Manufacturers' Monthly October 2010 by Prime Creative Media

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961

October 2010

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INSIDE The Safety Show Preview >> Fasteners & Adhesives >> Compressors & Pneumatics >> Cutting Tools & Consumables >> Welding & Profile Cutting >> Supply Chain Management >> Reducing Your Energy Costs >> Finance, Leasing & Rentals

REAL ESTATE >> Where to set-up your manufacturing business p.32

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

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Inside OCTOBER 2010

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Australia to manufacture bio-ethanol cars.

8 Analysis News ■ ■

Manufacturing slows, not just in Australia. European consumers choose Australian-made.

14 Supply chain ■ ■

‘Right now’ is not quick enough anymore. Smart warehouse management.

18 Finance ■ ■ ■

Protecting your profits in emerging markets. Being a smart manufacturer. Exporting hurdles lowered.

22 Industrial Real-estate ■

Water management scheme pays-off.

32 Compressors & Pneumatics

46 Cutting Tools & Consumables

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Energy audits slash pressure.

Setting-up your business.

Advances in metal cutting technologies.

38 Fasteners & Adhesives 24 What’s New ■

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Understanding your options.

The latest new products.

48 Welding & Profile Cutting

43 The Sydney Safety Show Preview

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30 Reducing Your Carbon ■

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Caroma’s award for sustainable water management.

manmonthly.com.au

ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961 October 2010

Published 11 times a year Subscriptions $140.00 per annum. (inc GST) Overseas prices applyPh: 1300 360 126 Printed by Geon Impact Printing 69 – 79 Fallon Street, Brunswick VIC 3056 Ph: (03) 9387 7477 ABN 80 132 719 861

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4 Editorial

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REAL ESTATE >> Where to set-up your manufacturing business p.32

All the latest products on-show at the event.

Virtual welding saves training risk. Lathe offers high-quality prototypes.

Behind the cover The new uvex carbonvision safety goggle is 43 grams of lightweight innovation and protection. Combining new uvex carbon technology, the goggle is one of the most innovative products in the uvex eyewear range. The intelligent use of ultra-modern materials results in a new injection-moulded face guard, for a positive seal and splash-proof protection. Its flexible, soft components adapt perfectly to different facial

shapes, ensuring the robust frame is perfectly balanced for all-day wearing. Carbonvision is a premium product demonstrating unparalleled comfort; the uvex carbonvision low-profile goggle ensures compatibility with half-face masks, helmets and bump caps, to assist in providing employees with a full uvex head protection system. For more information, please visit uvex at www.uvex-safety.com.au

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Kelvindale have been manufacturing in Australia since 1950. Our vast range of non-threaded & threaded products will suit most applications across many industries such as, Hydraulics/Pneumatics, Aviation, Engineering, Manufacturing, Mining and many more. We also have the ability to custom design and manufacture using injection, dip & vacuum moulding.

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Manufacturers’ Monthly OCTOBER 2010 3

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Editorial

SARAH FALSON – Editor

editor@manmonthly.com.au

One man’s trash An increasing demand for sustainable transportation options could see a range of new cars that run on fumes from kitchen waste on-sale in Australia.

irst our home entertainment systems offered ‘standby’ modes to consume less power, then we turned to energy-saving lightglobes and star ratings for household appliances to manage our carbon footprint. But the latest initiative born of the global obsession with carbon reduction is the Holden Commodore powered by household waste – yes, the rubbish you throw away could actually be used to get you to and from work. And Australia is keepingup with the eight-ball on this technology. Holden’s latest Commodore range being manufactured in Australia is a special edition model which runs on bio-ethanol and is destined for market in Brazil. A load of 600 cars from the series will initially be exported, however Holden is hoping demand will grow both overseas and in Australia. There are two models in the VE Series II – the V6 and V8 – which represent the first Australian-made vehicles to run on both bio-ethanol and petrol. This comes as great news for an industry that has had its fair share of bad press over the past three years, including millions of dollars of safety recalls and plants re-locating offshore.

4 OCTOBER 2010 Manufacturers’ Monthly

Holden’s VE Series II Commodores which run on bio-ethanol are destined for the Brazil market. © GM Corp.

But Holden isn’t the only automotive manufacturer that is taking the initiative to ‘go green’; the government will grant $63 million to Toyota to bring production of the manufacturers' next-generation, fourcylinder engine for the Camry and Hybrid Camry to Victoria. The new petrol engines will consume 4.5% less fuel and produce 5% fewer greenhouse emissions than today's equivalent engine. This could cut carbon pollution by up to 20,000 tonnes a year. The locally-produced hybrid engine – an Australia-

first – will consume just 6 litres of petrol per 100 kilometres and emit only 142 grams of carbon dioxide per kilometre. What this goes to show is that the demand for carbon-reducing technology is rife in Australia. Not only this, but Australian manufacturers and the Australian government are responding proactively to this trend in order to keep up with global demand. Though tech-savvy countries like Germany and Brazil have been using bio-ethanol for over a year to fuel cars – and even have

bioethanol service stations available for quick top-ups – Holden’s VE Series II Commodore line-up represents Australia’s first foray into the technology. Bio-ethanol, also known as E85, is said to be a cleaner burning fuel than traditional petrol. E85 can reportedly cut carbon dioxide emissions by up to 40% and the resource is said to be 20 cents cheaper per litre than normal petrol. Bio-ethanol is made from the by-products created through processing sugar, wheat and sorghum, and the resulting ethanol is then blended with 15% petrol to create the fuel. Caltex will make available its own E-Flex high-ethanol blended fuel from this month in 31 of its outlets in Sydney, Melbourne, Adelaide, Brisbane and Canberra, with this number to rise to 100 in 2011, which goes to show how serious the industry is taking this trend. In fact, Holden has already started looking in to the possibility of launching Australia’s first bio-ethanol plant to produce the fuel from household waste. This could not only be a niche area for automobile manufacturers looking to cash-in on heightening interest in bio-ethanol cars in Europe, but also more locally. Not to mention the millions of dollars of processing and infrastructure equipment needed if these plants get up-and-running on our shores. Good on you Toyota and Holden for staying ahead of the curve.

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Comment

HEATHER RIDOUT – CEO Australian Industry Group

Looking to the future With the new Government now in place, Ai Group will be looking for the next term of parliament to deliver for business. Heather Ridout writes for MM.

E will continue to argue for measures to restore Australia’s flagging productivity growth, to make further gains in workforce participation, to build our business capabilities and equip ourselves to manage the pressures that are associated with the minerals boom. The protracted negotiations with the independents led to much discussion about the importance of a stable government. Equally, we need a government that works. The strength of our economy, fiscal position, location close to the new centre of global economic growth and human and physical resources give Australia opportunities and choices. Despite this, recent reform efforts and policy execution have

fallen short. The Government needs to develop a positive reform agenda. This should focus equally on the processes through which reforms can be achieved and on the design of these. The Government needs to prioritise short- and mediumterm agendas and focus on achieving them. In the short term, three key issues are essential to Australia’s global competitiveness: investing in the development of a strong and growing skills base; encouraging innovation and business capability development including with a fully-functioning R&D tax incentive; and settling down the new workplace relations system. In the medium term, there will be major debates around climate

REACHING NEW HEIGHTS

change, taxation reform and population. The planned 'Tax Summit' could provide a valuable opportunity to consider and develop the positive directions set-out in the Henry Review; however, it will take much preparation. There is important progress to be made in the areas of infrastructure development, such as broadband, and we must also urge all parties to rebuild the integrity of immigration policy, perhaps through the appointment of a mediator. Climate change will be particularly high on the agenda of the next Parliament with the Greens’ majority in the Senate from July 1 next year. Australia is not alone in grappling with how to respond to climate change. Responses will

editor@manmonthly.com.au

vary around the world until a common position can be developed. If we are smart about it, Australia will build its response around the idea of least cost abatement. Though a carbon tax needs to be looked at, we need to acknowledge that all of the competitiveness issues that are associated with an emissions trading regime are also present with a carbon tax. Certainly, in the absence of a national plan we face underinvestment in electricity generation, a rise in costs as capital equipment ages and the threat of electricity shortages a few years down the track. While the ‘new paradigm' of the next Parliament will involve a much higher level of consultation on this and many other issues, it is also critical that other stakeholders, including business, are fully engaged to achieve lasting advances. Heather Ridout is the chief executive of the Australian Industry Group. Visit www.aigroup.com.au

Konecranes, with headquarters in Finland, is a world leading Engineering Group specialising in maintenance services and advanced overhead lifting solutions. As an AUD $2.2 billion global supplier of overhead travelling cranes used in all industries and branches in over 43 countries worldwide, Konecranes is enjoying steady growth globally. This growth is underpinning our business in Australia & New Zealand, with over 250 employees and 26 locations. Konecranes can offer excellent career opportunities in a specialist industry, with an internal training program and solid safety culture. We are currently looking for motivated people to ﬁll vacancies in ﬁeld services at a number of locations. Please forward your ‘application’ to www.konecranes.com.au/portal/career 1300 937 637

6 OCTOBER 2010 Manufacturers’ Monthly

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You might not have heard of our team, but you probably know all our players. In Australia and many other countries across the globe, Henkel is made up of over 750 brands. Every time you drive a car or travel by train or airplane, chances are that Henkel has helped to make it possible. You deďŹ nitely know our well know hair care products, But did you know that every time you open a food packet, unwrap a piece of chocolate, drink a can or bottled beverage, read a book, or use a mobile phone, Henkel products are likely to have been involved in its production process. The same applies to anything that is bonded, sealed or surface treated, whether it be in the home, business or industry. Henkel provides advanced, innovative solutions for Australian industry and for all of us individually. Take a closer look at the things around your workplace, at home or life in general and you will see just how we at Henkel make your life easier, better and more beautiful.

