Manufacturers' Monthly June 2013

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

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INSIDE How To Get Government Grants >> Motors & Drives Plant & Machinery Maintenance >> Materials Handling Rise Of The Smartphone

ENDEAVOUR AWARDS WINNERS >> Winners for our 2013 manufacturing awards announced!

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WINNER

2013 Technology Application of theYear Award

WINNER

2013 Technology Application of the Year Award

An award-winning innovative, com At BOC, we understand the challenges your business faces everyday. If we can help you increase productivity and keep costs down, then we’re doing our job.

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Publisher: Martin Sinclair martin.sinclair@cirrusmedia.com.au Managing Editor: Cole Latimer Ph: (02) 8484 0652 Fax: (02) 8484 0722 cole.latimer@cirrusmedia.com.au Journalists: Brent Balinski Ph: (02) 8484 0680 Fax: (02) 8484 0722 brent.balinski@cirrusmedia.com.au Alex Heber Ph: (02) 8484 0884 Fax: (02) 8484 0722 alex.heber@cirrusmedia.com.au Vicky Validakis Ph: (02) 8484 0964 Fax: (02) 8484 0722 vicky.validakis@cirrusmedia.com.au Editor-at-Large: Alan Johnson Ph: (02) 8484 0725 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) 8484 0737 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) 8484 0868 Fax: (02) 8484 0722 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) 8484 0868 anthony.head@cirrusmedia.com.au Published 11 times a year Subscriptions $140.00 per annum (inc GST) Overseas prices apply Ph: 1300 360 126

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Inside JUNE 2013

6 Editorial

■ The week that made the month

For daily news visit manmonthly.com.au

30

14

8 Comment

■ Jobs in manufacturing: A closer

look

10 Analysis News ■ What’s happening

14 IT@MM

■ Time to get on board

16 What’s new ■ ■ ■ ■ ■ ■

Portable welders Cable certifiers Injection moulding Conveyor belt cleaning Stirrup benders HD IP Cameras

30 Endeavour Awards

20 Q&A

■ A day in the life of: Production

Supervisors

22 Motors & Drives

■ Very Simple (Drive) Decisions

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0613 - AtlasCopco Front Cover - MM.pdf 1 8/05/2013 12:31:12 PM

manmonthly.com.au

ANALYSIS >> TECHNOLOGY >> SOLUTIONS

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■ Keeping machines running

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28 Plant & Machinery Maintenance

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Manufacturing’s night of nights.

ENDEAVOUR AWARDS WINNERS >> Winners for our 2013 manufacturing awards announced!

Lifetime Achievement Safety Scheme of the Year Exporter of the Year Environmental Solution Consumer/Trade Product of the Year Australian Steel Innovation Global Integration Industrial Product of the Year Young Manufacturer of the Year Technology Application of the Year Most Innovative Manufacturing Company

52 Enterprise Connect Significant Achievement 53 Manufacturer of the Year

54 Sensors & Analysers ■ Doing business better

56 Materials Handling

■ Forklifts, stackers and pallets

60 NMW

■ A wrap of National Manufacturing

Week

62 Insider Series

■ Don’t miss out on funding

Behind the cover ATLAS Copco has launched an innovation that heralds a new era in compressor technology.

The new GAVSD+ (Variable Speed Drive) is nothing short of spectacular: it offers improved performances (up to 12% increased capacity), extraordinary energy efficiency (50% less energy consumption) and the 2 smallest : 3 4 : footprint 2 8 PinMtheAmarket E S T(up to 55% smaller).

The GA VSD+ is the next big step in compressor technology and is suitable for all applications.

A compressor that realizes energy savings of 50% on average (compared to conventional compressors) not only benefits our customers, it also contributes to a greener environment.

Visit us at www.atlascopco.com/ gavsdplus

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Editorial

COLE LATIMER – Managing Editor

editor@manmonthly.com.au

The week that made the month May has been the month of manufacturing.

T

he second week of last month has to have been one of the most interesting I’ve had since starting as editor at Manufacturers’ Monthly.

Within the space of four days we managed to cram in National Manufacturing Week, the Endeavour Awards, and our Leaders’ Summit which gathered top names in the industry. The awards were an out and out success, with nearly 100 nominations across the board that we managed eventually to whittle down to a few; the calibre of the finalist really showed through.

In this edition we’ve featured the winners of the awards, and as you can see from those featured, it’s a pretty high achieving bunch.

The night itself was attended by the new chair of manufacturing Australia, Sue Morphet, and opposition industry minister Sophie Mirabella.

Greg Combet, unfortunately was unable to make it, however he did provide a pre-recorded video discussing the current state of the industry.

Luckily, before it turned into a political debate between the two A D _ our M AMC N Mfor AB BA P R Shane _ 1 3 ministers the night Jacobsen kicked off the event.

6 JUNE 2013 Manufacturers’ Monthly

A number of events in May highlighted the optimism and innovation of the industry.

There were many highs for the The issue of Asia and the crippling night, and no lows, and in this high Australian dollar were the current economic climate that is main points of focus, and what certainly a plus. manufacturers could do to avoid Our Leaders’ Summit was an being shackled by the current entirely different beast, where we difficult times. brought in top level manufacturers Many interesting points came out and those from governmental or of the debates, and the only thing industry groups, such as EFIC and that disappointed me was having to Australian Made’s Ian Harrison, cut short the conversation just when to discuss the current challenges it was in full flow. of manufacturing and the issue Now, National Manufacturing -that1affects 2 0 1 3 - manufacturers 0 3 - 1 1 T 1 8– : 4 1 Week : 3 8 and + 1 Austech 1 : 0 0 – the event did many offshoring. live up to the hype.

Seeing all those pieces of massive machinery cutting, turning, and grinding, people welding, lasers and plasma cutters doing their things, all of the automated processes and picking robots whizzing by and carrying out complicated movements at speed; it was amazing.

The only downside it the potential hearing loss we suffered going around the pavilion.

That many machines crammed into the space makes a serious din.

It didn’t seem to bother the 11 200 plus people who walked through the doors though.

The high number of attendees did much to prove to those both in manufacturing and those outside of the industry, that the sector is still valuable to Australia and has a real future. Speaking of future, the best news of the month would easily be Australia’s falling dollar.

Dipping below parity with the US dollar late last month, and it showing no signs of quickly rising again has buoyed manufacturers.

Hopefully it isn’t too late for many in the industry.

We can only wait and see.

After all that happened it seems as though May was definitely the manufacturers’ month.

manmonthly.com.au

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Industrial COMMENT Jobs in manufacturing: A closer look Manpower MD Lincoln Crawley examines the true state of employment in manufacturing.

I

t’s fair to say that the jobs outlook for manufacturing has been subdued in the past year. However, it appears to be recovering since hitting a low in September 2012.

The Manpower Employment Outlook survey, which measures employment sentiment and hiring intentions for the coming quarter, shows that the local manufacturing industry is slowly rebuilding its confidence. The outlook has been on a downward trend but appears to have turned a corner.

Interestingly, while the jobs market has softened, we still hear clients tell us they can’t find the right people for all of the roles they have open. We also hear experienced people tell us that jobs are hard to find. So, what is going on here?

There are two trends shaping this jobs market, and they are related.

Structural change We know that manufacturing is undergoing a fundamental change, as low-value work goes to cheaper, off-shore markets. Coupled with a persistently high Australian dollar, this trend is seeing the type of work we do here in Australia evolve over time, with the focus moving to more specialised manufacturing companies. This has flow-on effects to the labour market, as the skills in demand change along with the type of work being done. This has helped to create what we call a ‘talent mismatch’.

The Talent Mismatch: skills versus demand As the nature of manufacturing work evolves to use more technology and rely less on unskilled or semi-skilled workers, there is a mismatch between the talent available and the talent needed by employers.

This is by no means restricted to manufacturers: our Talent Shortage Survey has found that around 1 in 2 Australian employers can’t find the skills they need, with engineering, sales and skilled trades among the most acute shortages. However, given the manufacturing sector’s traditional need for less-skilled labour, the structural changes occurring at the moment make this trend even more pronounced. These trends impact both employers and job-seekers, who must navigate a changing job market.

Employers: investment in skills must be a priority The key to creating a robust talent pool is to develop training strategies that build on the talent an organisation already has, and builds the skills it needs for the future.

8 JUNE 2013 Manufacturers’ Monthly

Employment senitment has improved for manufacturing this year.

Innovation and creative thinking can help to make this investment in training more costeffective. For example, ManpowerGroup has developed customised training programs that tap into programs and funding available through government and education institutions. Over the last two years we’ve managed more than 250 traineeships through the Vocational Education and Training Solutions program, providing employees with qualifications from Diplomas in Frontline Management, to Certificate III and IV in Information Technology and in Warehouse and Logistics.

This partnership approach can resolve client issues around skills shortages, while providing nationally-accredited qualifications and skills growth for the individuals involved. Moreover, organisations that undertake these programs see reduced turnover, increased morale and improved productivity.

Jobseekers: skills and flexibility needed For job seekers in the manufacturing sector, flexibility is critical. In a constantly changing industry, individuals need to continue updating their skills, whether it’s through external education or on-the-job programs. The growth of online courses and government-funded training places means that education is more accessible than ever; the key is to find out which skills are in demand and focus your efforts in that direction.

When it comes to the job search process, it

is increasingly important to develop an online presence. Being active on professional networking sites such as LinkedIn will make you visible to recruiters, HR professionals, and people that might refer you to job openings. There are various LinkedIn groups for manufacturing professionals that promote job openings, and also provide industry news and issues for discussion.

Another option is to look at temporary roles, especially if you’re looking at moving into a different area within the industry. Taking a contract role can be a good way to get a foot in the door.

Ultimately, the economy is undergoing significant change, so job seekers need to focus on the areas that are growing and be willing to adapt.

That may mean moving locations, retraining or updating your skills. The key is to go where the work is and develop the skills that are in demand.

So…what’s next?

While employment in the manufacturing sector is under pressure, that doesn’t mean there are no opportunities available. There are still Australian businesses who believe that producing products locally is better suited to their customers, and these companies will continue to drive employment.

For employers, it is important not to lose sight of your long-term workforce strategy.

Investing in people needs to be an ongoing focus for management and leaders if they are to find the talent needed for today and tomorrow’s manufacturing sector. manmonthly.com.au

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Analysis NEWS Ford confirms Australian plant closures

F

ord Australia will stop all automotive manufacturing in Australia by October 2016. As a result, 1200 workers will lose their jobs.

The job losses will be from the company’s Broadmeadows car factory and its Geelong engine plant.

In a media conference, Ford Australia President and CEO Bob Graziano said that the company had lost $600 million over the last five years, including $141 million after tax in the last financial year.

He said that he believed costs made car manufacturing uncompetitive in Australia.

Graziano said that all 1200 will receive all entitlements owed to them and that they will be offered support over the coming three years.

“During the next three years it’s our intent to manufacture [the Falcon, Territory and Falcon Ute],” he says. “We will continue to work with our workers here during that transitional phase.”

“The decision was not made lightly ... we understand the very real impact of this decision.”

“It just doesn’t make sense for us longer term.”

In January last year, the federal government contributed $34 million to Ford’s $103 million upgrade, and the Victorian government an unspecified amount.

Speaking at a press conference this morning, Prime Minister Julia Gillard confirmed the federal government’s funding would remain because it is dedicated to new models that will continue to be produced until Ford ceases manufacturing in 2016.

In a statement, Gillard and Victorian Premier Denis Napthine said that they will be contributing almost $40 million to structural adjustment programs to support the economic development and diversification of the Geelong and northern Melbourne regions.

The Australian Government will contribute $30 million and the Victorian Government $9 million.

The AMWU has said it was taken by surprise by this morning’s announcement. Leigh Diehm, the union’s Victorian assistant secretary, told ABC News 24 that the union was “in regular discussions with Ford”, but was “surprised” by the announcement.

NZ industry acts on steel imports NEW Zealand may introduce a Europeanstyle compliance regime to ensure the quality of imported steel bolts and components used in construction is maintained.

This follows concerns that substandard imported parts were being used. The issue was raised with the government by the Institute of Professional Engineers (IPENZ).

According to the IPENZ, the concern was based only on anecdotal evidence and “at this stage IPENZ is unaware of the scale of the issue, or whether they were one-off instances,” a spokesperson said.

The New Zealand steel construction industry is developing the plan in partnership with the Australian industry.

The European compliance model includes the certification and auditing of “safety critical” steel building components by third parties, as well as random sampling and testing.

According to Alistair Fussell, manager of Steel Construction New Zealand, the system will be first introduced on a voluntary basis and will be incorporated into steel standards over time.

Eventually, imported bolts or prefabricated steel from any non-accredited manufacturers will face costly testing when they arrive in New Zealand. The problem is 10 JUNE 2013 Manufacturers’ Monthly

NZ wants to ensure quality imports. not limited to New Zealand. The Australian Steel Institute (ASI) has actually been more outspoken about inferior imported steel bolts and components than the IPENZ. According to Alan Marshall, a spokesman for the ASI, in the US steel was found to be the most counterfeited building material, while structural bolts were found to be the second most counterfeited.

Around 1200 have lost their jobs.

Drill manufacturer cuts over 1000 jobs MASSIVE cuts across the contract mining sector have come home to roost as drilling service and manufacturing company Boart Longyear slashes over 1000 jobs from its operations globally this year.

Chief executive Richard O’Brien yesterday warned investors at the company’s annual meeting that the company expects a sharp drop in profits, which have already been repeatedly revised down as industry sentiment continues to decline.

“The downturn in capital and exploration spending in the mining sector globally has clearly reduced the demand for drilling services and products,’’ he said.

Despite company wide cuts which will see Boart’s global workforce shrink by about 30 per cent, O’Brien said investors should expect further belt-tightening as conditions worsen, SMH reported.

“With market conditions where they are, we’re focusing our efforts on what we can control: total costs,’’ O’Brien said.

As miners cut exploration budgets, Boart has predicted utilisation rates for its drilling rigs could fall as much as 20 per cent compared to last year.

Some analysts report exploration expenditure this year has dropped 20 per cent.

The Utah based driller said revenue would come in at the lower end of analysts’ forecast range of between $US1.466 billion and $US1.726 billion.

“Our primary objectives in the short and medium term are to deliver improved margins and cash flow by creating a more a sustainable cost structure,” O’Brien said.

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Analysis NEWS

Quickstep gets JsF II program approval AsX-listed aerospace and defence manufacturer Quickstep Technologies has had its new production facility in Bankstown qualified to make composite parts for the F-35 JsF Lightning II program, supplying Northrop Grumman.

Quickstep’s facility, which opened in 2012, will make components for the planes’ centre fuselage.

The announcement made by the company this week states that it recently received approval from Northrop’s chief engineer to provide bismaleimide and graphite epoxy production parts.

Quickstep will supply composite parts for the strike figthers.

“Northrop Grumman helped celebrate the opening of Quickstep’s production facility,

and now Quickstep is successfully demonstrating its ability to manufacture and deliver parts that

steel created without carbon emissions ReseARcheRs at Massachusetts Institute of Technology have engineered a way to make high-purity steel without producing carbon emissions.

The ABc and others report that molten oxide eloctrolysis (MOe), an electrometallurgical technique, was found to be able to extract oxygen from lunar soil with steel – but no greenhouse gases – created as a by-product.

The MIT team was led by Donald sadoway, a materials chemistry professor, who received a NAsA grant to research oxygen creation on the moon.

A paper by the team and published this month in Nature details their application of MOe. The process developed by sadoway was successfully trialled on an asteroid impact crater in Arizona, according to the team’s paper. It has not been tested on a massproduction scale.

It is estimated that the 1.5 billion tonnes of steel produced a year contribute 5 per cent of the world’s greenhouse gases.

12 JUNE 2013 Manufacturers’ Monthly

will benefit the F-35 program,” said Northrop’s Michelle scarpella, its VP for the F-35 program.

“This progress is a testament to the strong industrial partnership Northrop Grumman has with Quickstep in producing the F-35 center fuselage, and with the governments of Australia and New south Wales in establishing this critical composite manufacturing capability in Australia.”

The industry team on the F-35 program is led by Lockheed Martin.

The Australian government joined the program in 2002 as one of eight international partners.

Fire damages Brisbane factory A fire broke out in a factory plant at Carole Park in Brisbane’s southwest.

Though the fire was quickly contained, it caused extensive damage to the property.

The fire occurred at Cobalt St, Carole Park and Emergency services were called to the site at about 10.30pm.

Nobody was hurt but one shed was extensively damaged. It is believed the factory had recently changed hands and was closed at the time of the fire.

Police are continuing investigations.

750 workers strike at shipbuilder

Steel making contributes to 5% of greenhouse gases.

The AMWU says 750 workers walked off the job at ship-builder Forgacs during two shifts in May. The union is currently intensifying its campaign against Forgacs, which is doing work on welded steel modules on Air Warfare Destroyers, and the move is timed to interrupt a planned barge shipment of hulls to Adelaide.

“This latest stoppage is timed to coincide with that operation,” said Daniel Wallace from the AMWU. According to a statement from AMWU last month on the May Day action that saw 650 Forgacs workers leave their jobs to march on Newcastle’s town hall, the union wants “improved job security” and a six per cent wage increase for its workers.

Forgacs has offered an increase of 3.25 per cent.

The AMWU would also like increases to afternoon shift and overtime loading rate. manmonthly.com.au

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Car sales hit record levels

The dollar is now below parity with the US.

Dollar drop welcomed by industry THE Australian dollar has dipped to slightly below conditions.” He said that job losses could be attributed parity with the US dollar. to the high dollar and added that, from the perspective The drop follows a fall in commodities prices caused of Australian industry, a competitive value is about by weaker than expected Chinese data. At 11.45 AEST US$0.88. on Wednesday the currency was trading at 99.99 US “If the dollar were to drop significantly, Australian cents, down from Monday’s close of 100 US cents. The industry would be exceptionally well-placed to take Australian Financial Review reports that Australian advantage of that.”

