospace export market. AW Bell recognised the need for high calibre expertise and equipment to improve their investment casting process. With support from Enterprise Connect’s Researchers in Business program, CSIRO’s Small and Medium Enterprise Engagement Centre facilitated the placement of CSIRO’s Materials expert, Dr Roger Lumley, into A.W. Bell’s business to develop this process. Three years after embarking on their new direction, the company is now transforming their research and development into a fully-fledged production system, with a $1.5 million Early Commercialisation grant from Commercialisation Australia. longWArry Food PArk The company has achieved a number of significant goals following the Enterprise Connect business plan implementation. It has seen a significant turnover increase, from $42 million in 2009-10 to $90 million in 2010-11. Milk supply increased from 58 ML to 155 ML, and the company has launched two new products. Since Enterprise Connect’s assistance Longwarry has increased its domestic market significantly, while at the same time reduced its energy consumption by 10 per cent and water consumption by 15 per cent. It has also increased the number of employees from 20 to 52. TuFF TonneAus Tuff Tonneaus (TT) completed their original Enterprise Connect business review in early 2010. At that stage, the Managing Director of TT, Nick Arthur had recognised that Continuous Improvement was an imperative for them to compete against international competition. Arthur adopted the recommendations of this original review by appointing a General Manager, Guy Bulmer, it then developed new markets by focusing effort into the OEM sector, developed new relationship with automotive manufacturers and importers. It has also focused on continuous improvement around standardised 38 APRIL 2013 Manufacturers’ Monthly

were undertaken by Integra with its internal resources and Tailored Advisory Services (TAS). These included re-locating to larger premises to ensure improved resource, time and cost efficiencies and improve office layout and privacy. Integra also carried out Activity Based Costing and improve management accounting practices, that was undertaken throughout 2011 by using TAS and provided us with an excellent platform to implement an ERP system in 2013, as well as complete a 5 year Strategic business plan.

processes and the engagement of all staff so that all employees are empowered to deliver improvements in the business. TT has recently completed the first round of their CIP engagement with Enterprise Connect and their BusEx and ManEx scores of 413 and 545 respectively place TT in the top quartile of all firms participating the in Enterprise Connect CIP program. JArius Jairus Pty Ltd, trading as www.tinyme.com.au completed their original Enterprise Connect business review in late 2009. At that stage, the Director of Jairus, Nick McLennan and Mike Wilson had recognised that Continuous Improvement was an imperative for them to compete to grow the international presence McLennan and Wilson enthusiastically adopted the recommendations of this original review by appointing an Operations Director, Ben Hare; expanding into new markets, primarily the US, with a US focused website, to offset the seasonality of Australian sales; completed a skills audit and an organisational redesign to enable increased customer focus by all employees; and focused in continuous improvement around standardised processes and engagement of all staff so that all employees are empowered to deliver improvements in the business. Jairus completed the first round of their CIP engagement with Enterprise Connect in early 2012 and are due to re-engage for the second round over the coming months. inTegrA In 2009, it undertook our first Enterprise Connect business review. The recommendations Paul Smarrelli laid out

Zonge enTerPrises In response to the business review conducted in 2009 Zonge undertook and completed a number of significant projects which strengthened and advanced our company. These projects included strategic planning and business, which included the integration of KPI’s to management meetings, project teams identifying waste, and succession planning; safety accreditation, with AS4801 OHSAS 18001 changing the safety culture within the company and along with assisting it to work in a safer environment we have been able to create new systems to improve work flow within the business. BAlTimore Aircoil A business review was undertaken 2010, by Business Advisor Trevor Stuart. Recommendations were to improve Lean Manufacturing and to develop BAC’s Australian Website, which ended up gong “live” late 2012; for a CIP (Continuous Improvement Program) BAC has been awarded the opportunity to further improve its processes. This Program is currently being evaluated, with commencement late 2013; and the creation of Vision Blue - which is a document that has been created to outline BAC’s goal to become Carbon Neutral by the year 2020. Through these programs Baltimore Aircoil has identified KPIs which assist it to understand where it can make efficiency gains with the resources that the company has, whether it is raw materials, waste products, or utilities such as electricity. Through working with Facilitator Katherine Foster, it has managed to source a company who is able to recycle an estimated 10 ton of PVC material. manmonthly.com.au

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2013-03-11T18:49:07+11:00

MM0413_040.pdf

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EndeavourAWARDS Industrial Product of the Year – 2013 Finalists

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Industry and innovation Coolon DLK Industrial LED Luminaire Coolon, has been nominated for the Industrial Product of the Year award for an industrial LED luminaire set to tackle all of the challenges of the existing industrial conveyor lighting. The DLK is specifically designed to be used along a conveyor system in industrial applications. Its features include an ability to withstand severe vibrations for a longer lifespan than any conventional alternative and has a lifespan over 50,000 hours. The unibody design is lightweight and versatile, able to fit industry standard spigot mount installations. Solar one Solar One project The SolarOne project was created from requests from a number of mining companies. It is a solar powered roadside device that can be used in mines in such a manner that an array, placed along side the haulage roads, could provide a delineated driving area as well as warn of hazards, corners, dips, etc. The lights are visible from the cabin of a large haulage truck, and be able to be seen from a distance of at least 500 metres, 100 per cent reliable, and turn on at dusk and off at dawn. TThey are also able to withstand the impact of heavy vehicles and machinery. enerpaC XC Series cordless pumps The XC-Series cordless pumps deliver oil flow of 2.05 litres (125 cubic inches) per minute at its low-pressure setting and .25 litres (15 cubic inches) per minute when operating at full pressure, up to 700bar (10,000 psi). The main innovation with the range of XC pumps is their cordlessness. It eliminates the dangerous trip hazards associated with conventional pumps. The lithium-ion battery ensures that users are provided with the battery runtime necessary to accommodate demanding application requirements. Modular Wall SySteMS ThermaPax Panel In direct response to the requirements of the APLNG Upstream project (Origin Energy and T1 builder Laing O’Rourke), Modular developed the ThermaMax Panel to provide a modular thermal heat control solution that was not previously available. ThermaMax Panel provides an innovative, one-step 40 APRIL 2013 Manufacturers’ Monthly