For more information on the world of Henkel, visit: www.henkel.com.au

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AnalysisNEWS Manufacturing slows, not just in Australia By John Allen

HILE August signalled the eighth consecutive month of expansion, Australia’s manufacturing industry growth eased during the month, reflecting a global trend of slowing new orders and waning inventory building. However, according to the latest Australian Industry Group – PricewaterhouseCoopers Australian Performance of Manufacturing Index (Australian PMI), much of the slow-down in Australia was a direct result of uncertainty related to the federal election coupled with a strong Australian dollar and higher cost of raw materials. Though the PMI fell 2.7 points to 51.7 throughout the month, partly due to slower growth in new orders and production, the reading was still slightly above the 50-mark which indicates an expansion in activity in the manufacturing sector. Strong mining, construction and infrastructure-related activity kept construction materials, basic metals and transport equipment in positive territory in the month, the PMI reported. The clothing and footwear manufacturing market also enjoyed a

8 OCTOBER 2010 Manufacturers’ Monthly

Uncertainty related to the federal election coupled with a strong Australian dollar and higher cost of raw materials impacted on manufacturing’s growth during August.

lift in growth, supported by the strengthening of employment prospects over recent months. The food and beverages, and paper, printing and publishing sub-sectors experienced the biggest falls. Australian Industry Group’s chief executive, Heather Ridout, said manufacturers have enjoyed a gradual expansion since the start of the year. “Although August saw a decline in the pace of growth and new orders were flat, there

are indications that the pace of recovery could strengthen in the months ahead,” she said. “In particular, the stronger performance of the clothing and footwear and wood products and furniture sub sectors is encouraging and suggests that consumer demand may be picking up.”

Global manufacturing Globally, manufacturing activity also slowed in August. The Global Manufacturing PMI, compiled by JPMorgan, fell in

August to 53.8 from 54.3 in June – its lowest since November but marking its fifteenth month above the 50 mark that separates growth from contraction. A spokesman for the bank believes conditions will continue to cool as the year progresses, but there looks to be sufficient traction to sustain the recovery. The global survey shows manufacturing employment increased for the eighth successive month in August, with the rate of jobs growth accelerating to its fastest since May. Staffing levels rose at the quickest pace in the US, were jobs growth hit its highest since December 1983 and employment also rose in the euro zone, China and the UK, but fell in Japan. Earlier survey data showed surging domestic demand helped manufacturing growth in China, and Russia picked up speed in August but conversely there was a slowing recovery in European factories. The Institute for Supply Management's US manufacturing PMI showed activity in US factories grew more quickly than expected in August. The index combines survey data from countries including the US, Japan, Germany, France, Britain, China and Russia.

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MAKING BUSINESS TRAVEL a breeze. Qantas knows the journey is about more than getting to your destination. The airline offers real value for money to take your business dollar further. They also offer products and services to make your business trips as comfortable and effortless as possible, every step of the way. Value begins with a choice of fares. Qantas offers a variety of fare types, including fully flexible fares that let you change your flight to suit your schedule. So if your meeting ends early, so can your day. Small to mid-sized businesses can make use of the American Express Qantas Corporate Card for cash rebates of up to 5%* on a minimum spend of $10,000 pa on many Qantas domestic and TransTasman fares. Qantas also offers travel management services. Qantas Business Direct gives your company control with self-managed bookings for flights, hotels and cars. Zero booking fees, free monthly reporting and competitive prices are an added bonus. Qantas phone-based Account Managers can work directly with you to help ensure your business maximises all the Qantas benefits available and will become a valuable addition to your team.

DAVID KOCH’S BUSINESS TRAVEL TIPS Qantas knows time is money and provides a host of time-saving travel services. You can check in online and request your seat before you leave for the airport. And breeze in and out of the terminal with Qantas Valet Parking or Qantas Chauffeured Transfer service. At the airport, stay productive with Web Connect workstations or Qantas Meeting Rooms. Eligible travellers can also enjoy The Qantas Club and Qantas Business Lounges, where you can keep on top of things at private workstations, with complimentary WiFi internet, drinks and snacks. While onboard, you can look forward to full service on every Qantas-operated ﬂight, with food, drinks and entertainment at no extra cost. Find out all about your seat, food and beverage choices, entertainment and more at qantas.com. There are further ongoing beneﬁts for business travellers. Qantas Frequent Flyers^ earn points to use towards travel, upgrades and Qantas Club membership. Visit qantas.com/business or your travel agent for more information.

Qantas, making your business travel a breeze.

* Terms and conditions apply. Visit qantas.com/business for more information ^ You must be a member of the Qantas Frequent Flyer program to earn and redeem points. A joining fee may apply. Membership and points are subject to the terms and conditions of the Qantas Frequent Flyer program.

• Technology has made your business more efficient. It’s done the same with airlines… download your boarding pass on to your mobile. • Cruise through security by thinking about what’s in your carry-on luggage and wearing travel friendly belts and shoes. • Just like when choosing a financial product it’s not all about price. It may be worth paying a little more for greater flexibility. • Airport lounges can be your travelling office. Catch up with emails and calls to ensure home time is family time… not work time. • A business trip must be productive. Get organised. List your appointments and what’s needed. Tick them off before leaving.

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AnalysisNEWS EVENTS

Performance system key By Derek Parker

OCTOBER 5–6: Operational Excellence National Forum This is a two-day event with pre and post workshops. Register at www.sirfrt.com.au 6–20: Intercad Innovation Day 2010 Sessions on the latest technical advances and information on services to optimise your technology. Register at ww.intercad.com.au/innovationday2011/ 12–14: JEC Asia 2010 Conference and Exhibition Take advantage of the growing composites export market in Asia and the Middle East. Go to www.jeccomposites.com 13–15: Lean Enterprise Workshop Series Introduction to the Lean Enterprise including understanding the basic philosophy of lean and identifying the steps to a lean transformation, and determining product families and correct waste. Visit nsw.apics.org.au 11–12: Coal Exploration & Developments Hotspots Conference The Coal Exploration and Developments Hotspots conference will bring together a panel of more than 20 of the world’s leading coal exploration companies at the Novatel Hotel in Brisbane. Visit www.informa.com.au/coalexploration 20: Measuring and Optimising Capability – Closing the loop for supply chain performance Are your supply chain people contributing to your operational success? And how do you know? Visit nsw.apics.org.au to learn more. 26–28: The Safety Show Sydney and Sydney Materials Handling An exhibition for OHS managers and anyone who needs to know about industrial safety, along with warehouse and operations managers, logistics and procurement managers, site managers, maintenance managers, production managers, forklift operators, foreman and plant managers. Visit www.thesafetyshow.com.au and www.materialshandling.net.au

10 OCTOBER 2010 Manufacturers’ Monthly

IGHTEEN months after Heinz acquired Golden Circle’s operations in Australia, the process of integration is going well and looking towards future growth, according to Gary Thomas, who was appointed as general manager, manufacturing, Heinz Australia, at the time of the purchase. “It was a bit of an eye-opener to some of the Golden Circle people, but they have come to see the benefits of working in a global group dedicated to expansion and continuous improvement,” Thomas told Manufacturers’ Monthly. The company is committed to upgrade site infrastructure and procedures to meet Heinz’ global safety and environmental standards. This will involve investment of around $20 million, with half having already been spent. Heinz now operates five sites in Australia, including the Northgate pineapple cannery in Brisbane – now one of Heinz’s largest factories globally – and the Melbourne Mill Park chilled juice factory. Part of the upgrade program has been the construction and development of a new 30,000-square-metre warehouse at the Northgate site. “We have been pleased to realise a few ‘quick wins’ in productivity since the integration, such as an increased output of around 30% on the tetra pack line,” said Thomas. “Savings have so far been realised through the consolidation of our buying power, together with Heinz Australia. Further savings will be realised once the impact of new investments in systems and infrastructure, as well as marketing to increased volumes, start to flow through.” A key part of the integration project involves the adoption of the Heinz Global Performance System, which pulls the entire supply chain into a standardised continuous improvement approach – a global program that everyone can follow, at their own pace. All the elements of bestpractice manufacturing, procure-

Heinz will make major investments in health and safety.