Industry group welcomed the news.

Even so, many exporters have come to accept that the Chief executive Innes Willox said, “even slight value will remain high for the foreseeable future. movements downwards in the dollar are welcome According to JP Morgan currency analyst Anna because they decisions, dollar to trade around MA 0 6 1affect 3 _ 0investment 0 0 _ MO B 1 they 2 0affect 1 3 - 0 5 - Hibino, 0 3 T 1 the 4 : Australian 3 9 : 5 8 + 1 0 :is 0likely 0 buying decisions and they affect immediate business 100 US cents for the time being.

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Despite four straight months of falls and the announcement of the upcoming closure of the Ford factory, car sales have still hit record levels.

Australians purchased 1.13 million cars in the year to April.

Commsec chief economist Craig James said that there was a very strong result in 2012 and the 1.6 per cent fall in sales in the month of April can be seen as a consolidation.

“Car sales basically are more consolidating near record highs,” James said.

“While they have fallen for four straight months, they’re still higher than a year ago and the fact is ... car affordability is the best since the 1970s.” the result comes as the nation debates the viability of Australian automotive manufacturing. there is disagreement about whether assistance given to the industry by governments is money well spent.

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IT@MM MOBILE TECHNOLOGY Time to get on board Following Australian consumers lead, industry should now be boarding the mobile technology train and embracing smart phones and tablets to improve productivity. Alan Johnson reports.

P

DA’s running Windows Mobile software remain a major part of manufacturing’s mobile technology landscape, however the meteoric uptake of smart phones and tablets in the consumer market has also led to a gradual acceptance of these devices across the shop floor as well as into management offices.

According to a recent Gartner research study, CIOs working at manufacturing companies now rank the investment in mobile technologies as a top priority.

This focus will have repercussions on how manufacturers allocate their IT budgets, resulting in greater mobility-related purchases such as smart phones, tablets, mobile security products, wireless networks and, most likely, cloud-based storage services.

These types of changes are expected to dramatically impact how processes are executed on the shop floor. To start, users will start requesting to execute production processes, input or view work instructions or evaluate manufacturing intelligence from their hand-held devices.

However, no purchase will be made unless a return on investment can be justified. Industry consensus is that workforce productivity will improve by extending the decisionmaking environment from the desktop aA mobile 1 .

A D to _ M N M Adevice, D F J Uresulting N_ 1 0 in increased employee productivity

BYOD is becoming the norm in manufacturing. and overall equipment effectiveness.

Access to greater operational intelligence, faster, can also provide sufficient benefits to ensure continued mobility purchases. As manufacturing research, design and production have become such global activities, gaining access and availability to these knowledge workers in real-time, on a 24/7 basis, offers the potential for even further productivity gains from the implementation of mobility solutions.

Naaman Shibi, VP Australasia with Techs4biz (Pervidi Software), says manufacturers are moving fast to 9 / technology.

1 , ptake d f advantage P a g e of 1mobile 6 0 5 / 1 0 “Technology is changing rapidly,

and mobile devices are now easily accessible, plus the new “digital” generation (Gen Y) is quite comfortable with mobile devices compared to Gen X and the Baby Boomers.”

Shibi says data accuracy and replacing paper are just two of the key advantages.

“By replacing paper in maintenance, QA, inspections, audit, observations, work orders for example, manufacturers are operating in real time, saving paper, saving data entry, standardising the process, with the ability to access emails and other while 0 : company 3 0 2 A applications 1 1 0 M away from the desk; now that most

of the warehouse, stock/inventory and material handling functions are automated, manufactures should move into replacing paper in other areas on the manufacturing floor such as recording maintenance of plant and equipment, safety inspections, pre-start checks for heavy machinery, audits, observations, and surveys.

“Companies should also look outside the plant, with field service/ maintenance of equipment recorded on mobile devices Shibi says smart phones and tablets now offer PDA-like functionality, often at a fraction of the cost.

“For example, the average size of a PDA screen is 3.5” whereas many smart-phones now sport a 5” screen and the average tablet screen size now at 10.

“This increased screen realestate increases efficiency whilst performing mobile inspections as well as markedly enhancing the end-user experience.

“Tablets and smart phones are also able to capture highresolution images which can then be annotated using the touchscreen, as well as using the in-built camera for barcode scanning. With optional hardware attachments now available to facilitate the use of RFID scanners, the need for a dedicated PDA unit to complete inspections in the field is becoming

sales

14 JUNE 2013 Manufacturers’ Monthly

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increasingly marginalised,” Shibi told Manufacturers’ Monthly.

Which operating system?

While recent surveys reveal Android as the dominate operating system outside the US, industry experts say manufacturers should first ask themselves where is there data?

For example, if you keep your contacts, mail, and calendar in Google, they say you should have Android. However, if you keep your contacts, mail, and calendar in the Apple iCloud, you should have an iPhone. Regardless of the merits of one phone over the other on an app by app, feature by feature basis, what normally matters the most is how seamless the phone integrates with contacts, mail, and calendar.

Although each of the big players provide some grudging accommodation of their competitor’s services, the experience is often sub-par. To have the optimal experience, one should stay all Apple, all Android, or all Microsoft.

Shibi warns that when it comes to flexibility, Apple is more of a “closed application” and is tightly controlled

by Apple.

“Regarding interface, most of the commercial applications are Microsoft based and a key issue is to seamlessly interface between the mobile device and the corporate applications. Currently Android has easier interface capabilities with Microsoft,” Shibi said.

Integration A recently published Deloitte Access Economics Report commissioned by the Australian Mobile Telecommunications Association (AMTA) ‘Mobile Nation: The economic and social impacts of mobile technology,’ revealed that the current upsurge of mobile technologies will result in an economic productivity benefit of $11.8bn for the period of 2012-2025.

That, according to Paul Goepfert, marketing manager with Pronto Software, is a pretty powerful argument for why every manufacturer should be assessing their mobile strategy in 2013.

“Mobile technology should be seen as a gateway for opportunity and a tool to facilitate all dimensions of a workplace. If CIOs aren’t acting manmonthly.com.au

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on mobile implementation, their employees will (or have already) beat them to it.”

Goepfert says anytime, anywhere access to people and information is a critical element to the success of business in this increasingly datadriven age.

“Whether we like it or not, decision makers need to be connected and available to manage information and make decisions quickly.

“In recent years, there has been a lot of focus applied to the way consumers use mobile devices and ways marketers can reach them through mobile apps, social media and advertising.

“However, there hasn’t been nearly as much attention applied to the way everyday people – executives, managers and employees alike – use mobile devices and connect to the world throughout their work-life,” Goepfert told Manufacturers’ Monthly.

“Mobile technologies are now woven throughout the fabric of the workplace. It is a very rare occurrence (for many) to be out of reach of our mobile device, which is connected to our personal and professional online information channels and profile.

“Once a phenomenon but now the norm, BYOD (Bring Your Own Device) is now a part of everyday life for most Australians who deal with an IT system.

“Manufacturing is no exception to all this, but it does have its own intricacies when it comes to using mobile devices and software to improve bottom line business outcomes.

“For a successful business in manufacturing to run efficiently it relies on flexible, reliable and real-time data. Business software solutions such as ERP have long been drivers of successful manufacturing processes.

“Today, with the integration of business intelligence (BI) and data analytics tools, the industry now has a wide range to tools that can support great visibility of processes via mobile devices.

“The integration of mobile technologies into manufacturing process allows employees to access data faster than ever before. From the warehouse, shopfloor and on the move through the distribution

chain, data is easy to source.

“The challenge for many businesses now, however, revolves around making sense of deep business information at our fingertips – there is a big difference between access to data and access to business intelligence and insightful data. For example production managers could view the output of their production lines and scrap levels on mobile phones in real time through a feed from the shop floor into their ERP system,” Goepfert said.

Industrial tablets With 2.4 million tablest sold in Australia last year, Jason Lee, Panasonic Australia’s Toughbook Marketing Manager, says the market is booming.

“While that figure includes consumers and industry, what works in consumerland almost always carries over to industry. We expect the industrial tablet market to grow 20% or more this year alone,” Lee told Manufacturers’ Monthly.

“Our industrial customers are demanding something portable and rugged to replace a various number of devices, including hand-helds, PDAs and laptops. The more mobile the better, but they still need the power of a laptop. A ruggudised tablet is ideal for manufacturers, as well as many other industries.

“Our recently released Toughpad FZ-G1 tablet, for example, is perfect for businesses in mission-critical and mobile roles in sectors such as manufacturing, defence, utilities, mining and healthcare.

“It features a 10.1” sunlight viewable touchscreen with next generation IPS outdoor display technology and WUXGA 1,920 x 1,200 resolution, for easy outside usage, and is powered by an intelligent Intel Core i5-3537U 1.9GHz vPro processor for faster operation and enhanced device management.

“The lightweight tablet boasts military standard specifications, IP65 certification, dust and water resistance, and is able to withstand drops from 1.2m.

“The 1.1kg tablet comes with a 128GB solid state hard drive, with 4GB of RAM, which can be upgraded if necessary.”

While it has no built-in keyboard,

Lee says it is ideal for manufacturers with check lists. “Plus it can be customised, with a bar code reader for asset tagging, LAN and Serial Ports and/or smart card readers for added security,” Lee said.

In the warehouse Freddy Fam, Intermec’s Product Marketing Manager for APAC, says the mobility component of computing devices is still a key requirement in warehouse operations.

“There is an increasing desire for mobile computing solutions to become an integral and seamless part of warehousing operations and processes.

“We design our mobile computers to seamlessly interact within the environmental constraints, effectively as an extension of the worker, not a hindrance to job performance.”

Fam says technological advances are enabling our mobile computers to do more in the warehouse environment, with less weight and size: “There was once a desire for mobile computers to work and almost mimic the pen and paper system as there was a perception that a shift too far away from these working styles would be difficult to adopt. Now we’re seeing a new generation of warehouse workers more comfortable using technology to complete their tasks efficiently.

This is making purpose built smart computers within the warehouse a more valuable asset than before.

“As with computers in the consumer space, warehouse professionals have increasingly been adopting a diverse range of operating systems for use within the warehouse in conjunction with their mobile computing devices.

“Where once Windows was largely the only operating system utilised within the warehouse and supply chain, we’re seeing organisations wanting applications to function agnostically across operating systems. The ability of a mobile computing solution to evolve with warehouse operations over time is a key advantage.

A mobile platform with a core architecture across form factors vastly increases the ROI of the project, as it is future-proofed against changes in the organisation,” Fam told Manufacturers’ Monthly.

Manufacturers’ Monthly JUNE 2013 15

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Cleaning roller for conveyor belt cleaning The K-Spiral Cleaning Roller, available from Kinder & Co is intended to provide a maintenance free solution to conveyor belt cleaning. The wear resistant polyurethane spirals help to clean off sticky carry back.

The cleaning roller consists of a standard return roller fitted with wear resistant polyurethane rings. The spiral is left and right hand configuration to assist in belt tracking and ideally the unit is positioned over the discharge chute or a collection hopper.

The unit may be employed on any part of the return belt section in the case of short conveyors. Alternatively, on long sections

it is beneficial to employ these rollers only up to the point where the material does not adhere any more to the belt surface.

These rollers should not be employed as snub rollers adjacent to the drive or return drums.

The cleaning roller is well suited to the mining, quarrying and process industries, where build-up on return rollers causes belt damage and miss-tracking.

Suitable for all belt widths, it is not affected by mechanical fasteners.

Kinder & Co 1300 270 017 www.kinder.com.au

Upgraded simulation platform MApleSofT has announced a new release of MapleSim, its system-level modelling and simulation platform. Available from Australian Scientific & engineering Solutions, the upgrade offers more tools for programmatic analysis and model development, and expanded connectivity options.

Version 6.1 is designed to help engineers meet and exceed system-level requirements. The company claims it reduces model development and analysis time while producing fast, high-fidelity simulations. Improvements to the simulation engine mean that the platform produces its quickest simulations.

Also, the Application programming Interface, a collection of procedures for manipulating, simulating, and analysing a model in the Maple document environment, has been expanded to provide more flexibility for model creation and analysis. other improvements include expanded connectivity options with the new Connector for JMAG-RT, enhanced support for Modelica, and a new transparency option for the visualisation of multi-body objects allowing engineers to add additional visual context to their models. Version 6.1 is fully compatible with Maple 17.

Australian Scientific & Engineering Solutions 1300 72 12 50 www.ases.com.au

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Granulate for powder injection moulding BasF has released two new products in its Catamold range for metal injection manufacturing. Catamold, a granulate for powder injection moulding, comes in metal and ceramic varieties and is a ready-to-use raw material for making geometrically complex parts.

The product has had two new stainless steel variants added to its range, named Catamold 17-4PH and Catamold 316 LK. according to the company, performance A D _ Mwill A be N Mthe D same A T Mas A the R_ 1 3 .

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Manufacturers’ Monthly JUNE 2013 17

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What’sNEW Portable welder

The elevator bucket offers a large carrying capacity.

Ultra heavy duty elevator bucket line 4B Australia has designed a new large sized ultra-heavy duty elevator bucket line intended for the most severe agroindustrial uses, such as port and river terminals, ethanol and fertilizer plants, or frac sand and aggregate operations.

The bucket offers greater carrying capacity, along with durability and wear resistance.

Available in six sizes, it has a thick front lip, front corners and walls for longer life.

AsM anAextension 0 5 1 3 _of 0the 0 heavy 0 _ PRO duty CC-S elevator bucket, it also

incorporates the long lasting Iceberg Edge front wear lip and the unique tapered bottom.

Designed for very close possible vertical spacing (up to 4.6 buckets/metre) the tapered bottom ensures efficient bucket fill and discharge, especially in low-profile configurations.

This design allows the buckets to nest inside one another, delivering transport cost savings and storage efficiencies.

4B Australia 1 2 0 1 3 - 0 4 - 0 9 T 107037112565 : 0 3 : www.go4b.co.uk/australia/

BOC has expanded its range of high-technology welding machines with the introduction of the Picomig 305 D3 puls TKG. Produced by EWM, the portable and compact machine is suited for experienced DIY operators through to light and medium industrial applications.

Intended for use on construction sites and assembly work, the welder is small, light and universal.

It features tough plastic casing and innovative inverter technology.

The welder includes modified short arc welding with with rootArc that provides a capability for straight-forward gap bridging and positional welding.

It also features pre-programmed jobs for the most common welding tasks as well as synergic operation with self-explanatory operating panel and is available in models for wire spool 1 diameters 3 + 1 0 :D300 0 0 for assembly work or production.

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The PCS SR cutting machine will make light work of even the heaviest steel plate It’s been designed to be efficient, of high quality and cost effective.

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Brought to you by

Cable certifiers Power Parameters has unveiled the newest LanTeK II series cable certifiers.

They are designed for comprehensive testing and certification of basic link, channel link, and permanent link testing.

The cable certifiers are available in three models with frequency sweep ranges of 350, 500 and 1000 Mhz thus permitting testing of cat 5, 6 and 7(C1) cables and networks.

They are available with fibre optic link testing for multimode (850/1300 nm utilizing LeD[C2] source) and single mode (1310/1550 nm with laser source) in full duplex testing configuration.

According to the company, they can complete Cat 5e testing within nine seconds and Cat 6 in thirteen seconds.

The testers provide on-board memory for test results, and in the case of Cat 6, 1700 test results complete with graphical information can be stored.

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Servo-driven stirrup bender

The servo-driven stirrup bender includes an integrated pre-feeding unit.

The Pedax Twinmaster 16 is an automatic stirrup Jig system combined with an automatic adjustment machine model which is intended to offer high output of the last roller in each straightening roller by means and performance. The machine processes hotof two joysticks. rolled and cold drawn wire ranging from 6 mm to 16 It features an ergonomic PC console, as well as mm and double strand up to 12.7 mm. It features motorised adjustment of the mandrel height from the differentiated roller sizes which are intended to front of the machine. Noise generated by the machine provide better straightening results for all diameters. is low impact and an anti-twist system is optional.

The servo-driven stirrup bender includes an Precision Metal Group integrated unit of two 1300 062 763 1 5 / 0 5pre-feeding / 1 3 , 2 : for 2 3the: threading 3 2 PM AEST wires, a straightening system, which uses the Quickwww.precisionmetalgroup.com

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Introducing the Altivar 32 variable speed drive. A total motor control solution featuring built in logic controller and safety functions.

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Q&A: THE PEOPLE OF MANUFACTURING Q&A: Production Supervisor As part of our new Q&A series we interview you, and find out what your job is day to day. In this edition we speak to Matthew Arblaster, a production supervisor at Bayer and a nominee for the 2013 Endeavour Awards Young Manufacturer of the Year award.

Manufacturers’ Monthly: What are your primary roles and responsibilities in your job? Give us a day in your working life.

Matthew Arblaster: I am responsible for production department of the Australian site of Bayer MaterialScience. In this role my biggest and most challenging task is to mentor the Production and Maintenance teams to ensure we have a culture of Safety, quality and efficiency. This involves me working with and developing team leaders and operators so that they can make the correct decisions and build on their knowledge to ensure the plant runs smoothly. I run and coordinate training days for the teams to align and develop skills and aim to create a development culture.

As well as this I help production operators and maintainers solve problems and address any critical issues that may arise. Another key responsibility is to work with scheduling to coordinate future production and develop new products. I also need to ensure that I am “on top” of the happens of the 24hr plant to ensure production runs according to plan and put things back on track when things go array.

Other parts of my role involve being the global lead for efficiency which involves coordinating the shared knowledge with my global counterparts to ensure we learn from each other and deliver best practices.

One of the things I love about my job is that no two days are the same, and even the best planned day can take a completely different course, which can create some new and interesting challenges.

MM: What training/education did you need for your job?