modular insulation solution which represents a major improvement on traditional, multistep installations. Comprised of an internal glasswool core, strengthened with 4.5mm fibre cement external skins with rigid lateral capping, ThermaMax is lightweight, rigid, easy to install and transport using existing skill and machinery. Seeley InternatIonal pty ltd Braemar non-condensing five star gas heating range In 2012, Braemar launched the world’s first and only non-condensing five star ducted gas heating range, which delivers a five star rating without producing condensate The five star non-condensing ducted gas heating range enables the traditional five star unit, which consists of three sections, to be reduced down to two, due to removal of the section where the condensate was produced and drained. The result is a five star unit which is one third smaller. The heating range is smaller, meaning a simpler and more costeffective installation, and is the same size as the popular three and four star series. t.W WoodS Group Compact transfer chute The company’s low-height transfer chute features a conical head developed by mining specialist designers to maintain high volume high flow rates (up to 2000 tons an hour) when conveyors change direction either underground or on the surface. The compact design can be fitted into lower overall heights than conventional designs, operating with a separation distance between belts of 1200-1500mm; and the chutes’ conical head is configured to provide a smooth transition through the turn for coal moving at typically 3m a second and dropping up to 1500mm onto a belt below. WrIGhtWay produCtS Wrightway Bin The Wrightway Bin allows the bin to be manoeuvred without effort (even in tight spaces), allows smaller stature operators to complete tasks without risking their wellbeing, and eliminates damage (and replacement expense) caused by dragging bins over non-slip flooring, without compromising the integrity of the bin itself. The bin is raised above ground level and as it never has to be dragged at any stage of relocation, worn-through bases are prevented. The addition of two small wheels under the

front of the bin makes the standard wheeliebin more manoeuvrable in tight spaces, protects the base of the bin, and eliminates the need for the operator to carry the weight of the contents and the bin. profIle CuttInG SySteMS 7500 BHP Profile Cutter Profile Cutting Systems has been nominated for the Australian Industrial Product of the Year award for the development of an Australian first profile cutter made entirely from Australian steel. The company’s 7500 BHP is essentially a very large profile cutting machine with a large drill on it. Profile Cutting Systems explained that on traditional plasma cutters such as X-Y CNC machines are able to cut steel plates, this latest development is the next level in cutting as it is basically an entire machining centre on ensconced on a single machine “so instead of only being able to cut a hole you can actually now cut and drill a hole for a perfect hole”. ptronIk pMC Master Control The PTronik pMC is a self-contained process controller for industrial dust collectors that continuously monitors the condition of a dust collector filters and automatically controls and manages the filter cleaning process. The installation of the pMC had significant impact on Impact Fertilisers operations via reductions in energy use, improvement in OH&S outcomes with air quality with trend data logging and diagnosis, savings in operational filter‐bag consumerable costs, optimised plant operating efficiencies by reducing plant downtime. rpC teChnoloGIeS Carbon Vent Tubes This line of product includes straight duct and standard fittings (such as elbows, branches, valves), but other custom fittings and add-ons can be supplied as well. The range is not set, it is forever evolving with the customers’ needs and requirements. The key features of the Carbon mine vent duct are light weight, strength to handle a high collapsible pressure, and Fire Retardant and Anti-Static (or FRAS) properties. The strength of the duct is critical to its performance, as it is used to extract coal dust and methane from the coal front, the ducts need to withstand the vacuum pressure required to carry out this function. manmonthly.com.au

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2013-03-11T18:42:52+11:00

Supporting innovation & success BOC is the proud sponsor of the Australian Industrial Product of the Year category in the 2013 Manufacturers’ Monthly Endeavour Awards. It is fitting that we are supporting the category which

BOC wishes all finalists the very best of luck in the tenth

recognises innovation in new industrial products, as it is

annual Manufacturers’ Monthly Endeavour Awards and

something that is very close to our hearts at BOC and an

encourages all businesses, big and small, to strive for

important hallmark of our own business.

continuous improvement with commitment, courage and creativity.

At BOC we aim to be admired for our people, who provide innovative and sustainable solutions that make a difference

For more information on BOC, visit stand 2717 at

to the world. These awards reflect and promote the same

National Manufacturing Week.

kind of spirit, and we acknowledge the terrific efforts of all entrants who share our passion to excel. BOC Limited Riverside Corporate Park, 10 Julius Avenue, North Ryde, NSW 2113 Australia contact@boc.com

MP12-0873-2 | 0313 | SG

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EndeavourAWARDS Exporter of the Year – 2013 Finalists

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Manufacturing’s international success Vulcanite Vulcanite’s experience, expertise and evolving technology in the supply of specialist components has seen it nominated for the Exporter of the Year award. The company’s main strategies in this growing market is where Vulcanite has built lasting relationships with end users by offering complete solutions from design to delivery. Strategic alliances with transit operators include several points of contact within an end user’s organisation and can involve number of different departments such as engineering and procurement. Vulcanite sees this industry as having the most revenue potential as well as the fastest growing sector for our products. anca With 98 per cent of all ANCA products exported, which makes ANCA predominantly export an company, it has naturally been nominated for the Exporter of the Year award. Its newly expanded MX range of tool grinders meets the evolving needs of the market and provides an outstanding alternative to competitor products. The MX5 is a recent release but so far orders are indicating increased sales for the MX range. Extra employees were required to manufacture components of the MX5. The MX7 is also experiencing strong sales growth, selling 26 (FY09/10), 58 (FY10/11) then 102 (FY11/12) in the last few financial years. Revenue from the MX7 has increased from $9.3million, to $19.9million, and then $36.6million in FY11/12. The MX5 has already achieved orders of 42 since it was launched July 2012. 23 of these orders have been delivered. Due to new more stringent CE regulations a specific CE Compliant model of the MX5 was required for sales into Europe. lindsay Pie Making equiPMent Lindsay Pie Making Equipment (LPME) has been nominated for the Exporter of the Year award. The company attributes its success to dedication and a constantly changing market, providing solutions and innovative equipment, responding to market trends, supporting the industry initiatives such as the OGAPC, IDDBA, APC and the NBIA providing exemplary service. In the past 18 months it has exported to the USA, UK, Denmark, Singapore, Botswana, PNG, Canada, Holland, Costa Rica, Switzerland, South Korea, Malaysia and NZ. Export sales are two thirds of its sales. 42 APRIL 2013 Manufacturers’ Monthly

LPME constantly reinvents the process of manufacturing, reducing the number of suppliers, increasing internal capability. JIT manufacturing enables better delivery times, reduces unnecessary financial burdens, keeps running costs lean and the labour force constant,using suppliers that have advanced manufacturing or global products. cook Medical In the past 12 months, Cook Medical became the largest privately owned medical device manufacturer in the world and a nominee for the Exporter of the Year award. This would not have been possible without the Asia Pacific region’s contribution: the region was responsible for 20.4 per cent of global sales in 2012 which is an increase of 3 per cent on 2011. Revenue in 2012 was US$389 million, an increase of 27.6 per cent from 2011. The total Australian manufactured product sales was $82 million – $72.5 million of this was exported, which equates to 88.4 per cent of Australian manufactured product exported. In the Asia Pacific region, Cook Medical employees numbered 1050 people, which is an increase of 17.8 per cent since 2012. Cook Medical Australia is an Australian R&D manufacturing company that has continually grown amidst the global recession. As an exporter, Cook Medical Australia believes that for it to be successful in our region it must embrace the local business culture of each particular market. It is this reason why it has a presence in all of the countries it deals with.