ment and logistics are sequenced in this system so they can be used at the right time in the improvement process. The ultimate goal is a devolution of responsibility to line workers and employees. “It’s a key step, and it’s designed to take place over a lengthy period, usually between five and seven years,” Thomas said. “There is still a long way to go in the Australian operations, but so far we are making good progress. It has been a major advantage that we can point to other Heinz plants around the world that are a bit further along with the HGPS, so the Golden Circle people can see where it leads and its advantages.” Thomas sees the integration of management information systems as crucial, making the point that this was one of the first areas for new investment after the acquisition. A common system of management information and performance data also allows for friendly competition between plants, the highlighting of best practice, and consistency across the group. Thomas plans to increase the transparency of the organisation so employees are aware of the larger performance picture while understanding where their own contribution fits. He notes that there are no plans to change the Golden Circle brand: “Both domestically and in the region, the brand is an

icon, a gold seal. It’s a keystone of our future expansion strategy. In fact, I think that we haven’t even started to tap the potential tied to the brand. One of my areas of focus is to improve operational and performance standards up to where the brand is, so we can make the most of that asset,” he said. Thomas says he has not found differences of culture to be a major hurdle, especially after the workforce realised Heinz planned to make major investments in health and safety, as well as sustainability. “One of my former roles was with the Environment, Health and Safety portfolio for Heinz North America,” he said. “I have found that a common feature all around the world is that people want a safe working environment. When the Golden Circle people understood that Heinz attached a great deal of importance to that, they realised that there was a lot of cultural similarity. “Even while I am determined to drive the improvement process forward, I have found a lot to admire in the Golden Circle operations. Some of the engineering solutions that have been developed by people looking for improvements in their own area, for example, are extremely good. These are things that the global organisation could learn from.” Heinz Australia 1800 037 058, www.heinz.com.au manmonthly.com.au

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AnalysisNEWS

SAGE lands $2.6m AWD contract BY MARGARET TRA

N 2006 Sage Automation made the decision to expand into defence manufacturing, and this month it has paid off after landing a $2.6 million contract with Spanish naval defence company, Navantia. Traditionally supplying to the water, infrastructure and mining industries, Sage has now entered a four-year contract with Navantia, supplying the defence company with 500 control panels for its Air Warfare Destroyers (AWD) project in Adelaide. The control panels are a critical component to the AWD’s Integrated Platform Management System (IPMS) which is used on-board ships and submarines, along with mechanical, electrical, and damage control machinery and systems. Sage’s contract came into effect this month, after signing a memorandum of understanding in September last year to become the Australian in-country support agent for IPMS on the AWD and Landing Helicopter Dock ship projects. “Sage researched the global market and improved our internal systems to ensure we met the stringent compliance and traceability requirements in the defence sector,” Sage group managing director, Andrew Downs, told Manufacturers’ Monthly.

“We are proud and privileged to be the first Australian company to be in contract with Navantia, providing solutions by integrating technology from our high quality Australian supply chain.” According to Sage, the defence sector is moving from completely customised products to commercial military off-the-shelf solutions which have been built previously and present a lower risk. The company claims that persistence and being proactive were the key factors in winning the contract with Navantia. “We took the initiative to go to Spain and put ourselves forward proactively. We made subsequent visits to show our commitment,” said Downs. For Sage, this project has opened the doors to other projects with Navantia which include upgrades to airfield lighting systems for RAAF airbases, engineering services for chemring countermeasures for the F35 Joint Strike Fighter, electrical and mechanical fit out of portable MCRC and high compliance of BAE systems. Sage claims the defence industry is extremely important to its company and aims to generate $6 million turnover next year, on its way to a goal of $25 million by 2018. Its current turnover is $50 million.

SAGE will build 500 control panels as part of a $2.6 million, four-year defence contract.

SAGE Automation 1300 007 243, www.sageautomation.com.au

Discerning customers choose Aussie-made BY SARAH FALSON

WITH the high Australian dollar and increasing competition in Asia, Australian manufacturers should look to European export markets to find lucrative niches for their innovations. Locals are excelling in areas such as Germany, Spain and Finland with their high-quality, innovation technology. Australian trade consultancy Austrade helps Australian companies enter the European market. According to Senior trade 12 OCTOBER 2010 Manufacturers’ Monthly

commissioner Western Europe, Nicola Watkinson, opportunities are rife in the medical research, wine technology and technical textiles industries in this region. “Europe is a market of very discerning consumers and people who are prepared to pay for quality over price. It’s not a price sensitive market like many other regions. Because of that it’s able to offer particular opportunities at the high-end of the advanced manufacturing sector,” Watkinson told Manufacturers’ Monthly.

Austrade and Watkinson have recently hosted a delegation of Australian manufacturing businesses in Frankfurt looking to get in to the automotive accessories market. “There’s a high interest in topend accessories for the automotive sector because we love our cars over here in Germany. There’s a real desire to be able to equip them properly and the Australian products do have a really good reputation in terms of four wheel drives and leisure vehicles,” she said.

The organisation is also working with the Victorian Government to host a large rail mission, with a view to help manufacturers enter large European supply chains. “If you can get in to the supply chain, the opportunity is not just to get in to the Europe market but also to Asia markets. That’s the sort of strategy we’re working on a lot these days,” said Watkinson. Visit www.manmonthly.com.au for the full interview. Austrade 13 28 78, www.austrade.gov.au manmonthly.com.au

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

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TechnologyIT@MM

Going direct-toconsumer takes at least a couple of transportation legs and a couple of stock holding points out of the supply chain.

‘Right now’ is not quick enough BY STEPHEN REID*

ONSUMERS want things immediately. And now customers at all points in the supply chain are becoming more demanding in their purchasing requirements. Retailers don’t want any stock, distributors want only the minimum amount of stock to ensure

14 OCTOBER 2010 Manufacturers’ Monthly

their customers don’t source elsewhere, and the same applies to the manufacturers who are moving towards the auto industry’s “just-in-time” model. To add further complexity, the traditional retailer is facing stiff competition from the direct-toconsumer web-based retailers, creating a very different supply chain model.

There is an increase in the use of more sophisticated Inventory Planning solutions to help manufacturers and distributors more precisely plan their inventory requirements. These solutions, in combination with Supply Chain Planning solutions which provide decision making support for sourcing, transportation, facility location, distribution lanes and the like, are helping organisations to fine tune their entire supply chain. At the execution level, more sophisticated solutions are being used across the board from Manufacturing Planning and Scheduling through to logistics execution systems such as Warehouse Management and more sophisticated Load Planning and Route Planning. The ultimate goal of any effective Supply Chain Management (SCM) system is to reduce excess inventory which lies in every part of the supply chain. By reducing the number of inventory holding points in the supply chain, it will reduce the amount of inventory and also have the added benefit of reducing the cost of transportation. Increasingly, companies are turning to Web-based applications as part of the SCM solution. Web-based applications provide better access to the underlying business systems but do not necessarily provide better decision-making support. The newer, more sophisticated best-of-breed solutions, webbased or not, are the solutions providing value to our customers. Generally, these more sophisticated solutions are working for the industry, but there is always room for improvement. Some of the programming and

visualisation techniques used in computer/console games are starting to appear in some logistics solutions. As they become more mainstream, they will be game-changers in logistics execution.

Direct-to-customer The traditional model for getting manufactured goods to consumers is changing rapidly. Traditional retailers are being bypassed as direct-to-consumer retail takes hold. But we are not consuming less, so the stock has to be stored somewhere. Going direct-to-consumer takes at least a couple of transportation legs and a couple of stock holding points out of the supply chain. This means overall stock levels, transportation costs and inventory holding costs are all reduced. However, logistics complexity increases. There are an increasing number of companies delivering direct to retail and/or consumer from crossdocking or consolidation facilities close to source. As the cost of manufacturing increases in the traditionally cheaper labour-cost countries, and the cost of transportation from these countries also increases, there are options for changing the manufacturing to a not-so-cheap country where quality can be at least maintained if not improved but where the supply chain is shorter. There are also options for adding value much closer to the end-user. The sophisticated tools needed to help with these decisions are available now and are being improved all the time. * Stephen Reid is SCM principle consultant with Infor.

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TechnologyIT@MM

Integration costs slashed

Superbike design

BY ISABEL WAGNER

project launched

EING competitive in today’s high-tech industry means taking economic advantage of global manufacturing and distribution facilities. For example, computer giant Apple interacts with dozens of trading partners, from resellers, to distributors and OEM manufacturers that help to form its global supply chain. Apple exchanged orders and business documents through a variety of means with its trading partners, most notably EDI. “While this method of document exchange was functional, it was not the most efficient or cost effective,” said Sankar Dhinu, Apple’s senior manager of emerging technology. Apple decided to implement Software AG’s webMethods Integration Platform to solve existing bottlenecks, and also serve as a platform for integrating new applications. The new environment is flexible enough to accommodate changes in Apple’s business processes and react to changes in the market. It is nimble and provides a consistent way of doing business with Apple trading partners. The exchange of business documents now takes place in seconds rather than hours. Cost savings have been achieved by moving off the Value Added Network (VAN) and replacing an outside EDI translator. The integration team can now bring a business partner online in a matter of days, largely by reusing components that have already been developed. Dhinu estimates Apple achieved a positive ROI on its investment within the first year.

16 OCTOBER 2010 Manufacturers’ Monthly

Platform has solved existing bottlenecks, and serves as a system for integrating new applications and services.