MA: I believe there are three areas of skill set in any job being technical, financial and people skills.

For technical skills my engineering 20 JUNE 2013 Manufacturers’ Monthly

focused subjects than more traditional engineering courses.

Since then I have completed a certificate 3 in Accounting, a Diploma of management and have attended the Bayer Leadership course and the Global excellence in operations course.

To improve my business skills I am currently completing a MBA at Victoria University

Arblaster focuses on the development of culture. degree gave me the problem solving skills I needed to be able to learn onsite more about my industry and how the equipment I was working with operated. For financial skills I am focused on completing the MBA as this gives me a broad understanding of all business disciplines. For people skills this is the hardest one as there is no set recipe that can be taught. I have been fortunate enough for Bayer to send me on leadership courses to give me the theory’s, but the real learning comes from reflecting on

conversations and thinking “how did that go, how could I have done that better?” and continually challenge yourself.

Due to my love of manufacturing as a child, spending Saturday mornings in my father’s factory and any other free time pulling apart my mother’s cake mixer just to see how it worked, I enrolled in a Bachelor of Industrial Engineering and Engineering at Monash university – this was the only manufacturing focused course I could find and had far more human and business

MM: How did you get to where you are today? Give us a bullet point career path.

MA: During my 3rd year at university I needed to complete a summer work experience for my engineering course, I applied at Bayer and I was lucky enough to be selected. Working there for 5 years I was given challenging and rewarding projects including managing the maintenance department, project managing a $6M new production line and a large upgrade to the existing machinery.

From here seeking new challenges, I moved to Fosters Wine Estates to become the plant engineer at the state of the art Wolf Blass Packing Center to help implement lean manufacturing. I then took a position implementing an environmental government program as well as Capital projects in the engineering team, which gave me the opportunity to travel to many of Fosters sites to work with the different local teams.

At this point I wanted to focus my career on people management and leadership, and for this I needed to understand what it was like to work on the shop floor and be managed.

To obtain this experience I took an opportunity at a Fosters winery in the Napa Valley in California USA, where I shoveled grapes, operated the crusher and drove forklifts.

Looking to continue developing leadership and people management I returned to Bayer to manage manmonthly.com.au

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production and work for my mentor Bruce Scott.

at the core of this task what function does this do and how do we do this simply.

MM: What tools and/or software do you use on a daily basis?

MA: Basic computer.

MM: What is the one thing that you are most proud of in your professional life?

MA: How my team has come together with a very proactive attitude and will challenge themselves.

For this we won the annual Bayer Achievement award in 2012.

MM: Biggest daily challenge?

MA: Balancing the daily demands of plant management to the longer term tasks.

This task is becoming easier by developing and empowering my team to make decisions, freeing me to focus my time on longer term goals.

Daily plant demands are the biggest challenges. logical, people are complicated and i am learning that it takes different styles for engaging different people.

MA: In the whole manufacturing industry we are all doing more and MM: Biggest career challenge? more with less, but it’s about finding MA: Many challenges, but when I simple ways to complete the new look Aback D _ they M A Nhave M S all C Hbeen 1 O human C T _ 1 2 .MM: p dWhat f Pisayour g e biggest 1 1frustration 3 / 0 9 / 1 2 tasks , 1which 1 : 5is4 easier A Msaid than done focused. Machines are complex but in your job? … in the end its about questioning

MM: What is the biggest challenge facing your business?

MA: Higher cost pressures are a problem for everyone in manufacturing around the world and we are expected to do more with less, through building a strong base of skill and flexibility in our teams and thinking long term with our equipment we can be competitive.

China’s costs are increasing rapidly which will open up more opportunities for Australian manufactures, by making sure our plants and teams are skilled and ready we can grab them.

MM: Is there anything else about your job you want Australia to know about you and your job?

MA: I really want to thank my Father and Bruce Scott who have both been amazing mentors to me throughout my career to date.

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Motors& DRIVES Equipment reliability key to manufacturer’s success Smart thinking coupled with innovative technology and ultra-reliable equipment are paying dividends for local exporting manufacturer. Alan Johnson reports.

D

espite the strong Australian dollar, OreKinetics, a Queensland-based electrostatic separation technology company, is exporting over 60% of its innovative machines to titanium mining operations all over the world.

Research by Peter Gates, OreKinetics Founder and Managing Director, in 1999 led to the development of the company’s UltraStat conductive induction separator, and the CoronaStat ionised field separator the following year.

“Our machines are very robust and capable of processing five to eight tonnes of material an hour on a continuous basis; 8000 hours a year or more in hot industrial mining environments, in truly tough conditions, where it is extremely dusty and gritty.

“So when it came to choosing the electric motors and the gearboxes to drive our machines we went with SEW-Eurodrive from the beginning, and still only use their equipment now 14 years on.

“They are good robust motors and gearboxes that can operate in extremely harsh environments,” he said.

“We also get excellent support plus they offer us the ability to get our larger quantities directly from Germany, by the container load.

“We bought well over 1000 gearboxes from them last year,” Gates said.

“Another key advantage for us is SEW’s MEPS 3 higher efficiency motors.

“With high efficiency motors we can set the machine’s overloads at a normal current setting with the benefit that we get slightly higher output torque giving us the capability to set higher brush tensions in our machines if required,” Gates added.

22 JUNE 2013 Manufacturers’ Monthly

High efficiency gearmotors John Bellert from SEW explained that OreKinetics produces a range of machines demanding different quantities of gearmotors.

“For example on one separator there are eight of our Spiroplan W Series and six parallel shaft helical F Series gearmotors.

“The Spiroplans are economical, robust right-angle gearmotors that feature low operating noise and lifelong lubrication.

“The gearmotors feature steel-onsteel gearing, special tooth meshing relationships and an aluminium housing ensuring they are very quiet in operation, wear-free and lightweight,” Bellert said.

He explained that the short design and aluminium housing make for compact and lightweight drive, while wear-free gearing and the life-long lubrication facilitate long periods of maintenance-free operation.

And as the oil fill is independent of the mounting position, the gearmotors can be installed in any mounting position without altering the quantity of oil.

“Plus, identical hole spacing in the foot and face as well as the equal shaft height to both provides users with diverse mounting options,” he added.

Bellert said the F Series gearmotors were also popular in the mining industry due their high power density, high permitted overhung loads and a multi-stage gear unit for low output speeds.

“These two and three-stage, extra-slim parallel shaft helical gearmotors are designed for heavy duty applications, high torque and 24/7 operation.

“The many different sizes and designs ensure that the gearmotors can be used in a wide variety of applications even under the most unfavourable conditions.”

“Many manufacturers come to us for our expert advice on motor and drive technology.

“We work with a wide range of industries including the water treatment, food and beverage, pharmaceutical, manufacturing, mining and waste water industries,” Bellert said.

Separation technologies

The separators greatly improve process efficiency, reduce plant complexity and allow separation of minerals not previously possible.

Bellert said SEW motors and gearboxes are widely used by heavy industry due to their efficiency, reliability and back up.

“All of our components are still manufactured in Germany, with the gearboxes and motors hand assembled here in Australia with excellent quality control.

Bellert explained that every SEW motor and gearbox has a unique serial number which allows customers, via a smart phone app, to instantly download a wide range of information on the equipment including type and quantity of oil required, maintenance procedures, and spare parts list.

As well as OreKinetics, Bellert said SEW work with many of its customers on their prototypes.

“When it comes to designing a new machine, we can work with manufacturers regarding recommendations on different motor power needs and speeds.

In the last 14 years OreKinetics has worked closely with the titanium minerals industry and has supplied its proprietary technology to virtually every processing plant in the world.

“Our machines performance and our delivery capability has seen us become the preferred supplier worldwide for our mineral separation technology.

“This year we have sold over 130 machines.”

Gates said the advent of OreKinetics CoronaStat has enabled new titanium mineral provinces, particularly where finer minerals are present, to be developed and processed in a viable manner.

“Our patented induction plate electrodes are designed to concurrently ‘force’ the charge decay of conducting particles as well as apply a holding force to charged non-conducting particles.

“Each electrode used in OreKinetics CoronaStat has a unique function which combined overcome the shortcomings of conventional ionised electrostatic separators,” Gates explained.

Today, OreKinetics is continuing the development of its revolutionary machines along with the development of new flowsheet and process control concepts particularly with a focus on reduced capitol costs and improved plant control specifically with respect to environmental influences. manmonthly.com.au

MA0613_000_SEW.pdf

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AEST

Gearmotors \ Heavy Industrial Solutions \ Electronics \ Decentralised Systems \ Services

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MA0613_024.pdf

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Motors & DRIVES

VSD – very simple (drive) decision More efficient variable speed drives are cutting energy costs by up to a third for one manufacturer.

M

anufacturers always aim to get the most out of their equipment for as long as

they can.

And with rising energy costs, ensuring a machine’s reliability is critical during manufacturing.

With CSR Roofing manufacturing terracotta roof tiles at its Vermont (Melbourne) factory for over seven decades, producing roof tiles that last generations, it was not surprising that the company chose an Atlas Copco VSD (variable speed drive) compressor to replace its aging machine.

John Tilli, maintenance manager at the Vermont facility, said longevity and reliability are very important for CSR Roofing as the factory operates 24/7, apart from just three weeks of the year.

“I have always been impressed with Atlas Copco’s reliability, but when I saw the results of the air measurement survey, that was the real clincher in the deal,” he said.

“Surveys showed that VSD technology can save CSR Roofing thousands of dollars every year, and with the carbon tax incentives and energy savings, we were able to get the capital funds needed for the new compressor, and very close to a 3-year pay-back period.

24 JUNE 2013 Manufacturers’ Monthly

“With electricity prices starting to rise, with some people talking about a 40 to 50 per cent increase, these energy savings, coupled with lowering our carbon footprint, are very important to us,” Tilli said.

He explained that CSR Roofing is continually striving to lessen its carbon footprint and reduce the environmental impact of its operations, in particular the amount of energy and water the company consumes.

“We measure key environmental performance indicators and each CSR business has set goals to reduce these indicators progressively over a five-year period.

“We have had Atlas Copco compressors here for over 20 years and the machines have always performed to what the company said they would, and we expected no less with this new one.

“They predicts our energy savings will be around 30 per cent,” he said.

“It could be more, but our plant runs 24 hours a day, seven days a week, with the compressor running all the time, even when we are not producing product. This is mainly due to our kiln, which runs 24/7, and needs a small amount of air to keep it operating.”

Tilli said many people don’t

realise compressed air is one of the most expensive utilities to produce, because you need another utility to create it.

“This is where the Atlas Copco VSD compressor really comes into its own, as they produce the world’s leading compressor regarding turn down range.

“Because if the compressor doesn’t turn down enough you don’t get any savings and as a result, the overall operating range of the machine becomes very important.

“So for us, it was important to get a machine with a really good turn down range and keep those energy savings going.

“For example, if we only use 20 per cent of the compressor’s capacity at night, and The VSD compressors were used in CSR’s roof tile factory. the turn down is not low

VSD compressors actively reduce energy usage. enough, say at 50 per cent, then we are wasting 30 per cent of the air on energy,” he said.

As well as Atlas Copco’s VSD technology to reduce CSR’s energy usage, Tilli said he is also looking at isolating parts of the plant at night when they are not in use.

“We can turn a section off so we don’t have to worry about air leaks in that section. We have a lot of old gal piping here, and you can’t stop it leaking.

“To change the piping, the cost involved would be massive and the payback could run to 10 to 15 years or so,” he said.

Tilli went on to state that the manufacturing plant, with just 30 people in total, is automated.

“We manufacture terracotta roof tiles here and all the automated machinery has some sort of air requirement with pneumatic cylinders and vacuum cups.

“So it’s important for us to have a constant supply of clean, dry air as manmonthly.com.au

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we can’t afford to have breakdowns and production downtime,” he said.

Tilli explained that the factory is broken up into two plants.

“One where we make our accessories and grind our clay, and the main plant where we manufacture the actual roof tiles, with one compressor for the whole site. At the moment, while we are waiting to install the new Atlas Copco Workplace design machine, a GA55VSDFF latest generation with in-built refrigerated dryer and DD/ PD filters, we are running a 25-yearold machine as a stand by.

“But it is producing a lot of water and causing me all sorts of problems with the machinery.

“Our main compressor, which was only slightly younger, and had done a considerable number of hours, eventually broke down and needed a full rebuild hence the search for a new more efficient machine,” he said.

Tilli’s advice to other manufacturers looking to reduce their energy costs and their carbon footprint is to get an air measurement survey and have a closeMlook A 0 at 6 1VSD 3 _ technology.

0 0 0 _ PI E. pd Igor Kotliarski, Sales Engineer

23/05/13,

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with Atlas VSD machine.

Copco’s “With CSR Industrial Roofing, Air Division, we were agrees, saying up against getting an air another major measurement air compressor survey is a manufacturer, smart first who also move. undertook its “The own audit. But compressed air Atlas Copco measurement audits have survey report the ‘smarts’ in is free and the software customers can to simulate see at a glance and accurately the upside predict future of investing energy savings. in VSD “CSR technology.

Roofing “Companies was very can clearly satisfied with the results see what their of what we compressor proposed and demand is on a daily basis, Accompanying air audit surveys increase efficiency. the detailed nature of Atlas and how much Copco’s air measurement survey,” electricity they are currently using. he said.

Our software can also simulate the for a fproposed P a g energy e 1 savings 7 / 0 5into / 1the 3 , 1 0 : Kotliarski 0 9 : 1 3 explained A M A that EST future should they wish to invest in a compressed air energy audit, Atlas

Copco engineers simply connect up their data loggers to the compressor, and leave them on site for a period one-week.

“With this in mind we usually ask our customers to select a period when plant is running at maximum capacity.

“We then collect the data loggers and upload the data into proprietary software and produce a detailed report on the proposed compressor for the client.

“Having an air measurement survey is very important, and Atlas Copco’s software is one of a very few programs on the market that can simulate the optimum size VSD machines and predict energy savings for the customer.”

Kotliarski said this makes it a lot easier for the customer to justify the purchase, as Atlas Copco can demonstrate to its customers the proposed payback and return on capital when customers invest in an Atlas Copco compressor.

“Our competitors can estimate the current used on an air compressor, but they have to rely on a certain degree of guesswork when selecting a new machine.

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Manufacturers’ Monthly JUNE 2013 25

MA0613_026.pdf

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Motors & DRIVES Compact drives

Electronic motors

ROCKWELL Automation has released the Allen Bradley PowerFlex 525 AC compact drives designed to help machine builders and end users simplify equipment design and operation, and speed up installation and configuration.

Featuring a modular design, the drive is available in power ranges from 0.5 to 30hp or 0.4 to 22kW at 100 to 600V input.

Features such as embedded EtherNet/IP, safety, USB programming, energy savings and a variety of motor control options make the drives suited for machine-level and standalone applications or simple system integration.

The drives provide a variety of motor control options to accommodate openand closed-loop applications which include conveyors, materials handling, compressors, fans and pumps.

To help simplify and streamline setup, users can configure the PowerFlex 525 AC drive through its human interface module (HIM), Rockwell Automation Connected Components Workbench software or Rockwell Software Studio 5000 Logix Designer.

Time-saving application sets, which are groups of pre-defined parameters for common drive applications are offered for users to apply ‘as is’ or customise for a machine.

Using a standard USB connection,

SEW-EURODRIVE has released a new permanent magnet synchronous electronic motor to complement its range of mechatronic drive systems.

The new DRC electronic motor can be directly coupled with SEW’s comprehensive gear unit range, making it highly flexible. With its efficiency surpassing IE4 Super Premium Efficiency class, the electronic motors are also suitable for worldwide use while saving up to 50% of energy costs compared to conventional electric drive technology.

The DRC electronic motor series consists of a permanent-field synchronous motor and matching integrated drive electronics. Also available as a brake-motor, the DRC series is suitable for hoists and inclined conveyors. A highly efficient bevel, helical or parallel-shaft gear unit can be mounted directly via the flange and output shaft.

Designed for functionality and efficiency, the DRC electronic motor features the unique Single Network Installation (SNI) technology from SEW that requires only one 4-wire cable for power supply and communication, reducing the amount of cabling efforts significantly and saving up to 60% of installation costs.

Variants with binary control and

The drives are designed to help machine builders and end users simplify equipment design and operation. machine builders can easily download the completed configurations and share with multiple drives, which greatly speeds up commissioning time.

Rockwell Automation Australia 02 9428 7222 http://au.rockwellautomation.com/

26 JUNE 2013 Manufacturers’ Monthly

AS-Interface communication are available for standalone applications or systems with simple drive functionalities. The fourth variant is equipped with the CANbased SEW system bus SBus, which provides excellent flexibility for integrating various fieldbus networks, increasing system performance for the realisation of sophisticated drive tasks.

SEW-Eurodrive 1300 SEW AUS www.sew-eurodrive.com.au

Geared motors with a smart head for positioning tasks

Air motors DEPRAG has released its enhanced range of Power Line air motors, which are designed to reach their high torque value required the instant they start.

The 54, 55 and 65 motors have been completely redesigned. The designers have standardised the structure with the aim of enabling a more effective, and thus more economical, manufacturing process for the drives.

The drives are now equipped with a standardised IEC flange connection, as used in electromotors and commercial gear connections.

The IEC flange now allows easier connection to different gear types, which may be planetary gears, spur gears, worm gears, bevel gears or other gear types.

The company says its standard range will now include these air motors without a gear, allowing it to be flexible in the

The DRC electronic series is available in two distinct frame sizes covering a power range up to 1.5 kW with a further 250% overload capacity.

The drives are now equipped with a standardised IEC flange connection. way it implement sthe speed or torque adjustment, using standard gears from a wide variety of manufacturers.

IDeprag www.deprag.com

NORD Drivesystems now equips its SK 200E inverters, which are available for installation near the motor or as motor-integrated models, with the same wide functional range as the centralised SK 500E series of cabinet-installed inverters.