B&s kitchens B&S Kitchens is a fully owned Australia company that manufactures both industrial and commercial kitchens and has been nominated for the Exporter of the Year award. In the last few years it has entered the export market, and has shipped to Asia Pacific and the Middle East with plans to expand growth in these regions on the back of increasing demand. B&S operates by first manufacturing the kitchen units as a whole in-country, and then shipping the fully constructed commercial and industrial kitchens, already fully assembled and crated up. The manufacturer has been exporting in this manner for more than a decade and is eyeing further growth in this capacity, with Australian made goods perceived favorably overseas. longwarry Food Park Growth driven both by Australian and overseas has seen Longwarry Food Park nominated for the Exporter of the Year award.Its innovative approach and strategies to promote its brand have increased sales by 60 per cent. It has actively used Austrade and Victorian Government offices resources in various markets, participation in government sponsored overseas delegations. It has also played host to overseas Government delegations, actively participated in overseas trade fairs Longwarry’s export success has mainly been due to its product quality and R & D ability to tailor a product to suit customer needs. The reliability of its supply and logistics chain and launch new products have also aided in its international growth. manmonthly.com.au

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WEâ&#x20AC;&#x2122;RE WITH YOU FOR THE LONG HAUL.

Championing innovation in Australian manufacturing. At EFIC, we have been backing Australian exporters for more than 50 years and the export category of the Endeavour Awards since their inception 10 years ago. Weâ&#x20AC;&#x2122;re proud to be a sponsor and to support excellence and innovation in Australian manufacturing.

Overcoming financial barriers for exporters. Visit efic.gov.au/awards

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EndeavourAWARDS Lifetime Achievement – 2013 Finalists

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Making a difference in manufacturing PAUL SMITH Managing director, Soy Products Paul Smith has been managing director of Soy Products (Sales) Pty Ltd since 1991, having joined the company in 1980. Though he studied architecture and landscape design after finishing school, he has been intimately involved with soy since the 1970s, in Australia and internationally as a processing consultant, and, after completing an MBA at Melbourne University in 1989, as the chief of SPS. Smith has been involved with upgrading and refining bulk soybean unloading, cleaning, enhancing processes and milling at the Bayswater-based company, whose main business is in soy health foods but also processes amaranth, buckwheat, chickpeas, lentils, polenta, brown rice, doongarra rice and white rice. Smith completed a review of the company’s roots, background, corporate philosophy and strategic direction, and, as well as improving the operations of the plant, re-though and re-aligned SPS (which dates back to 1932) with its original themes and corporate philosophy as a maker of unrefined products, moving it in a gluten-free direction well before this became fashionable. It was to take nearly a decade to totally phase out gluten from the facility and product range. In 2003 the company also embraced and has continuously maintained HACCP, Kosher, Halal and Organic Processor Certification. Smith’s company has also chased export markets and have sought to compete with cheap Indian and Chinese products through further innovations in product quality, product functionality and processing efficiency. He was recently appointed to the board of Soy Australia. RUSSELL HUGHES Engineering director, Integra Systems With 35 years of engineering, innovative product development and senior management experience, Hughes joined his son Paul at Integra Tooling Systems (now Integra Systems) in 1993 as joint director to develop his dream of harnessing innovation to develop engineering solutions for Australian industry. Hughes began his career in 1957 as an apprentice at the Maribyrnong Ordnance Factory. From here, Hughes moved to Caterpillar’s Tractor Factory where engineering design became his specialty. He later became an engineering & design contractor for companies such as Ericsson, International Harvester, Ford, Zenford and General Motors Holden. 44 APRIL 2013 Manufacturers’ Monthly

He has worked as senior engineer for Sidchrome, general manager and then managing director at Rymer Lighting and manufacturing and engineering director at Howard Smith Industries. At Integra, he developed the world’s first high speed coil processing line (Punch-IT Coil Processing) with son Paul, which was ultimately built as Integra’s first production machine. The processing line that would rival the steel punching competition by punching steel components at a rate that would ensure components less that 300mm wide were produced economically. Between 1993 and 1998, Integra brought Hughes’ idea to fruition and he and son Paul designed and built these machines, the “Punch-IT Coil Processing Line”, a 5-axis system consisting of an electronic feed system and a series of 4 punching stations suitable for most linear punching applications. Punching at a rate of 120 strokes per minute, coil is consumed and converted to finished parts at 20 linear metres per minute. The Punch-IT line was so advanced that the University of Melbourne’s Engineering Professor, Colin Burvile, presented a paper on the machine at the International Conference of Engineering Design (ICED). Hughes’ contribution to engineering design and development is highly regarded by the University of Melbourne and he is a member of the university’s Engineering Design Group. At 72 years of age, Hughes continues to strive for excellence in innovation for Integra and its customers and shows no sign of slowing down.

RICHARD HAMMOND Owner and director, Astor Metal Finishes After positions as General Manager at Clark Australia (a manufacturer of sinks and other kitchen products) and Irwell Bathroom Products, Richard Hammond bought Astor. Hammond has managed Astor since 1991 and has grown the business from 20 to 50 staff. Astor was established in 1954 in a small factory in Balmain and has since that time been known for excellence in electroplated architectural finishes. Before coming to Astor Hammond’s background included general manager of both Clark Sinks and Irwell/Fowler bathroom products, and studied Metallurgy (finishing with honours) at University of NSW. The first capital works at Astor to be done were in facility upgrades, streamlining production processes, custom designed administration system and very significant upgrades to environmental and waste controls. The combined expertise of three amalgamated business over the years brings together electroplating onto metals including aluminium, stainless for architectural, marine, industrial, medical, automotive industries as well as the chrome plating of alloy truck and bus wheel which is unique to Astor. As a result of years of R&D Astor are both the leader in environmental systems for their industry and the only Australian manufacturer to chrome plate alloy truck and coach wheels which are in place for exporting. As company owner and director, Hammond has invested heavily in R&D and environmental systems. The company now recycles 90% of its water in-house and has solar panels covering half the 4000 square-metre factory roof. manmonthly.com.au

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2013-03-11T18:25:04+11:00

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The new ifm gateways are the fast connection from AS-i to EtherNet /IP, Profibus or Profinet. Thanks to a colour display and web interface, the status of all AS-i slaves is recognizable at a single glance. The quick set-up menu and intuitive handling facilitate installation and diagnosis. Further, the web interface allows full remote access.

The OG cube wetline photoelectric sensors combine high optical performance in a robust stainless steel housing. The industry standard M18 cube design has IP69K rating and a superior sealing concept to ensure it will survive in the harshest wash down conditions.