To gain experience with the platform and meet the company’s implementation timeline, Apple also decided to bring the professional services organisation onboard for the first few projects. The team used the strategy of first attacking low-hanging fruit. They wanted to undertake projects that would allow the integration team to become comfortable with the technology and also demonstrate a clear ROI. The first project involved migrating the company’s largest trading partners off an expensive VAN onto the webMethods Integration Platform. “It resulted in significant cost savings and it was also fairly easy to attack,” said Charlie Nguyen, Apple’s manager of e-Commerce services. “It did not disrupt any of our business processes, nor the business practices of our trading partners.” With that initial success, Apple forged ahead on four other major fronts. While the company moved its largest trading part-

ners off the VAN, it was still using an EDI translator from another vendor. It made sense to use the Integration Platform to handle that work. “We didn’t want to have to support two or three different platforms, and support all the costs that go along with it,” said Nguyen. A third major initiative undertaken was an electronic commerce project. Apple’s large educational institution customers wanted to use a custom-built eprocurement application to purchase Apple products. At the same time, Apple wanted its customers to have access to all of the value-added tools and features it had built into its online store. Apple customers now are able to use their own e-procurement applications to tap into Apple’s online store, and the integration with back-end systems is automated. Software AG 02 9463 6400, www.softwareag.com

LOCAL 3D CAD/CAM distributor, Intercad, has joined forces with Triple Eight Race Engineering and Racetech Steel to champion the Electric Superbike Project, a community-based initiative which brings together budding and experienced designers, engineers and manufacturers to create and build a unique motorbike. The winning design will be auctioned off to the highest bidder with all proceeds going to Red Dust Role Models, a non-profit organisation seeking to improve the health and wellbeing of disadvantaged youth living in remote communities. Max Piper, CEO, Intercad, says the Electric Superbike Project is a chance for Australian and NZ design, engineering and manufacturing communities to come together and create something for a worthy cause. “It’s not often people have the opportunity to step outside their usual realm of expertise and be part of a larger project which challenges and extends their skills,” he said. Entries are now open. Entrants can submit a design in SolidWorks for any of the parts of the motorcycle or a complete design. To ensure safety, contestants are required to download a file with the structural parameters to create their own design. Interested parties should go to www.theelectricsuperbike.com. au for more information and instructions on how to enter. Intercad 02 9454 4444, www.intercad.com.au

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Smart warehouse = smart supply chain RONNIE O’HAGEN

MART warehouse control software (WCS) is critical to the success of automated distribution logistics solutions. It creates a single user interface for order fulfilment and provides the wide-ranging functionality necessary to drive and efficiently manage the range of transactions that take place daily in busy distribution centres. Dematic’s WCS interfaces with the user’s host computer, typically an ERP system or, in some cases, a WMS, facilitating realtime operations control. It monitors the flow of materials and orders, constantly reporting order status back to the host, enabling global inventory data to be updated in real time, and directs other processes including automated invoicing and shipping documentation. WCS provides real-time control and visibility of order fulfilment systems and personnel. It interfaces order picking technologies

manmonthly.com.au

System monitors the flow of materials and orders.

– voice picking, pick-to-light, putto-light and RF picking, plus automated systems including conveyors, ASRS, carousels, aframes and ergonomic picking stations – into a single integrated order fulfilment system. The software enables users to implement a variety of order picking technologies and apply them across alternative distribu-

tion methodologies including zone routing, batch picking, buffering and sequencing. This enables the most appropriate solution to be applied to different areas of the product movement curve, optimising performance and minimising costs. WCS provides immediate access to data to assist order management and decision sup-

port, dynamically manage the workflow, and balance the workload across the available order picking resources to maximise efficiency and productivity: order detail with zone-by-zone status; container contents and location tracking; picker and zone productivity reports; workload reports to aid allocation of resources; zone map selection to aid workload balancing; and reports of short orders. Dematic WCS delivers its functionality and real-time systems integration capabilities through a number of software sub-systems including: LCS (Location Control System for identifying stock put-away locations); MFC (Material Flow Controller for managing the routing of goods on conveyors); OFS (Order Fulfilment System to manage and balance the workload); PTL (Pick-to-Light functional software); MIS (Management Information System). Dematic 02 9486 5555,

www.dematic.com.au

Manufacturers’ Monthly OCTOBER 2010 17

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AnalysisMANAGEMENT Protecting your profits Foreign exchange is a challenge taken by importers when trading with flourishing countries such as China, but there are ways to mitigate the risks involved. Justin Logan* writes.

ARKET fluctuations, banking restrictions and payment processing are only a few factors that pose challenges for companies doing business in an emerging market like China. But there are ways to mitigate the risks involved, including the ways in which companies manage their foreign exchange requirements. By understanding the key processes behind international transactions, businesses can budget more effectively, negotiate better pricing options with suppliers and manage the risks of currency fluctuation on their bottom line. The first option for mitigating exposure to currency fluctuation is to pay suppliers in local currencies, for example the Chinese Yuan (CNY). This involves only one conversion for an easy and transparent transfer of funds, which eases the fees that local banks charge suppliers who receive international payments. What costs might a foreign supplier face on receiving a dollar payment? Foreign banks are likely to leverage the fact that the beneficiary has no opportunity to negotiate the exchange rate. Premiums up to 10% over interbank spot rates are not uncommon in some parts of the world, not to mention transaction fees. The costs and delays to a foreign recipient of dollars can be substantial, which presents an opportunity for the importer to negotiate a better price by reducing the costs faced by the supplier. Less money in the hands of the foreign bank means more money shared between supplier and importer. You could expect a discount of 2% to 10%.

18 OCTOBER 2010 Manufacturers’ Monthly

Paying overseas suppliers in local currencies isn’t a company’s only option.

But isn’t the importer now stuck with managing any foreign exchange costs and risks? It is important to realise that the payor has a lot more flexibility around associated risks. For one, the payor can review the offerings available from different foreign payments providers, and negotiate to make sure they receive competitive rates and fees. However, paying suppliers in local currencies isn’t your only option.

China’s nuance A key nuance in the Chinese market, for example, is that suppliers often prefer payment in US dollars rather than their own currency, CNY. In some industries, the Chinese Government even offers favourable tax treatment for local companies that are being paid in US dollars instead of in CNY. As a result, businesses are exposed to currency risk if the

Yuan rises against the US dollars and Chinese exporters increase prices to compensate for currency fluctuations. So, the second option available for manufacturers mitigating currency exposure is to use a Non-Deliverable Forward Contract (NDF). This allows you to continue to pay Chinese suppliers in US dollars while hedging the risk of the CNY’s eventual rise against the dollar. This also lets manufacturing businesses project expenses, plan fiscally and protect their bottom line. An NDF works the same as a standard forward contract where businesses lock-in an exchange rate for a future date. The difference is that at the time of its expiry the contract is closed-out instead of being delivered. This then results in a marketto-market gain or a loss for the holder. Let’s say you lock in a Forward Contract to exchange

US$1000 for CNY in three months time. Should the Yuan rise against the dollar in that period, you would receive back more than your original amount. This is because the CNY would now be worth more US dollar. An NDF balances out the appreciation of currencies like the Yuan against the dollar and ensures companies are protected against loss. With any emerging market, such as that of China, the ability to manage your company’s risk is essential for improved fiscal planning. It is also essential to protecting your business’s bottom line. By understanding the options available to you when dealing with international suppliers, you inherently place your business in a position to prosper. * Justin Logan is corporate branch manager with Custom House, A Western Union Company. Comment at manmonthly.com.au manmonthly.com.au

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AnalysisMANAGEMENT

Being a smart manufacturer BY PETER NICHOLSON*

O say the Australian manufacturing industry has changed is nothing new. Over the years, your business has undoubtedly had to evolve to fit the brave new world. If it hadn’t, it simply wouldn’t have survived. A critical part of a manufacturer’s success – and one which is sometimes overlooked – lies in its supplier relationships. Regardless of what a supplier provides – equipment, raw materials, packaging or finance – these relationships must be effectively managed. Just like any other supplier, your financier should provide you with surety of supply, a quality product and flexibility. Without those elements, it’s simply too risky to play in such a working capital- and technologyintensive industry. So how can you best work with your financier to not just overcome the current challenges, but strongly position yourself for the coming years? Some areas you should consider are: Communicate with your financier – Keep your financier abreast of what’s going on in your business – both good and bad. Financiers are usually willing to work with you through the tough times – but don’t surprise them with bad news. The outcomes are infinitely better when your bank or financier knows exactly what’s going on, the reasons for it and how you can work together to overcome any challenges. Plan, plan, plan – If you’re one of those organisations who has never planned before, now is an excellent time to start. Smart manufacturers have vision and a detailed view of what they want to achieve not just in the next one to three years, but in the next ten. Manufacturing is a capital-intensive game requiring a lot of long-term investment. If your business plan doesn’t reflect that, you’re limiting your chances of success. 20 OCTOBER 2010 Manufacturers’ Monthly

Think smarter when it comes to finance.