The decentralised frequency inverters not only provide an ample overload capacity of 200%, but also enable users to position the drive with high precision.

The relative positions (incremental or endless axes) or absolute values (rotary tables/ fixed, repeatable positions) can be controlled with binary values through the SK 200E’s inputs and stored within the drive.

Alternatively, they can be set via a fieldbus system. Positions can be detected via incremental encoders, or by directly importing position values provided by a CANopen absolute encoder.

Configuration is easy, fast and concise, requiring only a few parameters to be set for commissioning and optimisation.

The encoder signals can be used for speed control, enabling an unprecedented dynamic performance from asynchronous motors. The company can provide individually assembled decentralised drive solutions from a single source for similar situations.

NORD Drivesystems 03 9394 0500 www.nord.com

manmonthly.com.au

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AC drives take aim at inefficiency Cutting motors costs, increasing productivity.

M

achine builders and end users alike want AC Drives that are easy to configure, deliver flexible control, and offer efficient communication.

The equation is clear. Flexibility, ease of installation, reliable operation and simple configuration help cut costs and increase productivity. As such, Rockwell Automation has positioned its Allen-Bradley PowerFlex 525 AC drives as ‘next generation’ items.

Designed for quick installation, they offer fast configuration and flexible operation. The drives are suitable for a wide range of applications, including conveyors, material handling, compressors, fans and pumps. And, from a machine builders’ perspective, they are intended to simplify design and operation.

Users can configure the drives through a human interface module (HIM), Rockwell Automation Connected Components Workbench software or Rockwell Software Studio 5000 Logix Designer.

And the units come with groups of pre-defined parameters for common drive applications.

These application sets can be applied as configured by the manufacturer or they can be customised.

Designed for quick installation.

In addition, using a standard USB connection, machine builders can download the completed configurations and share with multiple drives.

This is intended to speed up commissioning time.

Removing the control module from the power module further reduces startup time because configuration and installation can be done simultaneously. MainsFree programming through a USB connection removes the need for main power during drive configuration, as well as the need for special adapters to communicate

between the drive and the programming tools.

The AC drives may be used with a range of network protocols, so the problem of integration within existing architecture is minimised.

Add-on profiles are intended to eliminate address mismatch errors, plus an ‘automatic device configuration’ function detects replaced drives and downloads settings.

Embedded EtherNet/IP connectivity optimizes integration with programmable controllers to deliver more application flexibility. Optional dualport EtherNet/IP connectivity supports device level ring (DLR) topology, providing a robust network infrastructure.

There is an embedded safe torque-off feature to help ensure that, if a safety circuit is tripped, the drive will not restart. Apart from OHS obligations, the feature protects machinery in the long run.

The feature is rated up to SIL2/PLd Cat 3, meeting ISO 13849-1 standards.

A compact unit in itself, the PowerFlex 525 AC drives need just 50 mm clearance on the top and bottom when installing into a cabinet.

They are rated up to 50 C, but when an optional fan kit is added, can withstand temperatures up to 70 C with current derating.

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Manufacturers’ Monthly JUNE 2013 27

MA0613_028.pdf

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Maintenance:

PLANT & MACHINERY

Keeping machines running Unplanned downtime is every production managers’ ultimate nightmare but help is at hand.

Alan Johnson reports.

W

ith high OEE (overall equipment effectiveness) increasingly important for Australian manufacturers in today’s ultra competive market, unplanned production downtime is an unwelcome occurance.

Obviously regular maintenance is the key to preventing breakdowns, but stopping machinery to check on bearings, electrical connections etc is not always possible. Instead many manufacturers are now using thermal imaging cameras as part of their predictive maintenance inspections.

Gunther Willems, Technology Manager at one of Europe’s largest condition monitoring consultancy agencies – Coservices, says thermal imaging is the fastest growing predictive maintenance technology on the market today.

“It is simply the only technology that allows users to immediately ‘see’ what’s wrong. We perform inspections at regular intervals so that we pick up faults as they develop. This allows repairs to be planned accordingly, allowing companies to fix issues before they disrupt the production process,” Willems said.

He says without predictive maintenance inspections companies are forced to use a method called preventive maintenance.

“This means that every piece of equipment is replaced at regular intervals to prevent breakdowns. But in many cases, pieces of equipment are replaced before their time, just to be on the safe side.”

Instead, Willems says, predictive maintenance inspections using thermal imaging technology can save money.

“With predictive maintenance inspections using thermal imaging technology, we can accurately determine whether a piece of equipment needs to be replaced or not.

“This is important information for companies, for the continuity of 28 JUNE 2013 Manufacturers’ Monthly

between objects, thermal imaging produces a clear image and is an excellent tool for predictive maintenance, R&D and automation applications.

Thermal imaging cameras

An overheating conveyor roller picked up using thermal imaging. production is guaranteed without unnecessary equipment replacement, leading to cost savings of thousands of dollars,” said Willems.

He also explained that the services provided by Coservices are not limited to thermal imaging alone.

“For the maximum effect we combine several technologies: vibration analysis, ultrasonic tests, oil analysis and inspections using thermal imaging cameras.

“The main advantage of thermal imaging is that users can locate mechanical and electrical problems very quickly and accurately. With thermal imaging users are able to immediately see which component is causing the problem, and are crucial to allow swift inspections.

“In some cases there are also simply too many pieces of equipment or equipment components to test using vibration analysis or other methods.

“If for example a production plant features a row of conveyors, the operator can walk along the conveyors and swiftly scan them with the thermal imaging camera - a major time-saver.

“The same goes for electrical equipment: if the operator is inspecting an electrical cabinet with 30 fuses, for example, they don’t

want to go and check each individual fuse using a spot pyrometer to find out which one is going to fail first.”

And according to Willems for some types of equipment thermal imaging really is the only technology companies can use.

“With refractory linings, for instance, thermal imaging cameras are the only practical condition monitoring tool available.

“Basically, what I’m trying to say is that a company that provides condition monitoring services cannot be complete without thermal imaging technology,” Willem said.

About thermal imaging Thermal imaging is the use of cameras constructed with specialty sensors that “see” thermal energy emitted from an object.

Thermal, or infrared energy, is light that is not visible to the human eye because its wavelength is too long to be detected.

It’s the part of the electromagnetic spectrum that we perceive as heat.

Infrared allows us to see what our eyes cannot.

Thermal imaging cameras produce images of invisible infrared or “heat” radiation and can see in total darkness and through fog and smoke.

Based on temperature differences

Thermal imaging cameras are designed to monitor continuous processes and can be used to collect information on product quality and/ or production efficiency that is difficult or impossible to capture using conventional means such as thermocouples or visible light cameras.

FLIR Systems, a world leader in the design and manufacturing of thermal imaging cameras, has recently introduced a range of compact thermal imaging cameras for automation/process control applications.

The company’s new Axx-Series is designed for those applications that require the benefits of a thermal image but do not need exact temperature measurement.

The cameras are described as ‘compact, complete and affordable’ and easily integrated into a machine vision environments.

Able to visualise temperatures between –40°C and +550°C, the camera is able to pick up temperature differences as small as 50mK become clearly visible on a crisp thermal image, and since the cameras come with Power over Ethernet, communication and power are supplied with only one cable.

Different versions are available.

While the A65 produces crisp thermal images of 640 x 512 pixels, users who do not need this high image quality for their application can choose the A35 which produces thermal images of 320 x 256 pixels, the A15 which produces thermal images of 160 x 128 pixels or the A5 which produces thermal images of 80 x 64 pixels.

FLIR Systems Australia 1300 729 987, www.flir.com manmonthly.com.au

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24/05/13,

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EndeavourAWARDS

Enter online at manmonthly.com.au

Celebrating a decade of excellence The 10th Annual Manufacturers’ Monthly Endeavour Awards night.

F

or the past ten years the manufacturing industry has gathered to celebrate excellence, innovation, and outstanding performance.

One night, manufacturing’s night of nights, sees the industry recognise and reward those who have made a real difference to Australia’s manufacturing landscape.

That night, Manufacturers’ Monthly Endeavour Awards, once more celebrated those that are excelling in the industry.

Despite the apparently gloomy pall that hangs over the industry, the mood amongst attendees was excitement and optimism in the face of difficult odds.

More than 200 people attended the night, which saw winners across 13 categories ranging from Lifetime Achievement and Young Manufacturer of the Year through to Technology Application and Environmental Solution.

The night was opened by speeches from the newly installed chairwoman of Manufacturing Australia, Sue Morphet, who discussed the need for a gas reservation policy to ensure manufacturers have access, in the

future, to a relatively cheap and constant energy source.

She was followed by Federal industry and innovation minister Greg Combet, who provided optimistic speech about the current state of manufacturing and its future under a Labor Government.

After his video address to all and sundry opposition minister for industry and innovation Sophie Mirabella took to the stage to respond to Combet’s address, painting a future under a Coalition Government, and the support that could be forthcoming.

After this the awards were announced one by one, and the winners were brought up to the front, showcasing what the industry has achieved.

All in all the night brought together the industry to highlight that in spite of a difficult economic climate caused by a high dollar and a slow down in manufacturing globally, Australian manufacturers are still innovating, and are still developing better, smarter, safer, and more efficient ways to works.

More than 200 people attended the event in Melbourne.

Manufacturing Australia’s chair Sue Morphet opened the awards.

The awards themselves ran across 13 different categories.

30 JUNE 2013 Manufacturers’ Monthly

There were close to 100 nominations for the awards. manmonthly.com.au

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10/01/13,

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28/05/13,

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EndeavourAWARDS Lifetime Achievement Award – 2013 Winner

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Enter online at manmonthly.com.au

A lifetime of excellence For his years of dedication and innovation, Russell Hughes has won the Lifetime Achievement award.

“I

think one thing that Russell’s instilled in what we do is not only embrace change but actually instigate it through innovation, and that really sets us apart,” said Paul Hughes, who proudly accepted the Lifetime Achievement Endeavour Award on behalf of his father, Russell.

Paul started Integra Tooling Systems in 1991, before dad Russell joined him and helped changed the company’s focus. Its name had to change, too, and in 1993 father and son were working together at Integra Systems.

Integra is a family-owned product development and manufacturing company, specialising in engineering and designing products and components built from steel and aluminium. It has three divisions – Integra Development, Integra Manufacturing and Integra Products. It offers a variety of product development and manufacturing services.

Russell is the company’s Engineering Director, and at 72, is continuing a proud career that dates back to 1957, beginning at as an apprentice at the Maribyrnong Ordnance Factory. From there, Russell moved to Caterpillar’s Tractor Factory where engineering design became his specialty.

Russell later became an engineering and design contractor for companies such as Ericsson, International Harvester, Ford (Geelong and Broadmeadows), Zenford and General Motors Holden. Russell gained a vast range of skills and experience and became the Senior Engineer for Sidchrome.

He took on the general manager role with Rymer Lighting, a Division of Howard Smith Industries, which then became Thorn EMI. During Russell’s 17 year tenure at Rymer Lighting, he was promoted to managing director, and manufacturing and

engineering director of Howard Smith Industries and lead the growth of Rymer Lighting from a $1m per annum turnover to $33m per annum.

In 1993, Russell joined Integra Systems as Joint Director with his son, Paul Hughes to develop his dream of harnessing innovation to develop engineering solutions.

“It’s been our constant drive for innovation and our trying to do things a little bit different,” said Paul of the company, and father Russell’s, approach. Russell’s inventive nature led him to develop the world’s first high speed Coil Processing Line (called Punch-IT Coil Processing), built with Paul, which was ultimately Integra’s first production machine.

Russell identified a niche in the Australian market for a linear high speed coil 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 Systems brought Russell’s idea to fruition and Russell and his son Paul designed and built these machines for a range of customers.

The Punch-IT linear coil processing line is a fiveaxis system consisting of an electronic feed system and a series of Russell is a mentor to the manufacturing community. four punching stations

32 JUNE 2013 Manufacturers’ Monthly

Paul Hughes accepting the award on behalf of his father. suitable for most linear punching applications.

Punching at a rate of 120 strokes per minute, coil is consumed and converted to finished parts at a rate of 20 linear metres per minute, at least six times faster than a turret punch press.

The Punch-IT line was so technologically 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).

In 1999, a strategic decision was made by Integra Systems to build an in-house Punch-IT line for component manufacture, and became the first production machine and manufacturing foundation.

Russell’s Punch-IT Coil Processing Line invention, engineering know-how and manufacturing experience lead to the foundation of Integra Systems and the variety of superior services it offered. The services offered now span beyond the Punch-IT Coil Processing Line, to a complete a manufacturing solution portfolio, but the Punch-IT line is a clear manufacturing differentiator for Integra. Russell is a mentor to not just his son and all at Integra, but to those at the University of Melbourne Engineering Design Group, where he is a member.

“It feels great that he’s been recognised for his efforts in the engineering and manufacturing industries,” Paul told Manufacturers’ Monthly.

The company is also proud of their veteran Engineering Director, saying “Russ was a finalist against others who are also significant contributors to the industry but he was recognised for his innovation and mentoring qualities and his ‘never say die’ approach to nutting out solutions”. manmonthly.com.au

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

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EndeavourAWARDS Safety Scheme of the Year – 2013 Winner

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A blueprint for global safety The implementation of a new safety system at a bottling plant has set a precedent for one manufacturer.

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or the development of a safer bottling plant and the enhancement of workplace safety culture, Diageo has won the Safety Scheme of the Year award.

Diageo is the world’s largest manufacturer of spirits, beers, and wines, operating in 180 markets and employing 25 000 people globally, with plants in the UK, US, Canada, Spain, Italy, Africa, South America, India, and Australia.

Diageo Australia has local operations in Huntingwood and Bundaberg.

A routine risk assessment identified that a number of the bottling lines at the Huntingwood plant required upgrading from a machine safety perspective.

The manufacturer’s risk assessment identified that it need to upgrade its safety standard monitoring system.

It explained that “the old system was a mish mash of different safety technology and provided for no consistent safety methodology relating to the operation of the plant”.

With no consistent safety practices the company found it difficult to further develop safer operating standards.

According to Diageo “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)”.

Diageo undertook a safety upgrade project for two of its bottling lines at the Huntingwood plant, with a view to creating a global best practice blue print which could not only be rolled out throughout its Australian operation but also globally.

A number of different 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 into the safe design process and were bought in to its implementation.

The project took around a year to commission, test, and then validate troublefree operation.

Diageo added that the entire process “required significant engineering input to ensure the functionality met Diageo’s safety requirements, did not impede production line productivity and throughput as well as improving the diagnostic and troubleshooting capability of the operators with regards to the safety system”.

The new safety control system for Diageo’s Huntingwood bottling lines facility dramatically improved all safety aspects when compared to the old system that was A programmable safety control system was implemented. in place.

Once the new safety system was The system was then designed and installed it specifically has achieved the following implemented by a third party safety contractor improvements.

(Brolton Engineering Group) to Diageo’s standards.

Almost immediately there was a higher level Diageo selected a state-of-the-art distributed of safety for the entire bottling process, from programmable safety control system which meets depalletisers, fillers, labelers case packers and the various system requirements and contained palletisers. almost 800 safe I/O spread across 13 remote There is now safe locking of guards in processing head modules distributed across the dangerous areas to prevent operator access while plant. machinery is moving and during cleaning (Clean The system operates over 130 discrete safety In Place), lessening the risk of accidentally injuring processes to ensure the machinery is constantly any workers on site. operating in a safe state.

Simpler diagnostics and troubleshooting The safety upgrade has resulted in a higher level information now to allow the operator to quickly of safety for the entire bottling process protecting identify safety breaches which are stopping the the 100 workers employed there. bottling line before it becomes a major issue.

A critical part of the project was the complexity The enforcement of the use of the standard of the system changeover as it was expected operating procedures providing more checks and to create little to no downtime with a significant balances that ensures the operator is following the amount of processes to test, as well as having a correct sequence and makes operating procedures short system rollback time if it was deemed not to more transparent for both the company and the move forward with the changeover. worker.

The final stage was a safety validation to ensure Diageo stated that this upgrade “has actively every safety aspect to the system is appropriately demonstrated a commitment to safety on the plant and thoroughly tested by a certified person leaving floor to employees as a result of the significant the machinery in its final operating state. project investment and re-enforces Diageo’s quest for a zero Harm safety culture”.

Importantly, this upgrade is not a one-off isolated achievement, as it was a test case for implementation and will now be used as a blue print for all future safety upgrade projects, not only in Australia but also globally where the Diageo plant in Ireland has followed a similar project process and design.

The Huntingwood facility.

34 JUNE 2013 Manufacturers’ Monthly

The judges said: This was a comprehensive approach to a complex set of risks from the bottling line, and is able to be used elsewhere. manmonthly.com.au

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EndeavourAWARDS Exporter of the Year – 2013 Winner

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Exporting success ANCA, which exports more than 90 per cent of its manufacturing products, has won the Exporter of the Year award.

W

ith the downturn in manufacturing in Australia, many companies have looked offshore for new opportunities, not to build overseas, but for new markets.

ANCA has won two Endeavour Awards, Exporter of The Year and the Overall Manufacturer of The Year for their efforts in not only defying decline during a downturn, but actually growing significantly and opening new markets overseas for Australian manufacturers.

Amazingly for an an Australian company, ANCA is able to export 98 per cent of its product, CNC tool grinders. In a time when the persistently strong Australian dollar is making life difficult for many of the country’s manufacturers, ANCA is not only surviving but growing its exports sharply. It exports to most continents. Its products are used in industries from aerospace to medical to automotive manufacturing.

The tools manufacturer is able to export 98 per cent of its products.

Last year saw the Bayswater-based ANCA grow its exports by 19 per cent, selling its “versatile, In addition the number of marketing, sales, going to determine where we sit in the market.” precise and user-friendly” machines, some of quality and service people have been increased.