Default setting at the factory makes adjustment to the medium unnecessary. Hygienic design with maintenance-free sealing concept. Robust stainless steel housing. Resistant to foam and deposits. Orientationindependent installation.

Safety monitor monitors transmitted code sequences in an AS-i network. In the case of message deviations or timeouts it ensures the safe state of the system. The safety-related extension is fully downward compatible and can be retrofitted on existing installations.

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EndeavourAWARDS Global Integration – 2013 Finalists

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Australia and the world Downer rail environments and cultures. This in The primary international partner for turn assists in maintaining strong local the Waratah Train Project is CRC, relationships and paves the way for the who partially manufactures the train’s development new products and business carriages. Other parts of the train have opportunities. Import replacement been sourced from partners in Germany, activity provided an export capability Czech Republic, Austria, Finland, South that accounts for almost 50% of turnover. Korea, Switzerland and more. The decision to use global suppliers was leussink engineering not made based on price, but rather Leussink Engineering has been throughputs: the NSW Government nominated for the Global Integration contract terms meant that no Australian award. It has been nominated for its work facility could produce trains at the with German bearings specialist Corts, speed required.It focused on improving Vulcanite where it sent six of its specialists from interactions with its other global suppliers, Vulcnite has been nominated for the Global Unanderra, NSW, to various locations in and reducing logistical inefficiencies such Integration award for using its global success Kazakhstan to machine six rolling mill stands as preventable delivery delays, faults and to build its reputation and markets locally. for ArcelorMittal. breakages. It achieved this by building Although small compared to others in The process combined the expertise of the right internal supply chain team and global markets, the company has an enviable Corts-Leussink, surveyors, on-site machine travelling to suppliers to build face-to-face reputation for quality, innovation and service operators and mechanical engineers to collect relationships based on partnerships rather in export markets in Asia, North America and the relevant data and modify the current than simply supply and demand. Downer Rail Europe. Export success allowed Vulcanite to status back to OEM specification. will continue to work with CRC until 2014 to remain competitive at a local level. Leussink’s technical staff took a holistic complete the delivery of the Waratah Train The export environment also makes a approach that included a thorough lasertodwork of all components, including M M 3 1 2 Project, 3 _ H PandS will U Mseek M I Topportunities _ 2 0 1 3 . p f P a gsignificant e 1 8contribution / 0 3 / 1 3 to , the 3 company’s : 5 0 : 4 3 P Mbased A E survey DT with CRC on future rail projects. pool of industry knowledge in a range of their current structural integrity.

SUPPORTING THE FUTURE OF AUSTRALIAN MANUFACTURERS Our second annual “Manufacturers’ Monthly Leaders’ Summit” will bring policy makers, industry leaders and other stakeholders together to discuss important issues affecting the performance and future of Manufacturing. This year we’ll be tackling the subject of, “How Australian manufacturers can benefit from the Asian Century.” The findings and discussions will be presented in the August edition of Manufacturers’ Monthly. If you are interested in participating, please contact our editor, Cole Latimer (E: cole.latimer@reedbusiness.com.au, Ph: (+61)2 9422 2352). PROUDLY SPONSORED BY:

Date: Wednesday the 8th of May Location: National Manufacturing Week 2013, Melbourne Convention and Exhibition Centre

46 APRIL 2013 Manufacturers’ Monthly

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EndeavourAWARDS Safety Scheme of the Year – 2013 Finalists

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Safer, sustainable manufacturing CONFOIL Return To Work program Confoil has been nominated for the Safety Scheme of the Year award for its consultative return to work program. In 2009 Confoil started to implement a new holistic, consultative Return to Work Program, involving a dedicated RTW Coordinator (who is also an accredited Workplace Assessor). Recognising the high number of mature aged workers (in 2012 one employee received their 35 year Service Award) Confoil decided to include personal injuries as well as work-related injuries in its policy, demonstrating the company’s commitment to its employees’ total welfare. Confoil’s RTW program involves the supervisor, employee, doctor, physio etc and the RTW Coordinator working as a team with the common goal to deliver suitable and ongoing medical and personal support to an injured worker to provide an effective return to work program. DIAGEO AUSTRALIA Line 4 Safety Upgrade For increasing machine safety on its bottling lines, Diageo Australia has been nomianted for the Safety Scheme of the Year award. A routine risk assessment identified that a number of the bottling lines at the Huntingwood plant required upgrading from a machine safety perspective. Diageo undertook a safety upgrade project for two of its bottling lines with a view to creating a global best practice blueprint which could not only be rolled out throughout in Australia and globally. The assessment identified the safe control system to monitor the safety aspects of the bottling line was required to satisfy Category 4 of (AS 4024.1-2006, Australia’s safety of machinery standard). A set of safety concepts were developed to share with the various stakeholders from operators, engineers through to the maintainers and managers to ensure various personnel had sufficient input. Diageo selected a state-of-the-art distributed programmable safety control system which contained almost 800 safe I/O spread across 13 remote processing head modules distributed across the plant. The system was then designed and implemented by a third party safety contractor (Brolton 48 APRIL 2013 Manufacturers’ Monthly

Engineering Group) to Diageo’s standards. The project took 12 months to commission/ validate. Diageo’s Huntingwood bottling lines facility saw a dramatic improvement on the old system. KONECRANES Ertech Wangara maintenance facility Konecranes has been nominated for the Safety Scheme of the Year award for ensuring safer lifting within a factory. New overhead cranes are being deployed by civil contractor Ertech in their recently completed equipment maintenance facility to service about 170 items of major plant, including scrapers, excavators, loaders and bulldozers. A 5-tonne and 10-tonne crane have been installed at Ertech’s headquarters in Wangara, Western Australia. Konecranes Australia-New Zealand business recently received the Group’s top global safety award for outstanding performance among Group operations spanning nearly 50 countries and more than 12,000 employees, all of whom are trained to operate in accordance with the Group’s global safety signature, “Hooked on Safety”. Radio remotes mean safety for operators, who can stand well away from the loads being lifted and shifted. The remotes also give freedom of movement, ensuring the operators can choose a position where they have the best view of the cranes and loads KONECRANES Abbot Point Bulk Coal Terminal For its safer lifting developments that are more resistant to wear and hazardous environments, Konecranes has been