So, sit down and put together a detailed plan which clearly sets out who you are, what you’re planning on doing and how you’re going to get there. Your financier will thank you for it because it will give them a better understanding of your business, and you’ll feel better knowing exactly what you’re aiming for. It’s not just about price – A savvy manufacturer will constantly look at ways to reduce costs, but don’t fall into the trap of thinking this is a panacea for you or your financier. Believe it or not, we care about more than just the expense side of budgets. Everyone’s doing it tougher at the moment on the back of a challenging economy and everincreasing competition from Asia. Price is important to customers, however successful businesses have the ability to identify and articulate their real value proposition and point of difference, and then ensure that they rigorously execute. In the same vein, the cheapest finance is not always the best and, like any supplier, a financier should be constantly reviewed to ensure you are getting exactly what your business needs. * Peter Nicholson is executive director, Corporate Financial Services, GE Capital. manmonthly.com.au

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Exporting hurdles lowered BY ALAN JOHNSON

ANUFACTURERS who recognise the numerous sales opportunities for their products in other parts of the world, but are not sure how to manage their finances for export or need additional working capital should read on. Whether exporting to New Zealand or Newfoundland, the need for dependable working capital support is critical if the venture is to be a financial success. To assist Australian exporters, the Government’s export credit agency, EFIC, has recently developed two such products that are distributed by 3rd parties. One involves a recent agreement between EFIC and Travelex. It provides eligible exporters with higher foreign exchange trading limits without the need for additional security from the exporter. The new EFIC/Travelex’s Foreign Exchange Facility Guarantee allows Travelex customers to expand their hedging programs; thereby protecting their profits. Melbourne-based GP Graders, which is Australia's largest designer and manufacturer of produce handling equipment, is taking advantage of the scheme. Travelex is providing a hedging limit that has now been increased by 50% with the help of the EFIC Foreign Exchange Facility Guarantee. After not previously hedging its offshore sales, and with no lines of credit for foreign exchange, the company is now utilising Forward Exchange Contracts to manage the foreign exchange risks associated with its export contracts. Richard Lim, Financial Controller at GP Graders, said with 75% of its products now being exported, and these predominantly to South America (contracts in US$) and Eastern Europe (contracts in Euros), this was a critical move. “We are now protected against currency movements,” Lim told Manufacturers’ Monthly. manmonthly.com.au

New schemes are designed to overcome financial barriers for exporters.

He admits some currency movements have worked in the company’s favour. “We have had some bumper years, but it can quickly go the other way,” he said. “For example, when we costed a contract with the Australian dollar at 91c to the US$, which then fell to 79c, we lost a lot of money on the deal. “We quickly realised then we had to do something to protect our profits. “With machines costing $600,000 upwards, we don’t want to commit ourselves to contracts and maybe end up making the machine for nothing. “Tracking currencies is very important.” According to Andrea Govaert, EFIC’s executive director for SMEs, the new scheme is designed to broaden the ways in which EFIC can help exporters manage the risks of international trade. “Designed to assist small and medium-sized businesses, the guarantee protects their export business from loss due to events beyond their control, and helps SME exporters move into global markets,” she said.

Working capital finance EFIC has also developed an exporting capital guarantee scheme which facilitates access to additional working capital through the exporters’ bank.

At this stage, ANZ has signed up to the facility, but other banks are expected to follow soon. The agreement will support the bank’s exporter clients with overseas contracts and/or investments and subsidiaries who require incremental finance to fill orders.

ANZ’s global head of trade & supply chain, Mark Evans, said the working capital guarantee supports financing requirements before and after shipment across a wide range of industries covering both goods and certain services. “The guarantee facility will assist small-to-medium-sized businesses with their export finance needs,” Evans said. Typically, the scheme is applicable for companies who find they don’t have enough working capital to deliver on new export contracts, especially large oneoff contracts. For example, the company might be short of funds to hire more staff, buy raw materials, manufacture the product, or deliver the goods to the buyer. The scheme can support a single export contract or multiple export contracts with different buyers. EFIC 1800 093 724, www.efic.gov.au Travelex 1800 730 400, www.travelexbusiness.com/au

MATERIALS HANDLING positioning DISPENSING INVERTING elevating LOADING LIFTING

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Ergonomics in Action Manufacturers’ Monthly OCTOBER 2010 21

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IndustrialREAL-ESTATE New kids on the block Traditional industrial hubs are making way for a growing number of manufacturing locations, supporting demand for advanced manufacturing, Emily Mobbs writes.

HE manufacturing sector has experienced a surge of positive energy and confidence in recent months: the industry continues to report strong growth rates; and, as editor-at-large Alan Johnson commented in a recent issue of Manufacturers’ Monthly, governments are beginning to realise the importance of fostering a vibrant manufacturing sector. In line with this shift in momentum, some manufacturing companies will need to look at business expansion either through investing in new facilities or relocating premises. Alongside the traditional industrial locations is a growing number of new areas in which governments are doing all they can to attract new business.

New South Wales Situated 10km north of Wagga Wagga, Bomen Business Park is said to provide an alternative to industrial estates often located around the coast of the country. According to Wagga Wagga City Council manager economic development, James Davis, the area is expected to become a major industrial hub, likely to contribute approximately $1.3 billion to $1.6 billion to the Wagga Wagga region’s economy in 20 to 30 years time. “Essentially it’s all about location. The park is equally distanced between Sydney and Melbourne and has the SydneyMelbourne rail corridor running right through the middle of it, which carries about 70% of the national rail freight task,” Davis told Manufacturers’ Monthly. The business park has just been rezoned, making an additional 1,400 hectares of land available to serve the next 30 to 40 years. The state government has also approved a $2.5 million infrastructure funding package 22 OCTOBER 2010 Manufacturers’ Monthly

spend. The Queensland state government offers a range of grant programs, including the Business and Industry Transformation Incentives Program (BITI), which aim to assist manufacturing companies looking to expand or relocate their businesses.

South Australia

The Bomen Business Park is already host to a range of industrial facilities.

for the estate which will be used to improve the road network in and out of the site. Davis says Wagga Wagga has a strong work force as well as a TAFE and university, which attract approximately 10,000 students per year. Both learning institutions have business managers to help tailor courses to specific industrial sectors. “In addition to this, we have developed a Live, Work, Invest program to help support people who have relocated because they have a sought-after specialised skill,” he said. The industrial park is particularly suitable for advanced manufacturing industries like renewable energy and bio-mass. “Wagga Wagga is geographically a hot spot for solar take-up because it has strong hours of sunlight and it is close to high voltage electricity lines which is always critical in investment terms,” he said.

South East Queensland In direct correlation with a rapidly growing population, South East Queensland has emerged as a significant industrial centre. Brisbane Marketing investment attraction manager, Alex

Smith, says the Brisbane manufacturing industry is innovative in nature. The sector is concentrating on specific niche areas such as green building materials, composites, plant and equipment, and recycling to ensure long-term growth. “It is hard to maintain any sort of competitive advantage in a lot of the heavy manufacturing in Australia, so you have to look at the smaller more high-tech industries where we’ve got the talent; we’ve got the skill base to actually manufacture something of a high quality as opposed to just bulk,” Smith said. “The development of high-tech manufacturing also helps to cultivate and attract talent from around the world, which helps to support Brisbane’s knowledge economy and strong long-term economic growth." He says industrial regions like the Australia TradeCoast – an 8,000-hectare trade and business precinct situated 10km from Brisbane’s CBD – provide progressive infrastructure facilities, access to a growing port and airport and close proximity to Asia. Ipswich is also primed to capitalise on strong population growth and a large infrastructure

Edinburgh Parks was established in 2003 and is South Australia’s largest industrial park situated 25km north of Adelaide. The estate offers access to major transport routes including: links to the national highway network; port facilities; and the Adelaide to Darwin rail line. Companies such as Inghams and Australia’s largest defence contractor, BAE Systems, have facilities in the estate. Land Management Corporation (LMC) chief executive, Wayne Gibbings, says the industrial land is suitable for businesses involved in manufacturing, defence, science and research, warehousing and processing.

Victoria Victoria is known for fostering a traditional manufacturing environment, but Victorian industry and trade minister, Jacinta Allan, says the state is also planning for the industry’s future. Businesses can gain assistance through the state government’s Manufacturing Action Plan under the Building Industries for Our Future package. “The Action Plan shows how we plan to help ensure Victoria remains the nation’s manufacturing and job-creation hub by assisting manufacturers to tap into new domestic and export opportunities,” Allan said. New business parks are currently being created in areas across Melbourne including South Dandenong and Casey. Brisbane Marketing – investment attraction 07 3006 6200, www.investbrisbane.com.au Land Management Corporation 08 8207 0801, www.lmc.sa.gov.au Victorian Department of Innovation, Industry and Regional Development 03 9651 9999, www.diird.vic.gov.au Wagga Wagga City Council 1300 292 442, www.wagga.nsw.gov.au manmonthly.com.au

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Where Will You Locate Your Next Plant? Bomen Business Park at Wagga Wagga - NSW's Largest and Fastest Growing Inland City! Nick Leywood weighed up the pros and cons of ﬁve potential regional locations but Wagga Wagga’s accessibility to most capital cities, cost-effective real estate and established infrastructure were decisive advantages for his business.

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Bomen offers: • Strategic location relative to the major eastern seaboard markets with direct access to the busiest rail freight corridor linking Sydney and Melbourne and connections to the three major highways • A large, loyal and skilled workforce • Access to all key infrastructure. Commercial Economic Development Directorate Wagga Wagga City Council business@wagga.nsw.gov.au www.businesswaggawagga.com.au 02 6926 9133 / twitter.com/waggaed

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

Cleaning machines

Jetting tank washer TECPRO Australia’s new Typhoon rotating cleaning head is suitable for large vessels, including food and beverage storage tanks, transport containers and chemical reactors. The cleaning head produces four high-powered jets that are said to give complete coverage in a quick seven-minute wash cycle. Even at high flow rates, the geared movement reportedly maintains an optimum jet peripheral velocity that increases impingement and chemical dwell times to maximise cleaning effectiveness. According to the company, the cleaning head was designed to be easy and cost effective to maintain over a long life.