The company’s export success has been which weigh seven tonnes, all over the world.

Revenue from the MX7 has increased year on recognised many times before, and it claimed “It’s a fantastic feeling, yeah,” offered co-founder year, doubling annually to reach three times its the Large Advanced Manufacturer Award at the and owner Pat Boland, who founded ANCA in original revenue in FY11/12.

Australian Export Awards last year, the second 1974 with Pat McCluskey, when asked how it felt The MX5 has already achieved orders of 42 time it has done so. to have the company’s success recognised. since it was launched July 2012.

Add to this seven Governor of Victoria Export “We are one of the few examples of - well a An innovation focused company, ANCA invests Awards and now back-to-back Endeavours number of Australian companies that make a about 9.5 per cent of its sales revenue in research for exports, and it’s clear that ANCA are doing high-technology product and actually sell it to the and development. something right. world,” said Boland.

It also invests heavily in people.

ANCA has expanded into Thailand in recent “It’s a very specialised product but when you Of its 400 employees in Melbourne, nearly a years, allowing it to make use of bilateral trade take a global market it becomes significant.” third, 120 of these, are engineers. relationships between Thailand and Australia and ANCA manufactures CNC tool grinders.

Innovation and the uniqueness of its machines Thailand and Japan.

As the major components and software are allow it to be highly sought after, despite the The engineering and software know-how and manufactured by ANCA and dollar’s strength. The focus on keeping up with IP the company possesses remain in Australia, ANCA Group companies, the pace of innovation though, and it is here where it will develop what’s Tool grinding through behind its success: its new innovations. machines in their investment will It continues to pursue growth, and Boland range include remain essential suggests that this will involve new products.

TXcell, TX7, MX7, to the company.

“There’s a couple of dimensions of growth.

MX5. Their recently “Our plan is We’ll grow in our existing market, we’ve got lots of expanded MX that we space to grow in the world,” he said. range has been continue to “But as well we’re hoping to have a horizontal a particularly invest heavily growth into new product areas. And a lot of our successful export. in our products, growth in the next years will be in those new ANCA employee because we sell product areas, ancillary to what our current market numbers have products against is, but different.” continued to international ANCA’s head office is in Melbourne, which is the increase overall due competition,” said major manufacturing site. A manufacturing site is to increased machine Boland after accepting also located in Thailand. ANCA has offices in the numbers and planned the award.

UK, Germany, Italy, Japan, China, Thailand, Brazil, strategic growth, some “It’s the quality and India, Mexico and the USA. of these work directly with These are supported by a global network of ANCA has expanded off innovation of those the MX range. agents. the export of its MX machine range. products that is really

36 JUNE 2013 Manufacturers’ Monthly

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

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EndeavourAWARDS Environmental Solution of the Year – 2013 Winner

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Striving for sustainability A total factory approach to sustainability has won the Baltimore Aircoil Company the Environmental Solution of the Year award.

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completely holistic approach to environmental management, from the way the factory operates and its approach to sustainability through to better design and sourcing of its products and its manufacturing processes has seen Baltimore Aircoil win the Environmental Solution of the Year award.

Baltimore Aircoil Company (BAC) is a worldwide manufacturer and marketer of evaporative heat transfer and ice thermal storage products that it says “conserve resources and respect the environment”.

It manufactures products at Somersby, on the New South Wales Central Coast.

All BAC’s products are designed and manufactured to ensure extended product operating life as well as provision for recycling materials once decommissioned.

A large majority of its products are produced from sheet metal material purchased locally to reduce the “carbon miles” associated with the equipment.

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 our sewerage system.

It developed its environmental approach through its aim of sustainability through lean manufacturing.

It came about after a business review from Enterprise Connect highlighted the need to gain

BAC presented the award by Atlas Copco.

accurate data relating to the manufacture of its cooling tower units.

Continuing with improvements, BAC then employed the services of Synergy Management Consulting Group who trained several employees in the principles of ‘Lean Manufacturing’, with the result being that they received Certificates of Competence for “Lean Six Sigma Green Belt” Program was completed June 2011.

BAC says that in order to be sustainable and operate with better environmental practices it is continually ‘reinvigorating’ lean manufacturing.

Part of this ‘reinvigoration’ process has seen it set an objective of reducing waste in various mediums through a process of small steps to make a large difference.

These objectives are intended to be achieved by setting comprehensive benchmarks, with measurements being taken and reported quarterly and yearly.

It has cut annual electricity usage and associated carbon emissions by 11 per cent year on year, which it achieved simply by changing lights within the factory and office; installing a new compressor; reducing from two brake presses Its new cooling towers no longer require chemical water treatment. to one brake press; and

38 JUNE 2013 Manufacturers’ Monthly

buying a more energy efficient photocopier.

Further reductions in electricity are expected in the next financial year as some changes were made in the latter part of 2012 and are yet to show in their total reduction Air conditioning adjustments have also seen a 30.5 per cent reduction in gigajoule usage when comparing a five month period Aug-Dec 2011 Waste Management Program Employees have been encouraged to improve all methods of waste disposal at BAC. Major changes have occurred in the way waste was treated and recycled over 12 months include recycling waste steel, with 144.09 tonnes recycled; 59.91 tonnes of wood reused; and a 20 per cent increase in the amount of paper recycled.

It also managed to reduce its carbon footprint by redirecting waste to a nearby tip, cutting 500 kilometres of travel annually.

However BAC states that culture change has been one of its most successful ventures, as more employees are becoming aware of its commitment to sustainability, and assisting change to protect the environment.

Looking ahead, Baltimore Aircoil plans to visit the Research and Development site at Newcastle University this year to investigate the solar paint that is being produced to reduce electricity costs.

Time frame is that the initial work will involve a two week study.

BAC says it is proud of its environmental performance through its commitment to reductions in resource use; designing products to boost end user efficiency while taking responsibility for its impact on the environment and respecting the communities in which it operates.

All BAC products are engineered to minimise lifecycle costs through a combination of low energy consumption and low maintenance.

An extensive array of product/options addresses such issues as sound, energy and reduced water consumption requirements.

BAC is currently enrolled in the Sustainability Advantage Program, with a plan to achieve Platinum recognition in three years.

It is also working through a Continual Improvement Program which involves benchmarking the company, in order to recognise opportunities and adopt ‘best practices’.

Internationally, Baltimore Aircoil is an employee-owned company, which encourages an entrepreneurial spirit throughout our organisation.

This culture helps BAC respond successfully to new opportunities and consistently improve its manufacturing methods. manmonthly.com.au

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0613 - FP - MM - Atlas Copco.pdf 1 15/05/2013 11:15:23 AM

Atlas Copco Compressors - First in Mind, First in Choice® when it comes to environmental sustainability

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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.

As a long term sponsor of the Endeavour Awards, Environmental Solution of the Year, we would like to congratulate this year’s winner, Baltimore Aircoil Australia.

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

Download a QR reader and scan the code for more information about our Products and Services

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EndeavourAWARDS Consumer/Trade Product of the Year – 2013 Winner

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The taste of success For taking beverages in a new, healthier direction, HJ Heinz has won the Consumer/Trade Product of the Year award.

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ustralian manufacturers are known the world over for the high quality of their food and beverage products.

When people are buying an Australian made drink, they are assured that the high standards within the industry are adhered to.

And now one company has broke new ground in this space, not only producing a high quality juice, but one that is also an entirely new creation.

For the development of an Australian first probiotic juice, HJ Heinz has won the Consumer/ Trade Product of the Year award.

The company initially launched Golden Circle Healthy Life Probiotic juice in May 2012.

The idea behind Golden Circle Healthy Life juice came about as the result of detailed research that identified immunity as the number one benefit sought by juice-consuming grocery buyers – mostly health conscious women who “can’t afford to get sick”.

There is a significant market opportunity for probiotic juice products that have shown to This was the first probiotic juice on the support the body’s natural immune defences.

Australian market and the combination of juice These target consumers are well-versed on with the unique benefits of probiotics (that deliver health and nutrition but time-poor, so robust to an untapped consumer need), gave them scientific and clinical validation of the probiotic entry into this new market while at the same time ingredient were critical before even providing a point of difference for their launching the product. product within the wider chilled juice The technical challenges were significant, market. top of the list, to identify a probiotic strain As the first non-dairy probiotic beverage that had robust scientific support and in Australia, the product offers the could survive in a low pH acidic added benefit of bringing probiotics environment that is typical of fresh to those lactose intolerant people juice, and to ensure the efficacy was who can’t consume, or simply maintained throughout the shelf life don’t like, dairy-based drinks. period.

It also addressed a problem The outcome, Golden Circle faced with many probiotic juices, Healthy Life Probiotic juice, is a and that is storage and transport, combination of fruit juice with a as dairy products need refrigerated mix of probiotics from Probi, and transport and storage, increasing according to HJ Heinz is also the costs and demands on the first non-dairy probiotic food product manufacturers’ supply chain. on the Australian market.

Every 200ml serving contains one The product range is based on billion colony forming units of Probi a unique immune support platform Defendum.

Probi Defendum and established a Probi Defendum is a combination new category of probiotic juices on of two specific strains of bacteria that the Australian market. together have been shown in clinical HJ Heinz found itself in a unique trials to support the body’s natural position of their own making, being defences when taken daily. the first beverage manufacturer to Probi Defendum is a unique realise that there is a significant probiotic platform based on the market opportunity for probiotic combination of two strains – juice products that can support the Lactobacillus plantarum HEAL9 and body’s natural immune defences. The first Australian probiotic juice. Lactobacillus paracasei 8700:2 – 40 JUNE 2013 Manufacturers’ Monthly

HJ Heinz’s presented the award by Sophie Mirabella. which have been shown in large clinical studies to prevent colds, significantly reduce cold symptoms and shorten cold periods.

The clinical trials in support of this particular probiotic combination were strong. However, it was not the only strain investigated.

Probi Defendum was one of a number of strains tested in the low pH environment of chilled juice.

Many strains did not maintain their efficacy throughout the product shelf life due to the acidic nature of fruit juice.

Probi Defendum maintained its efficacy until the end of shelf life due to the strain itself and the unique preparation and dosing procedure developed at Heinz Mill Park with the support of its supplier.

The Golden Circle Healthy Life juice was launched in May last year and managed to achieve a significant 1.3 per cent market share within the chilled juice sector within only six weeks.

After a year it still remains the only probiotic juice in the market despite the highly competitive nature of the juice category.

Competitors have tried to follow suit, in a hurry, with other products making similar immunity claims but these have not provided the support of clinical testing to back up their product’s claims.

The Probi Defendum brand is prominently displayed on pack to provide technical endorsement and to reassure consumers regarding the scientific basis of the claims of the juice.

Today, more than 1230 people work for Heinz Australia, with manufacturing centres in Echuca, Wagga Wagga, Northgate and Mill Park. manmonthly.com.au

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EndeavourAWARDS Australian Steel Innovation – 2013 Winner

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Crossing manufacturing’s boundaries A quick install, temporary boundary wall made from Australian steel has won this year’s Australian Steel Innovation award.

“T

his particular award for our QuikWall product is really in recognition of our relationship we have with our customers,” Modular Wall Systems’ sales and marketing manager Jason Harvey humbly offered when asked what winning Endeavour Award for the Steel Innovation of the Year meant to the company.

The Caringbah, NSW-based Modular Wall was nominated for no fewer than three Endeavour Awards for its achievements, won the Steel Innovation award, as well as getting a gong for Industrial Product of the Year with its ThermaMax Panel solution (see pg 46). They are the inventors of the modular boundary wall concept and claim over 5000 projects completed across Australia. “[QuikWall] came about through meetings with BHP, recognising that there was a noise issue in moving environments. And through Australian steel products, like BlueScope Steel and OneSteel we developed the QuikWall system.”

A brilliant concept can sometimes be a simple one, and the patented QuikWall design is simple, essentially a stackable steel barrier with a winch to adjust its height.

“It’s the first moveable, temporary noise wall, it’s adjustable in height, so it’s capable of going in lots of different wind regions and it’s just a great recognition for our team,” said Harvey.

Through collaboration with its clients – including big resource companies with particular demands for durable, effective equipment – MWS has come up with a reusable, relocatable, lightweight, easyto-set-up barrier against noisy, harsh environments.

The “CorroLink” composite acoustic wall panels and galvanised steel members, made from Australian materials, measure 2600 mm in height when retracted. They extend up to 4400 mm “in less than a minute” according to Modular, using a winch device, at 400 mm increments. Its design has come about through extensive collaboration with clients.

“One of the other real benefits that we worked hard on and it wasn’t in our first prototype, but over the last 12 months we’ve reduced the actual weight of the units,” said Harvey.

“We sit down with the client and we look at the holistic response. And we’re thrilled to keep working with those clients.”

The QuikWall is simple to assemble and spaceeffective when stored. A three to four-man team can install 90 linear metres a day. MWS says that a 25 + decibel reduction in audible noise can be achieved by its system.

“We’ve been capable of getting up to 400

42 JUNE 2013 Manufacturers’ Monthly

Bluescope presenting the award. square metres of temporary noise wall on a particular truck by using lightweight, insulated panels. And that’s taken a lot of trucks off the road.

So the environmental benefit doesn’t just stop with the acoustic solution.

“You can get pretty much a whole enclosure done in half a day,” explained Harvey. “They come pretty much pre-assembled and are very quick to erect and maintain.”

QuikWall is anchored to the ground by either a

ground plug (positioned over its legs and driven in by a hand-operated jack hammer) or by, in certain specific applications, a concrete counterweight.

The system, which can withstand wind regions A, B and C, can be compacted into racks for transportation and to be set up elsewhere after use. Three racks of 8 units each can fit into the bed of a semi-trailer. This makes a total of 396 m transported by one truck. At 125 tonnes it might not seem light, but compared to other solutions it’s extremely efficient.

According to the company’s sums, two trucks carrying a full load of QuikWalls would take 26 semi-trailers (assuming they were using shipping containers as an alternative) off the road and save 8904 kg of carbon emissions, to say nothing of the cash saving.

After being successfully adopted by big miners, Could we see MWS’s innovation in more and more places? Is there potential for growth into, say, the outdoor events market?

“It’s really an industrial product; the main use is around drilling environments and exploration and certainly where construction collides with residential areas,” explained Harvey, though he said there may be possibilities for uses other than in the resources sector.

“Our footing system has quite a wide footprint, and we have been approached by companies who do temporary events, but at the moment the application doesn’t really suit those kinds of environments.”

Built from Australian steel, the walls can be erected quickly on site. manmonthly.com.au

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EndeavourAWARDS Global Integration – 2013 Winner

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Australian skills overseas For utilising Australian skills, German engineering, and European steel, Leussink Engineering has won the Global Integration award.

S

mall Australian engineering and manufacturing firm Leussink Engineering have won the Global Integration Award for its work in Kazakhstan.

The group managed to bring together Australian skill, with German expertise and experience to machine an Indian mining and steel manufacturing giant’s mills through Eastern Europe and Central Asian Republics in conjunction with its partner Corts.

Corts is a German precision flat bearings supplier while Leussink Engineering is a diversified engineering designer and workshop that handles OEM and prototyping, large engineering and manufacture, on-site and off-site refurbishment and maintenance of machinery and equipment, re-engineering and high precision work especially for mining, public works, general engineering and heavy construction Leussink Engineering, in association with the German bearings specialist Corts, sent six of its specialists from Unanderra, NSW, to various locations in Kazakhstan to machine six rolling mill stands for ArcelorMittal.

The mills were run down and not operating near full capacity nor capability.

The process combined the expertise of CortsLeussink, surveyors, on-site machine operators and mechanical engineers to collect the relevant data and modify the current status back to OEM specification.

Leussink’s technical staff took a holistic approach that included a thorough laser-based survey of all components, including their current structural integrity.

Leussink accepting the award from ICN. What followed was an extensive level of planning necessary to bring the facilities back to the level they were when brand new, as per the Original Equipment Manufacturer design specification.

The Corts-Leussink partnership has quickly developed its capabilities and can make a complete refurbishment to even the oldest rolling mills (ferrous and non-ferrous) in the world to original specification and extend their lifespan to remain productive and work almost as if new.

ArcelorMittal is among the five largest producers of iron ore and metallurgical coal (or coking coal) in the world and has a geographically diversified portfolio of iron ore and coal assets.

The refurbished mills in Kazakhstan.

44 JUNE 2013 Manufacturers’ Monthly

ArcerlorMittal als has a network of steel plants worldwide. The company’s goal is to produce 100 million tonnes of iron ore by 2015, and it is pursuing this aim through expansion of existing assets and acquisition of new, high-quality resources.

The association with Corts was set up with full expectation of international potential, and it has been immediately returning on the investment.

The appointment of Corts-Leussink to refurbish six iron ore mills in Kazakhstan is a major success and shows that an Australian company based in the city of Wollongong has trained its technical staff to a level where they are being sought internationally.

Corts already has a strong recognition in Europe; but through its involvement in the partnership, Leussink’s reputation has grown immensely and is being viewed as an integral part of the supply arrangement.

ArcerlorMittal is arguably the largest in the world in its field and it would not make an appointment of this magnitude, with so much at stake, lightly, so Corts-Leussink is there on international merit.

Both partners of Corts-Leussink knew early on that this association carries something special and operates at world’s best practice levels.

So in quick succession, this Kazakhstan appointment is the third steel mill that Corts has done in Europe and its second with Leussink (the first was recently in Romania).

Since these early refurbishment the partnership has been approached to carry out more operations as well. manmonthly.com.au

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All the right connections for the manufacturing industry.

When it comes to finding new business opportunities, one of the biggest challenges can be breaking into new or expanding supply chains. Industry Capability Network (ICN) is an organisation that introduces local suppliers to the supply chains of major projects.

Even if you’ve never imagined your business supplying goods and services to a major state or national project, ICN could uncover an opportunity that’s just right for your business.