nominated for the Safety Scheme of the Year award. Konecranes is meeting the challenges of a salt air environment and a hard-working mature crane stock in fulfilling a maintenance agreement for cranes employed by Xstrata at Abbot Point Bulk Coal Terminal One near Bowen in Queensland. The work provided by Konecranes includes quarterly inspections, remedial work and certifications on 27 overhead cranes of a number of makes and types at the terminal. The terminal is operated by Abbot Point BulkCoal, a subsidiary of Xstrata. Terminal One was recently expanded to a capacity of 50 million tonnes a year. WILSON TRANSFORMER COMPANY Glen Waverley factory upgrade Wilson Transformer Company (WTC) is the leading Australian manufacturer of power and distribution transformers for the Electricity Industry. The company owns and operates one of Australia’s largest and most capable Extra High Voltage testing facilities which can test AC voltages of up to 500 kV and Impulse voltages up to 1,600 kV. As a result safety is a major priority and was a key factor in the recent upgrade of its Glen Waverley factory. The design for the new testing laboratory features a unique safety control system comprising the following: Mobile Modular safety locked fencing used to zone the large test laboratory so that testing of multiple transformers is possible simultaneously; Interlocks on all access points to test laboratory high voltage substations and motor generators – to prevent access during high voltage testing; Emergency stop buttons strategically located throughout the facility used to shut down test; and the system has a dual controller that can be monitored and operated from either the large power or medium power test control room The new safety control system for WTC’s Extra High Voltage testing facility dramatically improved all safety aspects when compared to the old system which had no safety interlocks in place. In addition to the dramatically improved safety, the new test facility has much improved capability and throughput. manmonthly.com.au

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COMPLETE SOLUTIONS FOR EFFECTIVE HEALTH & SAFETY.

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Materials HANDLING – CRANES/LIFTING Self-propelled electric scissor lifts

Heavy vehicle jacks

Genie Australia has introduces a new range of self-propelled electric scissor lifts designed by Terex AWP for tightly packed high rise indoor spaces. The new 11.75m Genie GS-4047 full drive-height self-propelled electric scissor lift can lift goods weighing up to 350kg to a maximum working height of 13.70m and a platform height of 11.70m. David Greene, Regional Sales Manager, ViC & TAS explains that the GS-4047 features dual front-wheel drive and zero inside turning radius, which combined with a compact footprint of just 2.44m long and 1.19m wide stowed, make it ideal for manoeuvring around tight restrictive work environments. The strength and rigidity of the unit will also help increase operator confidence when working from a narrow platform at full height. Key features of Genie GS-4047 self-propelled electric scissor lifts include a 91cm extension deck allows workers to utilise the maximum amount of platform workspace. The scissor lifts travel AD _ have M A Na M K Ospeed N A PofR3.1 _ 1 3 km/h and can handle a 25 per cent

DuRAPAC have unveiled their new heavy vehicle hydraulic jacks - the Safe D Lock jacks. The manufacturer says that these jacks stand apart as they are built to provide ‘fail-safe’ operation. used extensively for heavy vehicles, these heavy lift jacks are designed to be subjected to extreme, varied, and hazardous working conditions. According to the company the Safe D lock jack uses a patented oil-bathed internal locking mechanism that has been crated to automatically engage in the event of hydraulic failure. While the jack uses hydraulic pressure for raising and lowering the jack, during operation

Can handle gradients of 25%.

Fail safe lifting. the jack is always mechanically engaged except during the retraction phase. Absolute Equipment www.durapac.com

Compact scales

THe iCS5 compact scales from gradient to get up slopes and loading Mettler Toledo featuring colorWeight ramps. it is powered by a new 24V 300 coloured displays assist operators Ah battery pack. through better speed and error-free Genie Industries operation in checkweighing applications. 1 2 0 1 3 - 0 3 - 1 1800 8 T 0788 8 633 : 2 7 Manufacturers : 5 8 + 1 1 :that 0 0use checkweighing www.genieindustries.com.au as a solution for completeness control

have fewer missing components and incomplete packages. Completeness checks ensure customers receive the exact quantity hey have ordered. Mettler Toledo 1300 659 761 www.au.met.com

END OF DESIGN LIFE?

Cranes operating in Australia are required to undergo Assessment for Continued Safe Use when the Design Work Period (DWP) has expired or based on the calendar periods stipulated by AS 2550.1 2011 if the DWP cannot be adequately ascertained. Konecranes “Crane Reliability Survey” (TM) Inspection program provides cost effective solutions, ranging from Third Party Inspections and Major Assessments to Major Inspections, with added benefit of Engineering Conditional Recertification and NATA Accreditation.

Konecranes – not just another crane company, but a Crane Authority. 31 Sales and Service Locations across Australia and New Zealand. For your nearest branch please contact (Australia) 1300 937 637 (New Zealand) +64 9634 5322. Or visit our website www.konecranes.com.au

50 APRIL 2013 Manufacturers’ Monthly

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Manufacturing TECHNOLOGY

It is important to get the first prototype as close to production ready as possible.

Design and innovation critical to success Australian manufacturers urged to invest in design technology or risk failure. Alan Johnson reports.

hile Australian manufacturers are unable to compete with the most parts of the world when it comes to labour rates, there are no such restrictions when it comes to product design and innovation. Vernon McKenzie, managing director of endurasim, says the design of a product is critically important to its success on the market. “if Australian manufacturers are going to be competitive then the product’s design, and getting it right the first time in the most cost efficient manner, is probably the most critical element. And to get there, companies need to invest in 3D CAD. “it is difficult to design products quickly, physically test it, prototype it, or simulate it without 3D CAD,” 52 APRIL 2013 Manufacturers’ Monthly

McKenzie told Manufacturers’ Monthly. With manufacturers increasingly aware of the importance of sustainability, McKenzie says a major issue with products is making the most efficient use of the material in the first place. “People are using simulation of their CAD designs to better optimise the product. Getting as much of the design work up front as possible and optimising the designs before manufacture. “Obviously there is only a certain amount that users can simulate, as it is still important to physically test products for validation. The idea is to get the first prototype as close to production ready as possible,” McKenzie said. “The process of producing more sustainable products includes the

process of optimising them to use the least amount of material and being better at simulating the behaviour and validating the product so that those simulations can be relied upon more substantially,” he said. McKenzie says with the importance of increasing the speed to market critical, especially with high value and complex products, the idea that you trial and error test them is a thing of the past. “Australian manufacturers just can’t compete if they are taking that amount of time to make things work,” he said. interestingly, McKenzie doesn’t believe Australian manufacturers are behind the rest of the world when it comes to investing in 3D CAD, but believes the biggest challenge facing manufacturers is finding people with simulation skills locally.