The cleaning head has a cleaning radius of 9m and wetting radius of 17m.

It is constructed from only 48 parts, which can be easily dismantled and reassembled, and is supplied with a

basic repair kit of only 10 parts.

TENNANT Company has unveiled the 7300 mid-sized battery-powered rider scrubber and the 8300 battery-powered sweeper-scrubber. The 7300 product has multiple scrub-head widths and large-capacity batteries, said to deliver hours of productive scrubbing. It has three downpressure settings and a Superscrub mode to tackle dirt, grime and grease. The 8300 sweeps and scrubs at the same time. It uses the company’s patented Multi-Technology Sweeping and the MaxPro Scrubbing Technology, which maintains constant down-pressure on the brushes. Both are said to use up to 70% less water than traditional methods.

Tecpro Australia 02 9634 3370, www.tecpro.com.au

Tennant Company 1800 226 843, www.tennantco.com

Constant force springs

Rotary clamp cylinders

LINMOT has released a constant force spring (up to 60N) made from permanent magnetics. With no electricity required for operation, the springs can deliver a constant force over their entire working stroke. The springs are suitable for applications where weight load compensation, holding force or a constant force is required.

SMC Pneumatics’ MK series of rotary clamp cylinders reportedly offer an allowable moment of inertia three times higher than current products from the company. According to the manufacturer, the new units allow faster clamping performance for high speed machinery, while offering the same overall length dimensions and interchangeable mounting dimensions for existing and new applications. Rotary clamp cylinders are used in a variety of

Motion Technologies 02 95244782, www.motiontech.com.au

24 OCTOBER 2010 Manufacturers’ Monthly

With no electricity required for operation, the springs can deliver a constant force over their entire working stroke.

applications, from folding and closing cartons in packaging machinery to clamping products in welding processes. They may be specified in clockwise or counter-clockwise directions. All-round auto switches can be mounted on up to all four sides of the cylinder without the need for additional mounting brackets. For welding applications, magnetic field resistant auto switches can also be used. SMC Pneumatics (Australia) 1800 763 862, www.smcaus.com.au

manmonthly.com.au

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Robotics vision system

The R-30iA can interface with up to 32 cameras.

FANUC has combined its knowledge of articulated robots with camera systems to create an intelligent vision system that combines the R-30iA robot controller and Integrated Vision (iR Vision) vision system in one platform for flexible handling. The R-30iA can interface with up to 32 cameras through the Fanuc-supplied multiplexer hardware, and these cameras can be mounted remotely or directly on the robot end effecter. The camera package includes an integrated LED ring light that can be controlled through the robot program. The system is said to increase the accuracy of handling large parts by combining several individual camera images to get one accurate combined offset value; the system allows each camera to view a small section of a large part, thus increasing the resolution accuracy. The integrated vision system can be setup through the robot web-server that is accessed through one of the two freely-available ethernet ports on the R-30iA main board. John Hart Automation and Robotics 03 9542 6262, www.johnhart.com.au/automation

manmonthly.com.au

Manufacturersâ&#x20AC;&#x2122; Monthly OCTOBER 2010 25

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What’sNEW Radiometric measurement system RONAN’S new X96SI/R radiometric transmitter is said to be the first of its kind to be fully ethernet capable, enabling configurations, software updates, and data logging to be completed easily using the owner’s PC and a standard web browser. The transmitter includes an optical coupling that allows the transmitter and detector electronics assembly to be easily mounted to any detector configuration. The transmitter can also be remotely mounted in the field or control room, and is available in either explosionproof, weather-proof or stainless steel housing. The system is said to be ideal for difficult process applications including: continuous level, point level, interface level/density, density and mass flow. The unit is also useful for continuous weight measurement in extreme process environments including: mining and aggregates; power; refining, oil and gas; chemical; metals; pulp and paper; dredging; cement; and food and beverage. AMS Instrumentation & Calibration 03 9017 8225, www.ams-ic.com.au

The fences are suitable for industrial or commercial use.

Safety fences The system can be installed and maintained without downtime while the process is running.

NHP is now distributing ISF’s range of Industrial Safety Fencing, including standard modular safety fencing components that are durable and suitable for industrial and commercial use. The range is complemented by a line of accessories that includes light curtain protectors, stainless steel pushbutton stations and spreader bars and mounting brackets, meaning a tailored fencing system can be designed to suit any installation. The standard design of the range of ISF safety fencing is manufactured from mild steel, however, this can be substituted with stainless steel if specified. NHP Electrical Engineering 03 9429 2999, www.nhp.com.au

Signet catalogue showcasing adhesive tapes National warehouse, packaging and office supplies company, Signet, has released its latest catalogue of products which comprises a range of adhesive tapes including: machine-applied tapes; tape dispensers; and hot-melt glues. The company has reportedly received a Service Excellence award for its business formula that includes fixed prices until 31 December 2010, same day despatch, a 31-day moneyback guarantee, more than 2,000 product lines and accurate order-processing. According to Signet, it is also offering 10% price-beating guarantee which is a testament to its price-competitiveness. The new catalogue features brands

The catalogue features a range of adhesive tapes.

like 3M, Bollé, tesa, Kimberly Clark, Unisafe, Artline and Pentel. It also includes packaging products such as wraps, straps and cartons, warehouse products like signs, markers and protective wear and office supplies like labels and stationery. Signet 13 7446, www.signet.net.au

Safety sign and label printers KEMTEK Imaging Systems has launched a new range of in-house sign and label printing systems. The label printing units allow workplaces to produce their own custom safety signs and information, process marking, maintenance marking and evacuation notices. The SMS 200/300 desktop industrial sign and label system is suited for producing 100mm-wide safety signs, maintenance marking, pipe marking and process marking. It also comes complete with a range of printing 26 OCTOBER 2010 Manufacturers’ Monthly

materials and NiceLabel software. Another unit, the unique SMS CSA ‘stand alone’ desktop printing system, offers an in-built PC, complete with touchscreen and mouse. The SMS CSA is a dedicated sign and label printer that apparently will not compromise networks. It can also be used for other tasks and will always maintain the integrity of data and important label designs and templates. Kemtek Imaging Systems 02 9517 2902, www.kemtek.com.au manmonthly.com.au

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What’sNEW Drive filters

The filters are designed to prevent premature ageing of ac motors.

THE new range of Schaffner sinusoidal output filters are designed to ensure cooler and more reliable drives. According to the company, not only does the range offer the capacity to prevent premature failures and expensive downtimes but it is also precisely matched to the technical requirements of modern drive systems. The filters smooth the modulated output voltage of modern drives and provide the motor with a clean sinusoidal voltage with low residual ripple, thus preventing premature ageing and destruction of the ac motor. The range is available in a compact open frame design, FN5040, or as a user-friendly packaged version, FN5045 - IP20. NHP Electrical Engineering 03 9429 2999, www.nhp.com.au

Stub drills with curved cutting lips SUTTON Tools has introduced the DXS stub drills with curved cutting lips to reduce the length of chips. Called the TiA1N coated drills, the units are suited for materials up to 850N/mm2.

The manufacturer claims unlike conventional twist drills, the units do not produce long stringy swarf when machining certain materials. Sutton Tools 03 9280 0800, www.sutton.com.au

Electronic multifunctional counters AUTOMATED Control Engineering (ACE) has added the Hengstler Tico 772 ac version to its product line of electronic multifunctional counters. The counter offers totalising with presets, time and speed measuring as well as providing control signals. Features of the counter includes a large display of 48x48mm, with twoline display for easy reading, plus easy handling with only four large keys. Automated Control Engineering Group 02 4954 5004 www.aceg.com.au

Compact robot vision systems MICROMAX is now distributing the EOS-1000 PoE compact vision system from electronics manufacturer Adlink. Based on the Intel Core 2 Duo P8400 CPU, the unit provides four independent PoE ports and data transfer rates up to 4Gb/s. Multi-camera imaging capabilities allow it to be used for applications such as 3D vision robotic guidance in manufacturing facilities. Micromax 1800 634 766, www.micromax.com.au

The right combination of German made sensors and controls and local service and support Qualiﬁed engineering support 98% of products delivered within 24 hours Innovative customer solutions Convenient live availability check and online ordering www.ifmefector.com.au/eshop

Safe-grip industrial gloves When production workers are required to handle solvents, oils and other chemicals, a firm grip of wet containers and parts is an issue. Ansell’s AlphaTec58-270 glove was reportedly developed in response to market demand for non-slip hand protection that protects workers who need a combination of positive grip and advanced chemical protection throughout work shifts. According to Ansell, the glove provides manmonthly.com.au

comfort, precise handling, and grip and skin protection anywhere chemicals and oils are present, including oil-based chemicals, water-based lubricants or other greasy coatings. Microscopic channels in an ultra-thin nitrile layer direct fluids away from the grip surface, leaving a significant contact area dry with almost the same grip as under fluid free conditions, the company claims. Ansell 1800 337 041, www.ansell.com

We design and test sensors in conditions that far exceed your application environment. There can be no compromise when it comes to safety and uptime in your facility.