With more than 28-years experience helping Australian and New Zealand manufacturers find opportunities in major projects, ICN is a great place to start when looking to expand your business.

At the heart of our service is ICN Gateway, a powerful online tool that helps local suppliers find new business opportunities. With over $247 billion worth of projects currently listed, there’s never been a better time to register.

So, if you’re looking to expand your business opportunities go to www.icn.org.au or call your local ICN office on 1300 961 139

ICN0265_Manufact_297x235mm_FP.indd 1

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MA0613_046.pdf

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EndeavourAWARDS Industrial Product of the Year – 2013 Winner

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For industry, by industry In its second success of the night, Modular Wall Systems has been recognised for the Industrial Product of the Year.

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odular Wall Systems, who also triumphed in the Steel Innovation category, won the 2013 Endeavour for Industrial Product of The Year for its ThermaMax Panel product, designed for the mining and energy sector.

MWS has gone from strength to strength over the past nine years to become the market leading manufacturer in its sector, Australia wide. They are the original inventors of the modular boundary wall concept and have more than 6000 projects completed across Australia, “ThermaMax Panel provides an innovative, onestep modular insulation solution which represents a major improvement on traditional, multi-step installations,” explains the company’s material.

“ThermaMax cleverly combines existing materials in an all in one composite panel and sits in conventional beam and girt structures.”

In direct response to the exacting requirements for the multi-million dollar APLNG Upstream project (Origin Energy and T1 builder Laing O’Rourke), Modular Wall Systems developed the ThermaMax Panel to provide a modular thermal heat control solution that was not previously available.

“We sit down with the client and we look at the holistic response,” MWS’s sales and marketing manager Jason Harvey told Manufacturers’ Monthly.

“And we’re thrilled to keep working with those clients.”

The client, who had been considering the use of shipping containers at the start of the project, required a pre-finished, 10 meter high modular enclosure that could be built quickly and that would take 180 trucks off the road.

Before the ThermaMax solution, shipping containers were the preferred option to meet

BOC presenting MWS the award.

height, heat, insulation and finish requirements.

This bulky solution typically comes with a significant environmental footprint (a big number of trucks is required for transportation to site. Also, extensive concrete pad footings are constructed as a foundation for the containers.)

Shipping containers also require higher transportation costs, higher staff costs (a larger team is required to install a wall comprising shipping containers), longer installation and deconstruction times and a lack of customisation of the finish colour or overall look of the enclosure.

The ThermaMax Panel was developed through extensive research and development and in consultation with major mining and energy companies.

Challenges identified included meeting the exacting thermal requirements: – Testing the appropriate material and colours for the panel skins under a large variety or environmental and climatic conditions; The panels have replaced the use of shipping containers to build a wall.

46 JUNE 2013 Manufacturers’ Monthly

– Finding a solution for maintaining the sealed integrity of the structure under various environmental circumstances such as sloping ground and perforated openings; – Testing the individual properties within the composite solution under a large variety of heat conditions; – Exploring the best sheeting profiles (such as trim deck or corrugated steel) to meet minimal loading requirements; – Testing corrosive characteristics under a large variety of circumstances (tests pointed out that the ThermaMax Panel should not be in direct contact with the ground, but mounted slightly above ground. Base channel flashing was developed to maintain the integrity of the enclosure); and – Creating a modular enclosure solution, incorporating the ThermaMax Panel, to which tradesmen could easily adapt, using existing knowledge and machinery.

As with the company’s QuikWall solution, ThermaMax was developed in response to an industrial user’s needs. ThermaMax, says MWS, and its application in current multi-million dollar projects, demonstrates the company’s already solidly proven ability within the mining and energy sector. The product was developed and manufactured to meet the most rigorous OH&S, a 25+ year design life and all current and future requirements specific to the sector. Therefore, the potential for this product has been maximized from the beginning.

As with its QuikWall product, the ThermaMax solution offers significant environmental benefits to its user. For example, at the APLNG Upstream project, there are multiple flare enclosures required.

If shipping containers were used to contain these enclosures, 180 trucks would have been used. By using the ThermaMax Panel solution instead, the amount of trucks required was reduced to six. For seven sites, this represents a 1000 truck reduction.

The pre-finished ThermaMax Panel is designed to be extremely robust. It is manufactured out of Australian corrugated steel, which is damage resistant. With superior acoustic performance, it could be typically expected there would be up to a 25dB reduction in noise to surrounding areas.

This translates to a four to five-fold reduction in audible noise.

Typically, Modular’s projects span 2 to 3 months. The APLNG Upstream project, which will run until the end of 2013, will provide the company with a steady income stream, job security and increased credibility and loyalty within the mining and energy sector for years to come. manmonthly.com.au

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Supporting innovation and success BOC was the proud sponsor of the Australian Industrial Product of the Year category in the 2013 Manufacturers’ Monthly Endeavour Awards.

It is fitting that we supported the category which recognises innovation in new industrial products, as it is something that is very close to our hearts at BOC and an important hallmark of our own business.

At BOC, we aim to be admired for our people, who provide innovative and sustainable solutions that make a difference to the world. These awards reflect and promote the same 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 www.boc.com.au BOC is a trading name of BOC Limited, a Member of The Linde Group. © BOC Limited 2013.

MP12-0873-4|ML|0613

BOC wishes to congratulate the winners of the tenth annual Manufacturers’ Monthly Endeavour Awards, particularly Modular Wall Systems for winning the Australian Industrial Product of the Year category for their ThermaMax Panel. We encourage all businesses, big and small, to strive for continuous improvement with commitment, courage and creativity.

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EndeavourAWARDS Young Manufacturer of the Year – 2013 Winner

Enter online at manmonthly.com.au

Manufacturing’s future leaders For leading the expansion of his family owned company and growing the automotive aftermarket company in a downturn, Jason Oliver has recognised as the Young Manufacturer of the Year.

T

he Young Manufacturer of The Year’s CV begins with him working in the family business, Black Widow Enterprises, before half a year as an accountant following his uni graduation.

After throwing in the towel as a bean counter he moved back to BW, where he’s been in charge for 18 months.

“For some reason, they let me take over the company as CEO and we’re still going, somehow,” offered the unreasonably humble Young Manufacturer of the Year Jason Oliver moments after being given the award.

After assuming the reins at Black Widow at 27, Oliver overseas a thriving little business that manufactures four-wheel drive aftermarket accessories out of New Gisborne, with a turner last year of $6.1 million, 40 staff, and plenty of opportunities for growth.

“We’re in the aftermarket automotive sector, not the OEM, so we’re quite lucky that we’re not being swamped by all this doom and gloom,” said Oliver, who received his award the same week that CMI fuel systems was put in voluntary administration, SMR announced that it would cut 90 jobs, and receivers announced that aiDair’s Gisborne plant would be shut by the year’s end.

Oliver worked part-time at Black Widow, which his parents started in 1995, during his school years and went on to study business at RMIT while continuing to work on-and-off at the family business. In his third university year he dipped his toes into the world of management with a co-operative program at Exxon Mobil, before M A 0 6 1 graduating 3 _ 0 0 0and _ Egetting N W. apjob d fat anPaccounting a ge 1 1 5 firm.

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“I went and worked for six months at a chartered accounting firm, because I studied accounting at uni,” he told Manufacturers’ Monthly. come / 0“I 5was / 1going 3 , to 2 : 4 back 9 : 3into 1 thePbusiness M A E and ST do the accounting side of things but I was bored

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out of my brains at the chartered accounting firm and thought ‘this sucks’ so I rang up dad and said ‘look, I’m ready to come back’.

He planned to handle the books, but this wasn’t an option, it turned out.

“When I came back we only had about 15

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people working for us and there wasn’t a need for a full-time accountant.”

This worked out nicely for Oliver, who was happier on the factory floor and was chuffed to be able to roll his sleeves up get back to business with folks he knew.

He resumed work as operations manager.

“Over seven years I put it all in and the business has grown, I’ve thrown my hand back into the other side of the business and the day-to-day, but operations and lean are still my passion and I’m very heavily involved in that, or at least as much as I can afford to be [laughs].”

Lean manufacturing ended up being an important aspect to how the company was run, after Oliver bought a copy of The Toyota Way at a Singapore bookshop to pass the time on the flight home. What he read on the trip back struck a chord with the young man.

Here was a way of doing things that crystallised many of Oliver’s gut feelings about management.

“My goal was eventually to write a system where the guys didn’t have to rely on me as the firefighter or the guy to continually answer questions,” he said.

“I went about and tried to introduce that.

Had obviously no experience with it and failed in a few things.”

He sought as much information for himself and for his workers about the lean way of doing things.

“Then I got the guys enrolled into a Cert III into lean manufacturing, got a specialist out and worked with him very closely and implemented a lot of changes. And then from there just went about benchmarking and doing factory tours and talking to as many people as I could.”

What Oliver has implemented has worked a treat. According to the company’s figures, as operations manager, he saw productivity up 40 per cent, lead time down 73 per cent, and a decrease in average stock holdings of 25 per cent. In his 18 months as CEO, the 29-year-old has helped boost sales by 21 per cent, releasedb new products, and started exporting.

Currently, there’s quite a bit of interest from the Middle East, where the company has been exporting “for about a year or two” and elsewhere in Black Widow’s storage and organisation solutions.

“I’m going to Dubai in three weeks,” said Oliver a week after winning his Endeavour Award.

“We’ve got a heap of stuff going in Dubai and Saudi Arabia. The biggest opportunities for us at the moment are there.”

Black Widow is currently looking to expand its sales through targeting fleet vehicle solutions, working with a RIM Services, APV Safety Solutions, independent OH and S consultants, and Deakin University, who have been providing advice on lightweight materials.

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Oliver brought lean manufacturing principles to Black Widow. manmonthly.com.au

Manufacturers’ Monthly JUNE 2013 49

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EndeavourAWARDS Technology Application of the Year – 2013 Winner

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Getting the mix right In its quest to improve productivity and services for welders, BOC has won the Technology Application of the Year award.

B

OC has won the 2013 Technology Application of the Year award for the development of its new Mini Bulk Service Offer and Mix Onsite, which was designed specifically for the Australian welding sector.

The Mini Bulk Service Offer makes it easier to manage variable demand and offers significant productivity savings, cost-effective supply, consistent high purity liquid, low filling losses, modest installation costs and increased gas storage in a compact cryogenic liquid vessel.

Mix Onsite is part of BOC’s innovative Mini Bulk Service Offering which has changed the face of gas supply in the manufacturing sector, providing an intermediate solution between cylinder packs and bulk delivery.

BOC had originally developed the Mini Bulk gas supply offer to deliver nitrogen to the laser market segment, where it has been taken up successfully.

Leveraging off the skills of parent company, The Linde Group, Mix Onsite was launched with the objective of expanding into new markets.

An alternative to linked cylinders or manifold packs, Mini Bulk Service Offering – Mix Onsite is a state of the art gas-supply technology introduced to improve productivity, save space and lower costs for users.

Mix Onsite was specifically developed for the welding market, particularly for customers who use between 100 and 400 cubic metres of gas per week and are looking save on costs and space.

It was introduced in response to industry demand to make it easier to manage variable gas needs and offers significant productivity savings, cost-effective supply, consistent high purity liquid, low filling losses, modest installation costs and

BOC accepting the award for its innovative Mix Onsite system.

increased gas storage in a compact cryogenic liquid vessel.

The unique technology improves upon the original system of multiple linked cylinders or “manifold packs”, offering significant economic, production and space-saving advantages.

The system also helps to reduce the risk of handling injuries that are often associated with manually changing over cylinder packs.

The Mix Onsite system involves liquid argon and CO2 being delivered by a combination tanker into a range of compact customer argon and CO2 vessels.

A mixing panel is then used to blend argon and CO2 to the required shielding gas specification, with the shielding gas then delivered by pipeline to the required points of use.

An alternative to linked cylinders or manifold packs, Mini Bulk Service Offering – Mix Onsite is a state of the art gas-supply technology introduced to improve productivity, save space and lower costs for users.

The system is innovative in that the product is delivered by a small rigid road tanker into compact high It was designed to reduce the risks of handling injuries. pressure vessels

50 JUNE 2013 Manufacturers’ Monthly

with an integrated process vapouriser.

BOC’s high pressure filling technology reduces and minimises depressurisation losses of the vessel and the size of the delivery vehicle means tanker access is generally not a problem.

Other advantages for users include flexible delivery options to suit all customers, cost-effective supply, significant productivity savings, a flat base to spread weight over a wide area and a high pressure liquid transfer into vessel and three vessel sizes to choose from.

Vessel installation is also much simpler than a standard bulk installation for a number of reasons including: instead of hiring a crane, a fork lift can be used to unload and position the mini bulk vessel; the flat base means that the mini bulk vessel does not require a reinforced concrete plinth to support its weight (as opposed to 3 or 4 legs) and there is no 3 phase power requirement to run the delivery tanker filling pump.

The easy-to-use Mix Onsite unit is skid mounted for ease of installation and to save space. The unit comprises 1 or 2 CO2 storage vessels, CO2 vapouriser and gas mixer. There are various mixing panel options as well as leak detection.

Once the compact high pressure vessel is installed on site for modest set-up costs, the gases are delivered by BOC in small, rigid road tankers designed for easy site access.

BOC has a range of flexible delivery options and can even monitor a business’s gas levels remotely and schedule top ups when required.

With more than 62,000 employees working in 100 countries, the company develops safe, sustainable and innovative solutions for customers in many specialty sectors, heavy industry and medical environments. manmonthly.com.au

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EndeavourAWARDS Most Innovative Manufacturing Company – 2013 Winner

Enter online at manmonthly.com.au

Automation and innovation A company that started in a backyard shed is now leading the pack, and been recognised for its innovative practices.

L

eading Australian automation and industrial control systems company Sage Automation won the Most Innovative Company award, for its holistic range of products and services.

The company literally started out of a shed in a backyard in 1994 when Andrew Downs, founder and managing director, got tired of substandard work turned in by contractors where he worked, as the head of the electrical department at Bridgestone.

If he couldn’t get decent automation work done by contractors, then he’d have to do it himself.

According to a profile article, Downs left school in year 11, performed his apprenticeship at Uniroyal, and began contracting on the side, eventually striking out on his own after being told by his thenboss to stop moonlighting or be sacked.

Today, nearly two decades later, Sage is a highly awarded and highly diverse company, manufacturing all its industrial control cabinets in Australia and offering a broad range of technical support and business improvement offerings. It employs over 290 workers and turns over more than $70 million.

Its businesses include Sage Service, which supports Sage’s development the technology in customers’ operations, and is a 24/7 breakdown support maintenance, providing certainty and peace of mind for companies with leading edge technologies and critical production requirements; and Sage Didactic, initiated to advance the technical skills of Sage’s own workforce by providing education and training using the latest industrial automation and process control technology. SAGE Didactic is a national leader in industrial control and automation technology

training across all industry sectors. Sage also has a Business Optimisation (Manufacturing Execution Systems) operation, which has helped customers to implement MES systems which make them better positioned to customise products, provide rapid response and improve operational performance. It believes that the MES and MIS (Manufacturing Information Systems) will become more and more important to manufacturers facing tougher and tougher global competition, and looking to gain an edge through linking control systems with business objectives in real time.

Also of note is SAGE and Project Engineering’s joint venture, Prozess, which began in in 2012.

The company says Prozess creates “bankable process improvements” for manufacturers across industry sectors including mining, FMCG, building materials, food and beverage, and agriculture processing.

“Providing a solution to a client brief is just one part of the puzzle,” said Downs in a statement about the joint venture.

“To truly add value to a business you must first identify the core problem.

In many cases it’s the problem that the client is unaware of that is really restricting their growth or It provides advanced manufacturing. competitiveness.”

manmonthly.com.au

Sage accepting the award for innovation.

Prozess has so far performed projects for SPC Ardmona (water management and energy assessment), DBS (Diverse Barrel Solutions) (efficiency improvement to wine barrel rejuvenation process), Precision Components (a total preventative maintenance study, in conjunction with the Automotive Supplier Excellence Association) and Cheetham Salt (evaluation of manufacturing processes at its Price facility).

SAGE has benchmarked itself against the world’s best control system integration companies and in 2009 became the first Australian company to be accredited to the global quality benchmark of the Control System Integration Association (CSIA).

This certification, says Sage, demonstrates their commitment to the highest possible standards for excellence and puts them at peer status with the world’s best system integration companies.

Biannually, all aspects of the company’s operation are certified by thorough review by independent auditors on more than 76 criteria including strategic planning, general management, project management and methodologies, technical management, human resources, business development, infrastructure support activities, quality assurance processes and finance.

SAGE Automation remains the only Australian company with this certification.

Highlighting its dedication to Australian advanced manufacturing, Sage participated in the 20th Adelaide Thinker In Residence Program, in which Professor Goran Roos, a manufacturing business model world expert.

The purpose of the Thinker In Residence program was to provide input and transfer competence around business model innovation, drawing on technology change for small to medium enterprises in the manufacturing industry.

Manufacturers’ Monthly JUNE 2013 51

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EndeavourAWARDS Enterprise Connect Significant Achievement – 2013 Winner

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Geared for success An Enterprise Connect Business Review has led to a company getting lean, growing, and winning the Enterprise Connect Significant Achievement award.

F

or the implementation of a lean manufacturing process that has directly led to an increase in sale, export, and product Ronson Gears has won the 2013 Endeavour Awards Enterprise Connect Significant Achievement award.

Ronson Gears successfully applied for an Enterprise Connect Tailored Advisory Service (TAS) which was used to apply lean principles to its production of gears for the aerospace, agriculture, automotive, defence, energy, medical, mining and rail industries.

It also conducted a market analysis to locate growth markets and improve its planning systems.

With the assistance of TXM Lean Solutions, visual and 5S systems are being utilised resulting in the significant improvement in turnaround times for the gear manufacturer.