“When i first started, skilled engineers earnt around $50k a year and software cost $100k, with the necessary hardware a similar amount. however today, a very powerful computer with software that can do far more complicated work is only $20k, while engineers now earn $100k+. “Our biggest challenge in getting Australian manufacturers to adopt 3D simulation technology is making sure that they understand the skills required. if they don’t have those skills in-house then we have to help them develop them.” he says that’s not the case with 3D CAD, “as many people are coming out of university, not as experts, but have had some good exposure to it”. McKenzie says the learning curve associated with 3D CAD is a bit less than for 3D simulation, explaining manmonthly.com.au

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that the 3D simulation that is embedded in 3D CAD systems is like comparing a small Hyundai to a top of the range BMW. “They are both cars, but there are huge differences to what they are capable of doing.” However McKenzie says 3D simulation software is not just for complex products. “It can be used for injection moulds for plastic stools, to make sure they will survive certain statuary tests as far as weight and buckling is concerned. “While it’s a fairly simple product, the tooling for it is $100k+ to manufacture, and the cost of getting it wrong is substantial.” McKenzie says manufacturers need to manufacture their products with the least amount of material possible but still do the job. “Our customers are involved in products as simple as bull bars right through to full coal wagons and monster mining equipment. “Our products, which include Femap and Nastran, are all about simulating the physics, how things work in their operating environment. Could be suspension systems, stress and fatigue lines, for example, in advance of their manufacture. “The hardware available and the sort of physics that can be simulated means a broader range of physics can be solved on a person’s desktop in a shorter period of time. “The latest simulation products are capable of producing substantial efficiency gains in the design and performance of products,” he said. McKenzie explains that Endurasim offers a simulation service, as well as distributing 3D simulation software. “For manufacturers who only need to simulate new products once or twice a year, our simulation service option is very cost effective,” he said. When it comes to successful Australian manufacturers, McKenzie believes those who do reasonable well are those that produce products that are export worthy. “Even if they are not exporting their products, Australian manufacturers should always design and produce products that are good enough to export. If not they are likely to be swamped by products from India or China,” McKenzie said. manmonthly.com.au

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There has been a fundamental shift in 3D CAD functionality.

Critical factors Christian Ebel, a Director with Dassault Systèmes Australia/ NZ, says the design of a product has a fundamental impact on the experience users have when interacting with that product. “In both B2B and B2C, this experience drives sales, customer retention and the premium a company can charge. Design is therefore paramount for our clients,” he said. While Ebel admits Australia is not, and will not become, a cheap place to manufacture, he is confident companies can prosper, but says they need to come up with innovative products. “The manufacturers who do will strive, while the ones who do not will likely close their doors. “In this unforgiving context, innovation is not an option. To do so, you need time, therefore efficient tools and processes, and the capacity to test new concepts, and use strong simulation software. Collaboration between individuals and organisations is another must. “Australian manufacturers should follow the German example

and invest in modern tools to increase productivity and facilitate innovation. “Just next door, Switzerland, while small and expensive, has a competitive manufacturing industry. Australia can achieve the same,” Ebel told Manufacturers’ Monthly. When it comes to 3D CAD systems he says there has been a fundamental shift in functionality. “In a product such as Catia V6, we can now define in one unique environment the customer requirements (R), the functional definition (F), the logical definition (L) and the physical definition (P) of a product. “This provides full traceability across the RFLP process and the capacity to simulate the multiphysics of a product. “Similarly, powerful CAD systems continue increasing the spectrum of activities they cover: from styling with multi-division surfaces to 5-axis machining,” Ebel said. While many in industry believe Catia is just for large manufacturers in the car and aerospace industries, Ebel says this is not the case. “Most of the cars we drive

and planes we fly in are indeed designed with Catia, but so is the chinaware we use when going to any bathroom, and many of the clothes we wear are also designed, sourced and manufactured using the V6 platform.” Ebel says Catia V6R2013x, which has just been released, has many new capabilities including a new product, Composites Fiber Modeler (CFM). “It provides robust and accurate fibre simulation to optimise ply shapes and provide accurate manufacturing information”. “The new version also delivers multiple advances in systems engineering, including a multidisciplinary design methodology which integrates RFLP product definitions, and a live rendering feature which improves performances and offers the ability to render multiple photorealistic images in the background, while the user continues to work on Catai,” Ebel said. Endurasim 1800 367 332 www.endurasim.com.au Dassault Systèmes Australia 02 9216 6800, www.3ds.com Manufacturers’ Monthly APRIL 2013 53

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Manufacturing’s FUTURE CIOs driving innovation Is the future of manufacturing and design the cloud? Brent Balinski investigates.

AST year an interview with Autodesk’s CEO in Tech Crunch magazine got a lot of attention from those who follow CAD news. “I’d say two to three years from now, every one of our products will be used online,” Carl Bass said in April 2012. “The only way to use them will be online.” Whether or not he was speaking literally was argued on many a message board, and whether or not he was, there’s no doubting the company’s focus on cloud computing as both massively useful for its users and of huge importance to its own future. “Autodesk over the years has really established a name in a space that was primarily desktop PC-oriented,” the company’s CIO, Jeff Brzycki, told Manufacturers’ Monthly. “It was client-based software that ran in the customer’s premise, that was typically because it was graphically-oriented and really was focussed on trying to sort of – the tag line for the company is to helping people experience their idea before they’re real. “It really meant that there needed to be a significant amount of computer horsepower available to

Workers are demanding more flexibility. 54 APRIL 2013 Manufacturers’ Monthly

Is cloud computing the future? the engineers and architects when they were dealing with models that had any scale or size.” An example Brzycki likes to use when highlighting the benefits of the cloud to engineers and designers is in terms of simulation exercises. If you have a two-week timeframe on a project, and your current level of computing muscle allows you to draw and test one model per day, then in a two-week timeframe you can get through ten simulations and pick the best of them. “With the cloud you can actually change the paradigm by which you’re designing,” explained Brzycki. “What would it look like if you could throw 10,000 simulations simultaneously into the cloud and in a matter of one day you pick the best out of 10,000 as opposed to waiting two weeks and you pick the best out of 10? “So it’s a much more efficient and effective use of computer horsepower and you’re going to have a dramatic impact, not only in time to market, but also on the aspect of

quality and the ability to severely test out different designs before you incur the cost and overhead of prototyping and having an engineering or manufacturing line gear up for production.” And the company hasn’t just been talking the talk. In a recent interview Brzycki said that Autodesk had recently started running the company’s internal operations on an enterprise cloud. “Our product development people no longer have a separate IT infrastructure – it’s all in the cloud. We have a highly virtual environment, with web-based applications,” Brzycki told IT Wire. With the shift to the cloud in recent years – which has made available computing horsepower that could be expensive to purchase (for example in a rendering or computational farm) – as well as the changes to the range of Autodesk’s product suite, Brzycki has noticed the CIOs and senior IT staff of clients become more and more involved with what Autodesk offers.

“My perspective is that the CIOs must get involved with these solutions,” he said. “Because at the end of the day who has enterprise-wide responsibility for things like the devices that are connecting to the network, the security of the intellectual property that might be within their environment, making sure that – in a public company – they can be accountable and held responsible to external reporting requirements. “So we really think that the opportunity is to engage this cohort of peers in a way that really can put Autodesk in a new light. One that’s much more in line with where we expect to go in the future. “That’s the background of the program that we’re running and we’re going to be doing in a couple here in Australia.” Brzycki is offering live webinars on the topic of CIOs enabling innovation within companies up until May, and then visiting Australia shortly after that. manmonthly.com.au

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Production LINE SAFETY Safeguarding your workers How can you best protect your workers on the production line? Jason Jair writes.