The glove offers almost the same grip in fluid as under fluid-free conditions.

For more information, please call us on 1300 365 088, or visit www.ifm.com/au Manufacturers’ Monthly OCTOBER 2010 27

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What’sNEW Said to be the world’s smallest eight-channel ultrasonic testing instrument.

Ultrasonic testing instrument RUSSELL Fraser Sales says it has released the world’s smallest eight-channel ultrasonic testing instrument. AGR’s TD Pocket Scan features high-speed, real-time data collection to improve inspection speed, and extensive off-line analysis tools with built-in reporting. The small instrument allows it to be operated close to the work piece or on a scanner with comms to the computer via a single cable. Weighing 200g, the company says the instrument is ideal for testing pressure vessel welds, pipeline welds, structural welds, hydrogen damage surveys, corrosion surveys, forging and castings, aircraft components and complex geometries. Russell Fraser Sales 02 9545 4433, www.rfsales.com.au

Movable waste disposal unit EXIMO provides a range of ducted waste disposal solutions designed to suit industrial applications. The company’s SpeedLock Modular Steel Ducting is designed to provide a movable waste disposal unit within the manufacturing plant. The system can be used for wood and metal shavings, agricultural, milling, food and liquid waste. According to Eximo, the SpeedLock is manufactured using smooth bore technology, meaning it minimises the risk of waste settlement and system clogging. For applications where some clogging is unavoidable, the system’s easy access makes cleaning simple,

The unit can be unclipped and re-assembled simply.

the company says. Eximo 02 9757 1233, www.eximo.com.au

Water bottle re-fill stations ARROW Alpha Industries has designed a water bottle re-fill station suitable for industrial and commercial businesses. The system, called aquafil, is designed to be sturdy in harsh environments and is an option for companies that want a healthier and cheaper alternative for staff than

softdrink machines. The unit is also designed to lessen the number of water bottles put in the garbage at industrial sites. Aquafil has the capacity for promotional signage space. Arrow Alpha Industries 02 9737 0022, www.arrowalpha.com.au

• Limited access

• 360-degree access

• One hand for work

• Two hands for work

• No tool tray • Risk of falling • Fatigue & cramps

• Tray holds tools • Work platform security • Comfort & freedom • Truly portable

131 JLG (554) www.liftpod.com

28 OCTOBER 2010 Manufacturers’ Monthly

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What’sNEW Rotary position sensors

Digital positioners for process control

The sensors can provide an anaBESTECH Australia is now log voltage output proportional distributing the RSE 1500 Series to shaft rotation over a total rotary position sensors from range of up to 120°. manufacturer Macrosensors. The contactless, fractional-turn, absolute output rotary position sensors can provide an analog voltage output proportional to shaft rotation over a total range of up to 120°. They are suitable for measuring the position of quarter-turn ball and butter fly valves, flue dampers, weir gates, conveyor check weigher systems, dancer arm tensioners, and many other applications involving fractional-turn shaft movements. The rotary position sensors are also useful for other limited rotation applications like pedal position sensing for mobile equipment, and throttle lever position sensing in boats and cranes. The sensors use built-in electronics to offer dc input/output configuration. They are available for ranges of 0° to 30°, 60°, 90° and 120° with a true-zero 0-10V DC unipolar output.

BÜRKERT has released the 8791, 8792, and 8794 digital positioners for expanded process control possibilities with zero air bleed at rest position. The units have integrated process controllers, and are suited for use with quarter turn and linear process valves, and pneumatically controlled instruments such as valves, cylinders and dampers. Available as direct mount or remote versions, the positioners have IP65/67

Bestech Australia 03 9584 1133, www.bestech.com.au

housings for service in challenging environments. A large, backlit LCD display guides direct four-button programming, which gives the option of computer or direct inputs as well as direct parameter readout. They can control up to 150L/min for both spring return and double acting actuators. Bürkert Australia 1300 888 868, www.burkert.com.au

Multi-product calibrator FLUKE Corporation has introduced the new 5500E Multi-Product Calibrator said to offer excellent value to those customers that have a basic yet varied workload, with a better performance specification in the 5500 series instrument platform. The 5500E has a wide range of outputs available from a single calibration source. These include dc and ac voltages up to 1020V, dc and ac currents up to 550A (using the 5500A/COIL, 50 turn current coil accessory) and vari-

able resistances up to 330MÙ. The 5500E also provides continuously variable capacitance values up to 1.1mF. For temperature calibration applications, thermocouples and RTDs are simulated and thermocouple signals can be measured. It also generates digitally synthesised extended bandwidth sine, truncated sine, triangle and square waveforms. Fluke Australia 03 9633-0444, www.fluke.com.au.

Vibrating fork liquid level switch EMERSON Process Management’s new Rosemount 2160 vibrating fork liquid level switch is said to be the industry’s first IEC 62591 (WirelessHART)-certified unit of its kind. According to the company, the switch provides level detection in locations previously inaccessible or too costly for wired devices. Suitable for most liquid applications, the unit is reportedly unaffected by

flow, bubbles, turbulence, foam, vibrations, solid content, coating, liquid properties and product variations. The switch has been designed for use in extreme temperatures and harsh process conditions. Typical applications include overfill protection, high and low level alarms, pump control and pump protection or empty pipe detection. Emerson Process Management 03 9721 0200, www.EmersonProcess.com/SmartWireless

HAVE YOU EVER WANTED TO AUTOMATE or ROBOTISE SOMETHING THAT HAS NEVER BEEN DONE BEFORE? At APPLIED ROBOTICS we have an enviable track record in successful Automation/Robotics R&D, established over our 25 years of business. In the last 3 years alone notable R&D Projects have been: 1. Bricks and Blocks manufacturers - four-sided, hair-line cracks and chips detection, colour/hearting and overall dimensions & shape QC, on-line at over 10,000 bricks or blocks per hour. First in-line production system for Australia. 2. Australian Wool Testing Authority – production machines to prepare precise weight wool samples (or from any similarly tangled mass) fully automatically. Joint winner of the 2007 NSW Engineering Excellence Award for a world first technology. 3. OPAL Australia. Jointly with CSIRO developed vision system Gemstone Assaying Technology. We won the 2009 NSW Engineering Excellence Award for another world first. 4. Plastic Extrusion manufacturer – in-line, on-the-move, robotic hole boring on continuous plastic extrusion. A first for ABB robots. 5. Norwegian Govt Consortium – technology development for a future Automated Sewing System for fabric and leather assemblies. R&D project won against leading R&D organisations in USA, Japan and Europe.

Contact Dr Paul Wong Applied Robotics Pty Limited 15 – 17 Egerton Street, Silverwater, NSW 2128 PO Box 6788 Silverwater NSW 1811 Ph: +612 9737 8633 Fx: + 612 9737 9660 Email: sales@appliedrobotics.com.au manmonthly.com.au

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CarbonFOOTPRINT I

MPLEMENTATION of sustainable water management practices can result in significant cost savings and bottom line benefits for manufacturing enterprises, as well as a reduction in carbon footprints. CaromaDorf recently received the Green Globe Business Water Award for 2010 from the NSW Department of Environment, Climate Change and Water for outstanding sustainability performance at its Wetherill Park factory in Sydney. Through a range of initiatives, the company has actively sought to reduce water consumption and recycle wastewater into all stages of production. Operations development manager at the Wetherill Park facility, Dan Thompson, says one of the initial steps was to install flowmeters into each process area of the factory and then set targets for consumption per product. “This provided a focus on water usage and highlighted opportunities for optimal control and reduction,” Thompson told Manufacturers’ Monthly. “For example, reprogramming the vitreous china casting machines has resulted in saving more than 6 million litres of water each year.” “CaromaDorf is the only sanitaryware company in Australia to adopt world-best pressure casting technology in producing toilet suites. “This advanced technology provides the ability to minimise resource demand per piece of production in comparison to traditional casting techniques. “It also enables the design and production of products with higher precision fluid dynamics, which is critical in achieving lower volume toilet flushing.” The company has also invested in equipment designed to maximise the recycling of treated process water for later use in the pressure casting of its sanitaryware products. According to Thompson, an ultra-filtration wastewater treatment plant was recently commissioned with the ability 30 OCTOBER 2010 Manufacturers’ Monthly

Award shows sustainable water management pays-off A leading bathroomware manufacturer in Sydney has been rewarded for its endeavours to reduce water consumption and recycle wastewater in all stages of its manufacturing production process. Hartley Henderson writes. to save a further 32 million litres of water per year. “The plant will enable us to reduce our mains water requirement by 65% and reduce process wastewater dumping to sewer by 80%,” he said. “Other water-saving achievements include reprogramming raw material discharge to eliminate 800t of slip waste, 50% of which is water. “A further 200t of slip waste has been eliminated through redesign of a firing setter, and installation of a new glaze reclamation process has resulted in saving 9000L

of water for reuse in cleaning operations.”