“Traditionally, orders would tie up machines for a week at a time, holding up other work and bringing everything to a standstill. The reduction of batch sizes enabled us to deliver gearing to our bigger customers on time, more regularly,” explained Gavin New, Ronson Gears’ marketing manager.

“This approach also saw better turnaround times from our sub contractors and subsequently saw improved sales figures at the end of the month.”

In particular this had led to an increase of export sales of 272 per cent year on year while at the same time increase its sales of stock gear products by 50 per cent.

The company explained that is “has seen lead time reductions and we experience a cleaner more organised work environment daily”.

“Communication between is [also] more plentiful.

“We have also seen improvements in the way we plan our work,” the company stated.

“What was once a time consuming process and

Ronson Gears receiving the award from Enterprise Connect.

an inaccurate representation of our workflow is now far more accurate and a more efficient way of planning through better utilisation of our MRP system. By conducting an audit on our internal MRP system, M1, it enabled us to understand more adequately what we have had at our fingertips for some time.”

The introduction of lean manufacturing has had the most impact on the way the company does business.

Productivity has been increased due to a greater focus on work being planned and released to the factory more promptly.

By establishing a contract review process that identified new work and repeat work more clearly it enabled the planners to identify which jobs may take longer than others to plan which then allowed them to organise their day more efficiently.

This saw the company start jobs on time and further improve on our on time deliveries.

It also improved processes by purchasing a new CNC Ronson saw a 272 per cent increase in export sales. cylindrical grinding machine,

52 JUNE 2013 Manufacturers’ Monthly

which enabled Ronson Gear to bring more work back ‘in-house”, which gave it greater control over deliveries and helped to cut sub-contracting costs.

“Our other major purchase was the upgrade of our CNC rack milling machine ensuring Australian industry has access to competitive gear rack production.”

The machine is extremely accurate and flexible (it can gear cut large pitch racks and small pitch racks from 50mm in length to 6000mm in length).

“Other purchases that has increased our competitiveness over the last 12 months includes a new CNC machining centre offering faster machine times and increased accuracy and a CNC slotting machine providing us with extra capability beyond our broaching machine for internal gears, internal splines and key ways.”

Both purchases again enabled Ronson Gears to avoid having to send work off site for machining, addressing the cost contractors.

“Further sustainability measures have been undertaken in the purchase of new machinery, as mentioned earlier,” New added “The benefit of new machines is not confined to just increased quality and faster machine times, they also offer cleaner technology as they use less power and emit less pollution (both noise and environmental).

Following the acquisition of the CNC machines, Ronson carried out additional strategic planning.

“We needed to be more innovative in our thought processes,” New said.

“Innovation through our KHK Stock Gear Products, our service offering and our production processes resulted in some wins for the company” Previously Ronson manufactured its own stock range of gear and gear racks, providing some 200 items on the shelf.

“It was becoming increasingly evident that Australian industry wanted more from their stock gear supplier so through our international relationships established over the years we pursued a Japanese supplier who shares similar values to ours -a family run business that embodies quality gear products.”

As a result, Ronson now stocks over 2,000 line items (and has access to over 9,000 different gear related items) which has enabled Australian and New Zealand industry to keep producing with minimal downtime.

“With the current downturn our industry is experiencing it is fair to say that by addressing the action items in our Business Review has better positioned our company to be able to work through these tougher times,” New stated. manmonthly.com.au

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EndeavourAWARDS Overall Manufacturer of the Year – 2013 Winner

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Manufacturing’s manufacturer A manufacturer that helps manufacturers manufacture has been recognised as the Manufacturer of the Year.

O

ut of nearly 100 outstanding candidates, ANCA has won the Endeavour Award for Overall Manufacturer of The Year.

Also the Exporter of The Year, ANCA is a go-to for those looking to put forward the argument that Australian manufacturing companies can mix it with the world’s best if they’re smart enough.

ANCA, a Bayswater-headquartered maker of CNC tool grinding machines, managed to boost its exports (which make up 98 per cent of sales) by 19 per cent in 2012, open a new facility, and released several innovative new products, including the MX5 tool grinder, ToolRoom 2012 software and the MicroPlus workholding and tool support system.

Its focus on innovation is a big part of the success story.

“ANCA continues to innovate each year and spends approximately 10 per cent of its revenue on R&D each year,” CEO Grant Anderson told Manufacturers’ Monthly.

“This continued investment is a conscious decision to provide leadership in our product segment through working and employing innovative people and collaborating with relevant universities and suppliers in developing these new innovations.”

Along with its highly innovative workforce and willingness to invest heavily in improvements, the company’s customer service efforts play a part in ANCA’s achievements.

“In addition to the continued investment in Innovation and R&D, ANCA has developed a global sales distribution and service network which is focussed on being close to the customer, building strong relationships and providing fast response times,” said Anderson.

M A 0 6 1 3 ANCA _ 0 0 launched 0 _ E X two P . new p d products f P a in g the e last 1 7 / year. Its MX5 mid-range machine was developed

Bluescope presenting ANCA with the Manufacturer of the Year award. to focus on volume production of cutting tools.

It also developed another machine to erode polycrystalline diamond, enabling users to produce tools with a longer lifespan. Both are particularly suited to aerospace manufacturing, where cutting and machining composite materials requires longer lasting tools.

The continued expansion of industrial output of China, and its rising industrial sophistication, have been helpful to ANCA’s growth.

“During 2011/12, we had a significant increase in sales into Asia and specifically, into China,” explained Anderson.

0 5“The / 1China 3 , market 1 0 : continues 1 0 : 5 to 1 industrialise A M A and EST as more sophisticated manufacturing has developed,

so has the need for high-technology machines.”

ANCA has received many awards in recent years, and adds its two Endeavour Awards to achievements such as its induction into the Victorian Manufacturing Hall of Fame in 2003, seven Governor of Victoria Export Awards, and the 2011 Endeavour Award for Most Innovative Manufacturing Company.

Anderson and ANCA were rightfully pleased to have been awarded Overall Manufacturer of The Year for 2013, one award out of many for the nearly-four-decades-enterprise.

“Awards that ANCA receives provide recognition for all of the stakeholders at ANCA and particularly our employees,” he said.

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There are plenty of opportunities for manufacturing companies that supply goods and services to resource projects.

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manmonthly.com.au

Manufacturers’ Monthly JUNE 2013 53

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Product FOCUS: SENSORS Automation and manufacturing Sensors, test and measurement, and the future of manufacturing.

O

n May 5, 1950, Erwin Sick registered his selfformulated ‘light electric gate’ for a patent. The forerunner to Sick’s safety light curtains, the invention was designed to do two things – protect workers from dangerous machinery and increase efficiency.

Fast forward to 2013 and the desire for safety and efficiency has reached levels that Erwin Sick wouldn’t have dreamed of in 1950.

(Ever seen photos of New York construction workers taking lunch breaks way up in the sky-line in the 1930s and 40s? Do you think those guys had heard of OHS or ‘Efficiency Experts’?)

The drive for safety and efficiency remains. What has increased almost exponentially is the potential to develop new automation and safety systems.

Technology has opened a lot of potential doors to efficiency experts and engineers alike.

So where is automation headed?

“Automation is a big word. It can mean a lot of different things,” National Sales Manager, Sick Australia & New Zealand Jeff Walker told Manufacturers Monthly.

“At Sick, we’re focused on four things. We talk about flexible automation, quality, track and trace and safety,” Furthermore, Walker says, the company concentrates its efforts on what he calls ‘three pillars of industry’: Factory automation, encompassing the core business of food and beverage, packaging, print, labelling, etc.

Process automation, including industries such as oil and gas, mining and process automation in general.

Logistics automation, covering everything from RFID kiosks use for airline check-ins to the automation of internet commerce and the code and traceability solutions required by that industry.

54 JUNE 2013 Manufacturers’ Monthly

Is automation a panacea to manufacturing’s problems?

Let’s focus on the first pillar, factory automation.

Factory automation and the need for flexibility Walker points out that the need for flexibility in automation is driven by the size of the Australian market place.

“Our customers have to have the ability to be flexible in their line. So one line has to be able to package, bottle, fill, and label all different shapes and sizes of product.”

The challenge for Sick is to deliver each customer a dynamic, flexible solution that saves them from the need to constantly have to make manual adjustments to their production lines.

Sick needs to allow them to “dynamically adjust a sensor by changing a program on a PLC to say they are going from a 600 ml bottle to a 400ml (or 300 ml) bottle very easily and quickly,” Walker says.

The equation is simple. This type of flexibility “increases the uptime of the machine, decreases the downtime and therefore increases productivity,” he says.

Thus, an item such as the Lector 620 code reader is designed to be flexible and simple. As a single devise, it can read and decode all

code types. The customer doesn’t need to change the production line to handle different items.

And it is compact. It can be quickly integrated into a variety of packaging machine IT environments and it opens up a range of analysis and diagnostic possibilities.

The one unit can identify the packaging of all types of non-food goods, including food, beverages, pharmaceutical and cosmetic articles. And it can ensure complete product control and tracking.

The limits of automation Talk of automation leads naturally to discussion of the limits of automation.

Walker is open to possibilities of technology and says, “....the limitations are only driven by the imagination and sometimes the resources of our customers.”

But he isn’t tempted to follow any science fiction fantasy in his answers. He keeps his focus on the needs of his customers in the real world.

“Our customers have a driving need to increase efficiencies, to work on smart manufacturing strategies and continue to grow. So for us it’s a continuing challenge,” he says.

In other words, he doesn’t foresee

any automation for its own sake.

Any advances are driven by sober business decisions and the goals of efficiency and smart manufacturing.

Sick’s minitwin light curtains, for example, were designed with smart manufacturing in mind. In this case, innovation was driven by the demand for compact machines.

They offer workers reliable protection from hazardous machinery and are specifically designed for applications in space-constrained areas.

They provide innovative safety solutions for flexible serial production of small batch sizes and for low-level serial production. miniTwin miniature light curtains are often used in applications where workspaces are designed in more ergonomic ways, requiring workflows to be optimised.

Will we lose jobs to automation?

Walker keeps his feet on the ground when talking about that ‘big word’, automation. He doesn’t overstate the power of technology and he is confident that it doesn’t pose a threat to employment.

He says that, far from wanting to put people out of work, most manufacturers who invest in automation are actually investing in their people.

“By introducing automation, they are up skilling their people and getting them involved in it. What it’s created is opportunities for employers to grow the education, the knowledge and competencies and capabilities of their own people.”

Walker is optimistic about the capacity of Australian industry to change. He sees plenty of talent in this country.

“We are blessed with very talented engineers who take on technology at a rapidly growing pace,” he says.

“We’re fighting in a global market place and we have to increase our efficiencies....that’s primarily done through smart manufacturing solutions.” manmonthly.com.au

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Known as the 45mG, it is an advanced ultrasonic thickness gauge with a number of standard features and software options. the basic configuration of the 45mG is a simple and straightforward gauge that requires minimal operator training to tackle most common thickness gauging applications such as wall and coating thickness, mineral deposition and corrosion.

Additional software options and transducers turn the 45mG into a significantly more advanced instrument that allow it to be used for applications well beyond a typical entry-level unit. examples include fibreglass (to 100mm), rubber, very thin materials (<200µm), and high precision quality control (to 1µm resolution). According to Graham maxwell, national technical & key account manager at olympus, all the options are built-in to the unit at manufacture and accessed by purchasing ‘unlock codes’. “each function is controlled by a separate software module so additional features are available by upgrading the software,” maxwell said.

PoWeR Parameters have unveiled the newest lanteK ii series cable certifiers. they are designed for comprehensive testing and certification of basic link, channel link, and permanent link testing. the lanteK ii series is available in three models with frequency sweep ranges of 350, 500 and 1000 mHz thus permitting testing of cat 5, 6 and 7(c1) cables and Comprehensive networks. testing and the testers are available certification of links. with fibre optic link testing for multi-mode (850/1300 nm utilizing leD[c2] source) and single mode (1310/1550 nm with laser source) in full

Requires minimal training to operate. the 45mG is built for operation in difficult and rugged environments, for example those encountered in the marine, aviation, refinery and pipeline industries. it has a rugged, sealed construction meeting the iP67 standard, and has also been shock and vibration tested using mil-stD-810G. in addition, the unit can be used in a wide range of operating temperatures. the 45mGhas been designed for easy operation with a simple keypad that can be used by both right- or left-handed technicians. the display is a colour transflective QVGA monitor that is bright both indoors and in direct sunlight.

Olympus 03 9265 5467 www.olympus.com.au

Surge measurement WeiDmulleR has released its new Varitector logger 20 to register and document large current pulses as well as the frequency and time of the incidents. the plug and play product counts the current pulses greater than a set threshold value which are discharged

by Pe conductors on surge protection devices. Any lightning strikes and surge voltages are continuously recorded. each measurement is issued with time a stamp accurate to the hour and the time and date of the event. using this information engineers can then design and implement appropriate systems as well as tweak existing ones to protect against surges. for the accurate measurement of currents the Varitector logger 30 features an external sensor with a ferrite toroid. clipped to the earth cable, this logger detects current peaks on the Pe conductor which can be caused by events such as lightning or power surges.

A large two line lcD display provides the operator easy visualisation of current/incident data; while its buttons manmonthly.com.au

duplex testing configuration.

According to the company it is fast in conducting tests, completing cat 5e testing within nine seconds and cat 6 in thirteen seconds, and is on average a third faster than many other certifiers. the testers provide on-board memory for test results, and in the case of cat 6, 1700 test results complete with graphical information can be stored. A lithium-ion battery provides energy for up to 19 hours with display on maximum.

Power Parameters 1800 623 350 power@parameters.com.au

Tape extension sensor AutomAteD control and Asm have launched a tape extension sensor that provides up to four metres measuring length in a compact industrial housing. the WB61 sensors have been designed to operate in harsh conditions, making them ideal for installation on cranes, excavators, forklifts, and access platforms.

Due to the design of the sensor and the inherent strength of the stainless steel tape, the WB61 range of sensors can be found in environments and upon applications where other traditional pull-wire sensors struggle to survive. the durability of the extension tape allows for the reliable use of directional changing pulleys and also within applications where icing may occur or dusty, gritty environments. these features make the sensor ideal for safety critical control functions within the mobile equipment market.

Automated Control www.automatedcontrol.com.au

Sensor storage Records current surge discharges. allow the menus to be easily navigated.

Weidmuller’s Varitector logger 30 also features a an internal cR123A replaceable 3-V battery with around four years of service life which allows the surge measurer to be connected to the mains at all times.it complements type-ii and type-iii VPu surge protection devices, and can quickly and effortlessly be installed on the terminal rails in switch cabinets via its plug and play housing.

Weidmuller 02 9671 9999 www.weidmuller.com.au

ActisAfe has released secure storage cabinets for electrical and electronic sensors. the high density storage cabinets are designed specifically for industrial and general manufacturing applications. A distinguishing feature of this product is its lockable top cupboard for larger items which don’t normally fit into a drawer space.

Actisafe, a ‘Defence Recognised supplier’, has developed these cabinets to meet the growing call for secure facilities in storage applications. these secure storage cabinets are also customisable. Whereas most commercial brands normally manufacture ranges in selected dimensions, these can be manufactured to specific dimension for those industrial companies that often

find it difficult to fit catalogue sizes in specific locations. All shelving and fittings can also be made to order, so little aspects of the products – inside and out – such as handles, shelf inclusions, Secure sensor cabinets. rollers etc can be procured to the exact requirement.

Actisafe 1300 852 397 www.actisafe.com.au Manufacturers’ Monthly JUNE 2013 55

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HANDLING – FORKLIFTS, STACKERS

Covering all the materials handling bases From humble beginnings, Lencrow Group has grown to become a significant materials handling supplier. The company has extensive sales, hire, and service offerings.

Matt McDonald reports.

T

he Lencrow Group begin life as Allforks Hire back in 1976. Operating from Silverwater in Sydney’s western suburbs, the company began with a fleet of 14 Hyster forklifts. As Lencrow Managing Director Ross Grassick told Manufacturers Monthly, “we have been operating for 37 years with the same owners and we still have an operation at the site we started at. We still even have some of the customers that we have working with for over 20 years.”

So some things have remained the same since 1976, but much has changed, both for Lencrow and for materials handling in general.

For the company itself, things have grown.

As a single entity, it now encompasses several subsidiaries, including Nomad Lift Trucks, Pacific Rentals, Allforks Hire, Pro-Fork Materials Handling, Hilift Materials Handling, and Hilift Pacific. In geographical terms, it has expanded its operations and plans to continue to do so.

“Both our short and long term plans are based on increased country coverage. This will in turn offer an increased level of service for our customers Australia wide,” Grassick says.

Most recently, the company opened a branch in Rockhampton. For local customers this will mean less down time, faster service back up and access to specialised parts.

Technological advances Of course, Lencrow continues to update and expand its product range. When asked about where materials handling is headed, Grassick points to technological changes within the industry.

“Forklifts are like all mechanical devices in the fact that the industry is constantly evolving. Right now changes to electric powered units are making them a very viable alternative to fuel powered units,” he says.

These advances, he says, can deliver unit life cost reductions of up to 30 per cent and contribute to reductions in greenhouse gas emissions.

Japanese manufacturer Nissan and EP from China, both of whose products are available from Lencrow, have been at the forefront of advances in electrical operations. However, Grassick points out that, with a world market for components, the significance of country of origin is becoming less and less. For example, the EP Chinese product uses transmissions from Germany, motors and controllers from Italy, electrical fittings from the USA and hydraulics from China.

56 JUNE 2013 Manufacturers’ Monthly

Technological changes, such as the growth of electric powered forklifts, are changing the face of material movement.

“They are all world units.” Grassick says.

Grassick says that the new technologies are also throwing forward advances in forklift safety.

“Right across the ranges we now have drive systems that offer increased safety as well as better unit protection.”