N the early days of the industrial revolution, labour was cheap and there was little regard for the pain and suffering of injured workers. In more recent times, the welfare of workers has become a primary concern for employers and the wider community as a whole, with more value placed on the safety of people who work with machines. To ensure the safety of these workers, a continued focus on the development of safe guarding measures for existing and new machinery is required. The biggest challenge here is to improve the safety of existing machinery while managing new hazards that arise through advances in technology in a manner that aligns with what is expected from employers. The modern day engineer, whether designing, producing, or maintaining is faced with more and more complex machinery that requires increasing levels of protection, and existing machinery that needs to comply with the relevant laws, regulations and standards of the day. The overriding safety principle when designing any safeguards for machinery and plant is that it must ensure safe operation without risk to the health of the operators. Experience shows the most cost effective way to achieve this is to consider the potential risk of exposure to hazards during the design phase. This will enable the designer to design out any exposure to hazards, taking into account the need to reduce speed, temperature and pressure to an acceptable level. As with all hazard minimisation the hierarchy of control is the primary tool used when considering design and implementation of safeguards. The first step in developing safeguards for machinery is to understand the relevant laws, regulations and standards, and to consider elimination, substitution and engineering controls.

A single standard for all The new national harmonised 56 APRIL 2013 Manufacturers’ Monthly

Worker safety is critical. Work Health and Safety (WHS) laws promise to remove confusion and provide a transparent national legislative framework for industry to follow. Currently there are two states that are yet to enact the changes. Victoria and Western Australia have not joined the harmonised WHS system because their governments have opposed implementing laws mirroring the model WHS legislation. Harmonisation will happen; it’s just a question of time for the Federal Government to provide the necessary concessions to enable the states to work towards passing the bill. There are also concerns from some sectors that these new laws are a step back in their safety regulation, and do not match the current safety benchmarks. Regulations and Codes of Practice provide guidance as to the relevant Australian Standards that will ensure the correct safety system has been designed and installed, based on the risk of exposure to the hazard. The law requires the elimination risk and, if this is not possible, then the utilisation of engineering means as a measure to control risk, as described in the Code of Practice for Plant.

When access is not required the use of permanently fixed guards is applicable. The perfect example of a fixed metal guard is of one welded into position, or a casing enclosing an electric motor. If access is required during operation, maintenance or cleaning, a guard must be provided that is interlocked. An interlock guard is one that is movable or has a movable part. The movement of the guard interacts via a switch connected to the control system which prevents movement of the dangerous parts

Standardisation is key.

of the machine while the guard is opened. Referring to the relevant Codes of Practice reveals that there is more that needs to be considered when using an interlocking system. The standard AS4024.1 – 2006 Safety of machinery provides the necessary guidance required when looking at an interlocking system. The standard is divided into six sections covering Safety Principles; Risk Assessment; Ergonomic Principles; Design Parameters; and Ergonomics and Displays (controls, actuators and signals). The Standard incorporates both European (EN) and International (ISO) safety and design standards of best practice for machine guard safety. Where the use of a welded or interlocked guard is not appropriate a fixed barrier that can be removed by the use of tools may be suitable. Caution should be exercised if selecting this option, as the tool selected for removal must NOT be in the possession of the operator of a machine.

The right approach A useful approach here is the ‘what if?’ method: what happens if the operator does not put the guard back into position? The answer is a potential to cause harm and injury due to the ability to run the machine without the guard fitted. Having considered elimination, substitution and engineering controls, the focus can be turned to administrative controls and personal protective equipment. Operators never think unsafe; they attempt to perform their duties in an efficient manner and assume the guarding will protect them. One may wonder why an operator would manipulate or bypass the very device introduced to protect them. Generally this occurs through lack of ergonomics or a poorly designed guarding. The point here is that where possible, consideration should manmonthly.com.au

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be given to the potential for manipulation, and assurances made to ensure that this is as difficult as reasonably practicable. A recent five year study in Germany found that 37% of injuries caused by machines were a direct result of a machine that had been manipulated. Even more concerning, a further investigation found that with 8% of the manipulated machines, the operators were not even aware of the risk they were taking. If physical guards are not suitable the hierarchy of control allows for the use of presence sensing systems such as safety light curtains, safety scanners and safety danger zone through the physical mats or bumpers. On this point, gate without applying a tag or using it should be noted that the ideal the captive key system. This problem solution for guarding is the one can be prevented by utilising a that is reasonably practicable. Even safety scanner to monitor if the though presence sensing systems operator is in the danger zone of are the last step in the hierarchy of the machine, avoiding unexpected control, they are essentially the only start up. Safety scanners are also solution when looking at frequent used on AGVs as a solution against access. When used correctly they anti-collision and for personnel can offer considerable productivity protection. improvements such as the ability to load and unload machines more Unexpected start ups efficiently by reducing the time taken to open and close doors, and It may not be immediately obvious the removal of potential hazards which method of guarding should introduced through the use of be used for a particular application. physical barriers. A good example First and foremost when designing of the use of presence sensing a machine, the possible risks should systems is on the entry and exit of be analysed and, where necessary, palletisers, where muting sensors additional protective measures can be used to differentiate between should be taken to protect the products and humans. operator from any hazards that Captive key type systems may exist. To aid the machine encounter the problem of trailing, manufacturer with this task the where an_ operator can 1 . pstandards 9 / 0 5 /the 1 , AD MA N MA D follow F J UN_ 1 0 df P adefine g e and 1 describe 6 1 0 another operator into the machine process of risk assessment.

approach is often a system that on paper looks great and complies but within a short period of time after installation is bypassed and manipulated because it was a hindrance to the operation of the machine.

The risk assessment process

Worker buy in is crucial in maintaining safety. A risk assessment is a sequence of logical steps that permit the systematic analysis and evaluation of risks. The machine should be designed and built with the results of the risk assessment taken into account. Risk reduction follows a risk assessment by applying suitable protective measures. A new risk should not result from the application of protective measures. The repetition of the entire process of risk assessment and risk reduction may be necessary to eliminate hazards as far as possible and to sufficiently reduce the risks identified. A collective approach is recommended when working through the assessment, to prevent the engineering department from designing a safety system that complies, but does not take into account the requirements of the operators of the machine, generally around 0 : 0 3cleaning 2 A Mand maintenance. 1 1 0 The end result of this isolated

Requirements for the protection of machinery have changed more and more with the increasing use of automation. In the past, safety systems were mostly a nuisance. For this reason they were often not used at all. Innovative technology has enabled protective devices to be integrated into the work process. As a result, they are no longer a hindrance for the operator, and indeed they often even help productivity. Ultimately decision makers in industry are responsible for their employees as well as for smooth, cost-effective production. Only if management makes safety part of everyday business will employees embrace the subject. To improve sustainability, experts call for the establishment of a wide-ranging â&#x20AC;&#x2DC;safety cultureâ&#x20AC;&#x2122; in the organisation. This is pertinent given that nine out of ten accidents are due to human error. The last point to note is it is very important that the needs of operators and maintenance personnel are included in the planning at concept level. Only an intelligent safety concept matched to the operator task and the personnel will result in the necessary acceptance and buy in.

sales

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Manufacturing FOR MINING Protective enclosures A harsh working environment requires protection that is up to scratch. Isaac Leung investigates what’s needed for enclosures.

ITH the continued opportunities afforded by the mining industry in Australia, many electronics manufacturers are engineering products for use in mines. But Australian mines are tough environments for electronic products, and a properly built enclosure is essential. Intex specialises in enclosures, connectors and precision accessories for demanding environments. The company custom designs or modifies its hardware from off-the-shelf products. Manufacturers’ Monthly talked to Nick Cumming, director of Engineering at Intex Enclosures, about the enclosure requirements for Australian mines.

Ingress protection The while underground mines demand enclosures which are intrinsically safe (Ex enclosures) for hazardous environments, which control flame paths and arcs to manage the risk of ignition, for most mines, however, the key demand is for ingress protection (IP rating), and for mechanisms to protect the electronics housed within the enclosure. “From an electronics point of view, [ingress protection] is about making sure that the enclosure will protect whatever’s put inside from dust and water,” explained Cumming. Standard enclosures from Intex start at IP66 rating, which means they are waterproof from rain and hosing down, and will keep dust out. “Given the harsh environment we have in Australia with both water and dust, a lot of electronics and automation companies are looking for a higher rating than that,” said Cumming. The answer from Intex is IP68 enclosures, which can be safely immersed in water, and allow the 58 APRIL 2013 Manufacturers’ Monthly

Protective enclosures are located in the heart of mines. electronics inside the survive floods and waves. “We recently did a project with IP68 enclosures going on the wharfs,” Cumming said. We had to do stress analysis on wave surges, how it would perform under 10m of seawater for 10 days, etc.” But while designing a selfcontained enclosure to be water- and dust-proof may seem to be a simple matter, things can get complicated when the electronics systems inside require standard features like cabling for power and data, user interfaces, and screens. “If we have a box certified to IP66, the moment we drill a hole in it, we’ll have to deal with that hole, because it is no longer IP66,” Cumming pointed out. “If we put a hole in there for cable management, we will always use similar material, and similar or greater IP rating. If we cut a hole in

the box and put in cables and power, and it’s an IP68 box, we will put an IP68 stainless steel cable gland in there.” According to Cumming, there have been cases where customers have bought an enclosure, then drilled a hole and installed a cable gland, only to experience dust ingression and leaking. “It’s generally a lack of knowledge and maybe a subcontractor trying to get the job done quickly,” he said. “We try to work with the customers and ask them what they are trying to do, the application, the environment, and what they need. If they need two cable entry holes, we put those in with the cable glands, so all they have to do is to feed the wire through and we know it’s going to be safe.” “It’s the same if we are putting touch screens, connectors, switches or RFID readers, we install that to

make sure it’s all nicely sealed, the screens are IP66, and it meets the requirements of the application.”

Materials Enclosures can come in a range of materials, and can vary according to the application. In gold mines, for example, there may be a focus on corrosion-resistive materials due to the harsh chemicals used in the extraction process. While polyglass, aluminium and composites may be used for junction boxes, the mainstay for industry in Australia is 316 stainless steel, prized for its hard-wearing properties, and its ability to stand up to corrosion. “There are a lot of composites coming out at the moment but realistically nothing beats 316 stainless steel for Australian environments,” said Cumming. manmonthly.com.au

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Tailored mechanisms Heat management and cooling is a big issue for electronics used in mines, and various enclosure mechanisms are available to mitigate both heat emitted by the electronics themselves, and from exposure to the sun. “We do a lot of kiosk and touch screen systems for automation and mines at the moment, for weighing trucks and management,” Cumming explained. “We [also] do a lot of work with big mining companies that have extremes of temperature.” After assessing the application and equipment requirements, Intex takes standard commercial-off-theshelf (COTS) enclosures and installs a skin over it with a baffle to create a sun shade, reducing the radiant temperature from the sun. To further protect the electronics from outside heat, the company installs insulation inside, and puts in filtered fans to vent hot air from the electronics, while preventing dust ingression. Of course, with a fan system in place, the enclosures cannot reach IP68, but IP66 is possible with fan shrouds that protect against dust and water. “You can still hose it down,” Cumming told Manufacturers’ Monthly. “It’s all about controlling where the water and dust goes and keeping it out.” In some cases, the baffles serve a dual function, providing both a sun shade, and a sloped roof. Sloped roofs are a standard requirement at mines, since they prevent a build-up

may also choose to mount their PCBs on a gear plate inside the enclosure, and shock-mount the plate.

Optimising protection

They need to prevent dust ingress. of dust, and also allow easy washdown. This is particularly important in coal mines, where a build-up of flammable dust can be a hazard.

Shock and interference Besides heat, dust and water, vibration and electromagnetic interference are also common dangers on mine sites that can drastically shorten the life of electronics. “EMC (electromagnetic compatibility) is a huge consideration especially when you start to get into communications and data,” said Cummings. “We have special EMC o-rings that we can put into our enclosures, but we also look at it mechanically, as far as wall thickness of our enclosures and what gear we put

There is no one-size-fits-all solution for electronic enclosures used in mines, and the importance of protecting the equipment should not be under-stated. “Generally, whatever is going into the enclosure is high-value, and vitally important to [the mines’] infrastructure, so we must protect that very carefully,” said Cumming. “There’s some smart engineering coming out to solve some of the unique problems we have in Australian mining, and it’s really at next to each other to eliminate a lot the design level.” of that.” By properly assessing the And while many systems on mines environment, potential issues, are static systems, for electronics on and the equipment requirements, plant equipment or vehicles, shockcompanies like Intex can apply absorbent mount systems are a must. design and engineering expertise to These consist of a cradle or a their enclosures to ensure optimised A D _ Mwhich A N Msits T Eon A rubber A P R _shock 1 3 - protection 1 2 0 1of3 high-value - 0 3 - 1 equipment 8 T0 8 : 5 3 : 5 1 + 1 1 : 0 sub-plate mounts. Electronics manufacturers on the mine site.

Enclosures face some of the harshest areas of the mine.

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