In Australia, Electric forklifts are currently the most popular choice for those aiming to reduce their carbon footprint. In contrast, the European, British, and American markets have seen a greater up-take of other clean energy forklifts, such as hydrogen fuel cell powered units.

Where is Lencrow headed?

From its roots as a hire company, Lencrow now offers rental, sales, and service divisions. Today, 60 per cent of the company’s business is devoted to rentals and 40 per cent to sales, with servicing covering both sectors. Customers range from single person operations to national businesses with multiple sites and machines. However, it is not necessarily easy to distinguish the buyers from the renters. The types of customers who buy and hire are quite similar. It comes down to personal choice. “Many companies prefer hire as it allows them to get a final cost budget and the equipment

is not on the books with 100 per cent deduction.

They also do not have to manage the units as the hire company looks after maintenance and repairs,” says Grassick.

On the other hand, “The people that buy can see the advantage of depreciation over a number of years and they tend to have a lower usage requirement that requires less maintenance,” he adds. Lencrow aims to be a one stop shop for materials handling. It can offer the full range of material handling equipment required. For example, it offers several brands with unlimited configurations and distributes products by Nissan, Ausa, Carer, EP, and Terex equipment, and more.

The one-stop-shop philosophy means that customers are offered a range of hire and sales options to suit their individual needs. Or, in some cases, a combination of hire and sales may the best fit.

“We have modelled the company on the basis that customers are time poor and do not have the time to go looking at many locations for the equipment that suits their requirement.

“They also need, in multi unit operations, a range of units to both give optimum performance while delivering the best level of safety.” manmonthly.com.au

MA0613_000_TOY

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Offers subject to change without notice and whilst stocks last. Images used for illustration purposes only and not indicative of forklift models available. Actual colour of products may differ from images displayed.

TMH0374 TMB FP_MM.indd 1

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Materials HANDLING – FORKLIFTS, STACKERS

Coupler shifting Manufacturing is all about efficiency and productivity.

I

f a worker can do a job better, faster, safer, then they are going to look to the technology to help them do that.

For a relief team at an Australian mine’s workshop, heavy duty hydraulic pullers are helping them repair couplings and gearboxes faster and safer.

“The boys used the puller to remove two couplings from a gearbox and a Warman pump. It took no effort at all and a quarter of the time it would normally take with a lot less gear,” said Anthony Calleja, the Relief Team’s leader explained.

Enerpac’s Posi Lock manual and hydraulic pullers include models from 1.81 to 90.71 tonne capacity.

Available in two and three-jaw configurations, the pullers feature a patented ‘Safety Cage’ jaw retention system designed to enhance operator safety, increase operational precision, M A 0 and 6 1 minimise 3 _ 0 0 0 the _ KON. p d possibility of damage to components

Available in two and three jaw configurations. being worked upon. The pullers’ slim tapered jaws are designed to overcome the common problem of difficult access to important machinery components during foverhaul P a g and e routine 1 1 5 maintenance. / 0 5 / 1 3 , Both the manual and the hydraulic

Posi Locks offer efficiency as well as safety, because one man can do a job that often requires two men with other tools.

The pullers will even grip on 1 surfaces 0 : 1 9 where : 2 2 normal A M pullers A E S Twould slip off – for example, on tapered

bearings, according to the company.

When matched with Enerpac pumps, valving and special-purpose tools, the Posi Lock slices time, effort and risk from tasks such as lifting, forming, fabrication, bending, bolting, pressing, pulling, production automation and maintenance.

Features of the Posi Lock range include manual models in capacities of 17-356 kN with roll-threaded shafts for less effort when applying high torque.

Available with inside and outside pulling configurations, the expanded range includes maximum reaches from 101-355mm; spread ranges from 12-635mm; and weights from 1.4-30.8kg.

Hydraulic EPH models have 101-498 kN with maximum reach from 203-355mm and spread range from 19-635mm.

The EPH range is available with ram point sets, long jaws and lift plates.

CLX Chain Hoist A safer and more productive way of lifting

CLX chain hoists are designed for flexibility and durability in industrial applications. With variable speeds and a load range from 60 kg to 2,500 kg, they are extremely versatile. You can use this hoist at a workstation, on an overhead travelling crane, or with a jib crane - a high duty factor means it really lasts. Konecranes CLX electric chain hoists are an ideal solution for all these applications. With the built-in control panel and 6:1 speed ratio it provides an economical solution to enhance productivity and safety.

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

58 JUNE 2013 Manufacturers’ Monthly

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Space saving pallets

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Dual fuel forklifts

Cabka-IPS, a manufacturer MLa Holdings has introduced of sustainable pallets, has the Mitsubishi Grendia for released a new range of greater benefits to the planet, space saving pallets. and the operator and the The new size 1140 x 1140 employer. Grendia offers forklift mm (Nest C5.2), augmenting users a choice of diesel/dual the existing pallets in size fuel engines and electronically 1100 x 1100 mm Nest C5. controlled gasoline engine The large Nest C5.2, that complies with all 2007 Provides is available as a nestable Weighs only 12.5 kg when empty. emission standards. all round driver pallet with nine feet or in a The forklift is equipped visibility. version with six clip-on runners. This pallet is a space-saver: 15 empty with features like Integrated pallets stack to a height of just one meter. This permits dense storage and Presence System (IPS), neutral safety, higheconomical transport of empties. The result is lower shipping costs and mounted rear combi lamp and clear all-round reduced CO2 emissions. The new pallets also save space when they are visibility. For driver comfort, there is a floating in service.

The Nest C5.2 makes optimal use of the space in an ISO container (2320 mm inside width): two pallets fit side by side. Five can be lined up in a 20-foot container (5710 mm inside length) and ten in a 40-foot container (12 40 mm inside length). Thus the pallets fit snugly in containers of both THE Combilift Straddle Carrier is a cost lengths, whereas other pallets often require additional packing material. effective and flexible container handling Die Nest C5.2 is very easy to handle. Its square base allows fork lifts to solution. It offers complete independence and pick it up from any side. flexibility when moving containers and similar Workers have no trouble moving it by hand, because it weighs only 12.5 oversized products on a site. kg when empty. The weight-to-load ratio is high, with the pallet coping Users can position the container wherever with static loads of up to 4000 kg and dynamic loads of up to 1500 kg. they require for efficient stuffing and destuffing.

The pallet is available with or without a closed top deck. container MA 0 6 1 3 _ 0 0 0 _ A D A . p d f P a g e 1 1Cabka 5 / IPS 0 5 / It1takes 3 , just 2 three : 3 3minutes : 0 3 to Pload M aA EST from the ground onto a vehicle and it reduces www.cabka.com

power train with Mitsubishi Powershift transmission, which delivers power and gradeability with minimum noise and vibration.

Other features include a suspension seat with a hip support mechanism, acrylic roof for comfortable operation in outdoor conditions, and a fully hydraulic power steering fitted with steering synchroniser.

This automatically matches the rear wheel angle to the steering wheel.

MLA Holdings www.mlaholdings.com.au

Container stacker

manmonthly.com.au

on-site congestion for a safer working environment. It has a 35-tonne capacity and is diesel powered with LP gas engine option.

It comes with synchronised hydraulic steering and a 2-wheel hydrostatic drive. The super elastic/solid soft tyres allow for operation in harsh weather conditions.

Combilift Australia www.combilift.com.au

Manufacturersâ&#x20AC;&#x2122; Monthly JUNE 2013 59

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Exhibitions & EVENTS: NMW National Manufacturing Week: The wrap Manufacturing industry upbeat following a focus on manufacturing’s success.

M

any outside of the manufacturing industry have already condemned Australia’s manufacturing sector as dead in the water.

They refer to it as a twilight industry.

Someone has obviously forgotten to tell the industry itself, as this year’s National Manufacturing Week drew thousands of visitors through its doors at the Melbourne Exhibition Centre.

National Manufacturing Week 2013 drew 11,223 trade visitors, according to preliminary figures The event saw more than 11 200 people pass through the doors during the week. given by its organiser, and satisfied the key need of introducing attendees to new technology. realise that the climate is difficult, innovation and technology: “The While the week started slowly, we hope that there was enough initial feedback from the exhibitors with many exhibitors trepidatious interest stimulated through the is very positive and a stepping stone over attendance, by the second show to create activity in the market for us to continue working with them day visitors began flowing in and place over the coming months,” to generate business.” by the Thursday there was a line Austech exhibition director Shane Speaking at a panel session with to enter leading from the front Infanti stated. There were several other advanced manufacturing door of the exhibition hall almost activities and new initiatives that industry partners at the to the entrance of the Melbourne kept the floor buzzing throughout Manufacturers Pavilion, Bruce Grey, Exhibition Centre. the four-day event. Among them managing director of the Advanced Run in conjunction with Austech, was the Manufacturers Pavilion, Manufacturing CRC, said that which focused on metal cutting and which featured presentations AUSTECH was an excellent forum machining, it acted as a key driver from renowned industry experts, for the industry and showcased the for the local manufacturing industry. discussing the possibilities latest developments in the sector.

A D _ AMTIL M A N M(Australian K E R D E C _ 1 2 . pofdimproving f P a g manufacturers’ e 1 2 9 / 1 0 / 1 2 , Across 2 : 3 8the : 2floor 2 at P National M AEDT “Whilst Manufacturing Institute Limited) competitiveness through research, Manufacturing Week, the wide

range of products and services for manufacturers was a focus.

Reed Exhibitions, which runs NMW, said the event’s highlights included the all-new Metals and Composites product zone, which introduced new manufacturing materials to its visitors.

“At NMW, we’re targeting the right people for us,” said Simon Heading, technical sales consultant for Lavender Composites.

“The contacts we made last year – at our first NMW – were CEOs, designers, decision-makers. In fact, we got solid sales from the event last year – at a time when others were closing their doors. This year’s show has been equally strong – and we’re confident of good outcomes again.”

Exhibition director Paul Baker said that being able to see new technology first-hand was essential to making the event relevant.

“Almost everyone comes away from NMW having seen gamechanging product or service,” he said, adding, “most years, I hear someone leaving NMW say ‘I had been thinking that there should be a product that does X – and I’ve seen it today at NMW’.”

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1300 537 742 | sales@kerrick.com.au | www.kerrick.com.au 60 JUNE 2013 Manufacturers’ Monthly

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GovernmentGRANTS Don’t miss out Times are tough, but the Federal Government has money to give away, if you know the right people to talk to. Alan Johnson sheds some light on some valuable opportunities.

F

ree money from the organisations well worth a visit government. No that’s not a including Enterprise Connect, ICN, misprint, the government really EFIC, Austrade, and then there are has billions of dollars to give away to the state governments with money to manufacturers in the form of grants, hand out. and that’s just from those in Canberra.

Admitedly you might need to AusIndustry spend some time on the application, The first step is to visit www. but as hundreds, probably thousands, ausindustry.gov.au and work your of manufacturers can attest, the way through the nine program. Mark effort is truly worth it.

Gadd, MD of Autonomous Energy, The big problem is knowing where says CTIP is a great program, with a to start. There are so many programs significant amont of funding. available that it can be difficult to “It is a well managed competitve know where to start, and visiting program and is funding all types some of the different websites can be of upgrades to existing plant and intimidating for the first time user. equipment that saves energy and AusIndustry is probably the carbon. first stop, claims lighting A D but _ F while E N SitWI F E to B _be1 3 . p d“While f Pa g e 1is very 2 1popular, / 0 1 / 1 3 , a one-stop-shop, there are other what many people are doing is

Metal Pressing & Stamping Call 1800 626 525

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9 : 5 9

AM

Could be an early Christmas present for some manufacturers. aggregating a number of costeffective projects, including lighting.

Could be electric motors, heating and/or refrigerating systems and solar and putting it all together into one project.

“The guys at AusIndustry look at the weighted average value for money in terms of emission reductions versus dollars invested.”

Gadd points out that a consultant’s fees used to calculate enery and carbon savings can be added to the project and will receive a percentage of funding depending on the company’s revenue, if the project is successful.

“A phone call to see if eligible is the first step, and we are happy to confirm eligibility pro bono.

“We find that many of our clients would be doing the project anyway. so if you can get the government to pay 50 per cent is a real bonus.

“This is free money from the government, but you have to be in it to win it.”

Gadd explains that energy audits are not essential, “we can work with the manufacturers to look how they are using energy and advise them of what projects they should consider.

“It is competive and merit based grant, so there are no guarantees of funding. The applications involve a reasonable amount of work, with methodologies, verifications, timelines and milestones, it’s not the case of ticking a few boxes.”

He said solar energy is becoming very popular with manufacturers, “especially now that it costs less to generate electricity from solar panels than it does from buying it from the grid”.

“Plus it’s now possible to get solar systems installed with no outlay, then pay for it out of the savings manmonthly.com.au

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from the company’s electricity bill.

It’s a no brainer.

“However this grant is not going to be around for ever, if you have any interest in reducing your on-going energy costs consider putting an application in and try to get some free government money,” Gadd told Manufacturers’ Monthly.

However, while the present government says the Clean Technology Programs are all open until 2017–18, if Australia has a change of government in September that will not be the case.

Sophie Mirabella, the opposition’s shadow industry minister, told Manufacturers’ Monthly that as well as scrapping the carbon tax, all programs linked to the much hated tax will also go if the Coalition comes to power in September. So readers are advised to move quickly to take advantage of these programs.

Enterprise Connect While AusIndustry is promoted as the ‘one-stop-shop for industry, many SMEs might be better advised to talk to Enterprise Connect first.

Through a national network of manufacturing centres, over 100 skilled business advisers are available to deliver integrated, practical services to help manufacturers improve productivity and capitalise on their growth potential. They can provide valuable access to a vast array of industry contacts, tools and resources.

Enterprise Connect’s services begin with a comprehensive, confidential, and independent business review, delivered at no charge, which provides an independent snapshot of a company’s current business strategy, and points to new ways to transform its operations.

Following the review, Enterprise Connect contributes half the cost of approved projects, up to a maximum of $20,000.

Typical projects may involve business strategy planning, supply chain management, human resource issues, lean manufacturing, export strategy or business and quality management systems.

One manufacturer who recently took part in the scheme was Sydneybased Airchange Manufacturing, a leading manufacturer of manmonthly.com.au

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projects and increase access to global supply markets for major projects.

“SAMP also saves companies time and money when it comes to finding the right suppliers for their projects.”

Since its inception, the Australian Government has allocated more than $15.1m of SAMP funding across 147 grants.

Other funding opportunties

A high number of manufacturers are using grants from the Clean Technology progams on new solar power systems. (Photo courtesy of Autonomous Energy) high efficiency commercial air conditioning systems.

Steve Atherton, CEO of Airchange, recommends other manufacturers to take advantage of the scheme.

“I was particularly impressed with how the various government agencies worked together to make the process easy and accessible,” Atherton said.

“It’s a good to have an experienced person come come in from outside, with a fresh pair of eyes, to take a look at the company to highlight the company’s strengths and weaknesses.

“Through Enterprise Connect, we picked up on some government grants that we didn’t know were available. The Clean Technology Innovation Program grant was worth $500,000 to us. Enterprise Connect identified the program for us, and helped us with all that.

“As a result of the review process and the tailored advisory service grant, we now have two of our core engineering staff taking Master of Business Administration degrees to further their careers and our accountant is completing his CPA. “We are now also working on a more strategic marketing plan to underpin growth and tap into new market opportunities.” Atherton says for many manufacturers, marketing of their products is the biggest challenge.

“We have some great manufacturers in this country, but it is their inability to market their products is what often holds them back.

“They are often great engineers, designers or inventors, who can produce some of the best products under the sun, but if they don’t promote it properly, people won’t buy them.

“The reality is manufacturers have to get out there and market their products. While this not normally an engineer’s strength, without good marketing and sales you are dead in the water,” Atherton told Manufacturers’ Monthly.

ICN (Industry Capabiltiy Network) ICN might be one of the least known industry assistance organisations in Australia, but for many companies involved this not-for-profit organisation is one of the most important for their growth and survival.

It’s somewhat surprising to hear that not every manufacturer/supplier in Australia is registered with ICN as the organisation must offer the best opportunity to get involved with new projects around.

ICN is an independent organisation financially supported by Australian, NZ, state and territory governments.

As part of its role, ICN operates the Supplier Access to Major Projects (SAMP) program with offices throughout Australia.

Derek Lark, CEO of ICN explained that SAMP increases opportunities for Australian industry, especially SMEs, to participate in major

Two other organisations that demand a brief mention are Manufacturing Skills Australia (MSA) and the Export Finance and Insurance Corporation (EFIC).

MSA is the national body responsible for workforce development in manufacturing and acts as a broker for many of the government’s funded initiatives. It works with companies to determine what their skill needs are, what options are available to address them, and how solutions can target manufacturing workforce issues.

Programs include the National Workforce Development Fund (NWD) with funding available for upskilling existing employees, or to provide opportunities for new workers, and the Investing in Experience (Skills Recognition & Training) (IIE-SRT) program with $20m of funding to support up to 5,000 mature age workers (aged 50 years and over) to gain nationally recognised qualifications.

EFIC, the federal Government’s export finance credit agency, on the other hand provides finance and insurance solutions to help Australian exporters overcome the financial barriers they face when growing their businesses overseas.

The organisation can assist companies to secure finance for export trade when their bank is unable to provide all the support they need, and can work directly with exporters or with their banks to provide loans, guarantees, bonds and insurance products for large and small exporters.

AusIndustry 13 28 46, www.ausindustry.gov.au Autonomous Energy 1300 797 652, www.autonomousenergy.com Enterprise Connect 13 17 91, www.enterpriseconnect.gov.au ICN 1300 961 139, www.icn.org.au MSA 1800 358 458, www.mskills.com.au EFIC 1800 887 588, www.efic.gov.au Manufacturers’ Monthly JUNE 2013 63

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