Recycled water treatment The treatment plant, installed by Aquatic Engineering Australia (AEA), processes the water used in production and cleaning and is designed for a maximum flow of 185m3/day. According to AEA managing director, Josh Bucholtz, the plant utilises a proven process with a high level of automation and monitoring. “Significant benefits include reduced chemical and operating

costs over the site’s existing water treatment plant, high quality product water, simple operation, and excellent return on investment,” Bucholtz said. “Wastewater from the manufacturing process is collected and pumped to a 25,000L equalisation tank where the pH is corrected and suspended solids monitored via a suspended solids meter to prevent potential overloading of the ultra-filtration (UF) plant. “In the first pre-treatment stage the wastewater is pumped through a hydrocyclone to sepamanmonthly.com.au

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rate heavy solid matter which flows into a sludge storage tank. Clean water flows to a clarifier for further removal of solids and then to the UF feed tank via a weir. “Following pre-filtering, the water enters the UF membranes and the product water flows into the recycled water storage tanks where it is automatically chlorinated for disinfection purposes.”

Flowmeter technology The 16 new flowmeters installed at the plant were supplied by FoxAll Fidera. Chris Econ, applications engineer with the company, says the Foxboro IMT25 magnetic flow meter transmitter, combined with a Foxboro 8001A dc magnetic flow tube, was chosen because it offers the best all-round value for this application. “In addition, features including large surface area electrodes and automatic excitation polarity change provide superior stability and low power consumption,” said Econ. “The stainless steel perforated grid imbedded in the flow tube lining adds durability, and this coupled with the ‘keyed’ fixing of the liner to the flanges makes the 8001A impervious to temperature swings and vacuum.” AEA 02 9569 5504, www.aquatic-engineering.com CaromaDorf 13 14 16, www.caroma.com.au FoxAll Fidera 02 8825 6222, www.fidera.com.au

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Manufacturers’ guide to carbon management By Rob Stummer*

Manufacturers are under increasing pressure to document their environmental impact as customers are making purchasing decisions not only on the basis of price and quality but on contribution to global warming. But where do manufacturers start? Data on environmental impact originates from every part of a company and can take many forms. This means that, technologically, it is a major challenge. But the nontechnical barriers to launching an effective program are not to be underestimated. Many of the problems companies experience as they try to implement an environmental program of this type stem from the lack of clear ownership. Who within the company owns the issue? An effective environmental management program is only possible once it becomes an issue at the ‘board of directors’ level. Once this is part of the corporate strategy, a company is in a position to put much harder policies into place and can force the different departments and cross functional teams to collaborate around the issue. Adequately tracking environmental footprint data is almost impossible while using ad hoc systems like spreadsheets because outside of an enterprise

application, no combination of spreadsheets is comprehensive enough to do the job. True environmental footprint management can involve a complex and huge body of data and the natural place for that data and where most of it is already to be found is within the enterprise system, the ERP system. Currently, manufacturers with any degree of environmental footprint measurement rely almost exclusively on either standalone carbon footprint software or on one-off integrations between ERP tools and either packaged or custom software. To this end, there are a few questions to ask enterprise software vendors that claim to offer a solution in this area. Questions about the flexibility and broad capabilities of these enterprise software tools are particularly important. Do they allow you to measure how your product is used, how much energy it consumes and whether it emits any substances? Before selecting any environmental management solution, be sure to think not only of your immediate needs but also how your needs could change in the future and how the various enterprise solutions can continue to accommodate them. *Rob Stummer is managing director of IFS Australia and New Zealand. Visit www.ifsworld.com

Print solutions key to carbon reduction TO reduce carbon emissions, innovative businesses not only consider manufacturing processes, but also the role of back office functions like document management. Many manufacturing business operations are heavily reliant on paper-based processes such as invoices, proof-ofdelivery slips, consignment notes and order forms. Studies show each piece of A4 paper accounts for 8.4 grams of carbon per sheet, therefore if a company is printing 1,000 pieces of paper per day, they are effectively emitting 8.4 kilograms of carbon. A managed print solutions company, such as Upstream Print Solutions, works with manufacturers to build tailored solutions for this purpose. These tailored solutions include: Uforms, which remove the dependency on pre-printed stationary, replacing them with electronic forms stored on the printer and integrated with document management and business software; and Uscan and Uarchive, which facilitates fast and easy document recognition using Optical Character Recognition (OCR) and barcode technology. Upstream Print Solutions 1300 772 772, www.upstream.com.au

M Rutty & Co PTY LTD www.mrutty.com.au

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Compressors& PNEUMATICS made. It is worth consulting with a compressed air energy expert. Choosing to upgrade to a frequency controlled screw compressor will not be the right option in every application. Introducing a control system that monitors and optimises the compressed air system can also assist in reducing energy costs.

Airline system

Leak detection will often form part of a wider compressed air audit such as the Boge AIReport energy efficiency check-up service.

Invest in air to save There are key areas within a compressed air system where investment can, in most cases, pay for itself through sustainable reductions in energy costs, writes Simon Sharwood.

NERGY is the most costly part of running a compressed air system, accounting for 75% of the lifecycle costs of the system. However, compressed air is one technology where most businesses can improve efficiency and in doing so reduce their associated energy costs.

Frequency control Compressed air demand fluctuates depending on shift and production patterns. For some users these fluctuations may be greater in the current economic climate. Producing more air than is required creates unnecessary cost. 32 OCTOBER 2010 Manufacturersâ&#x20AC;&#x2122; Monthly

Where appropriate, investing in a frequency controlled compressor can exactly adapt to demand fluctuations producing the required volume at a constant pressure, thus reducing energy costs. Controlling frequency minimises idling time and evens out air demand fluctuations by working strictly in accordance with the compressed air demand, therefore producing the exact volume of compressed air at the pressure required. A correctly-sized frequency compressor will virtually eliminate off-load running costs and stop starting current peaks. As a result, energy savings can be

It has been estimated that the leak rate on an unmanaged compressed air distribution system can be as much as 40% of the output. And, just one 3mm leaking hole can cost roughly 3kW which equates to some $3,400 per annum (depending on your local kW power cost). Additionally, unmanaged air leaks heighten the maintenance required on the associated equipment as unnecessary compressed air is produced. Significant low cost savings can be made by simply identifying and repairing leaks. It is even possible to identify air leaks while also assessing the efficiency of your compressed air system yourself. At the end of a working day record the pressure on the air receiver before you turn the compressor off, then start your stop watch. By timing how quickly the pressure drops in the receiver, you can determine the rate of air leakage in your compressed air system. If your system is efficient, the pressure will remain the same once the compressor has been switched off and, in an ideal world, it should still be the same when you come to switch on the compressor the next day. However, if the pressure has dropped it is a sure sign that the system is inefficient and that you have air leaks. Of course, the most comprehensive method is leak detection. By using an ultrasonic leak detector, a compressed air professional can detect and locate the air leaks precisely. Leak detection will often form part of a wider compressed air audit. You may also want to assess the airline distribution system. Traditional screwed steel pipe

Controlling frequency minimises idling time and evens out air demand fluctuations by working strictly in accordance with the compressed air demand, therefore producing the exact volume of compressed air at the pressure required. A correctly-sized frequency compressor will virtually eliminate off-load running costs and stop starting current peaks. As a result, energy savings can be made. can develop an average leakage rate of 10 to 15% in old compressed air systems. Opting for modern aluminium piping can improve flow rates reduce pipe diameter and eliminate leakage.

Heat recovery Almost the entire energy consumption from the supply net of a standard compressor is converted into heat. Taking the example of an oil lubricated screw compressor, up to 94% of the input electrical energy is available for heat recovery. Heat recovery provides another energy saving opportunity for many compressed air users. The waste heat generated by the compressor can be re-directed into heating spaces, such as workshops, or for pre-heating domestic water. The associated energy costs can therefore be reduced.

Invest to save Although a number of efficiency remedies can be made at no or low cost (such as repairing air leaks) most of the opportunities will require investment. The good news â&#x20AC;&#x201C; most will be self financing in terms of the energy savings they will create! Where investment into low carbon technologies is recommended a compressed air expert will be able to identify the likely payback period. Simon Wood is Boge national sales manager for Boge. Contact the company on 08 9528 2157 or visit www.boge.net.au manmonthly.com.au

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Compressors &PNEUMATICS

Wolfgang Huber, Geofabrics manufacturing and maintenance engineer (left), and Daniel Castley take a closer look at the Champion solution.

Energy audit slashes pressure A recent energy audit at its manufacturing facility paves the way for Geofabrics to optimise its on-site compressed-air system, Michael Knowles writes.

OR the past 23 years, Geofabrics has manufactured a range of innovative geosynthetic solutions – such as ‘spunbond’ non-woven continuous filament needle-punched geotextiles – from its headquarters in North Albury. The manufacturing process is highly reliant on compressed air – clean and dry compressed air at constant pressure is vital to the success of the fibre-drawing process. In fact, compressed air generation accounts for approximately two thirds of the site’s electricity consumption. Recently, Geofabrics carried out a site energy audit, confirming the company’s suspicions that its manufacturing process had become somewhat energyintensive. As a result, the company executed a plant-wide overhaul of its manufacturing process. Central to the overhaul was the upgrade of the site’s compressed-air system. Here, Geofabrics implemented a customised compressed-air solution 34 OCTOBER 2010 Manufacturers’ Monthly

from Champion Compressors.

Accuracy essential According to Geofabrics operations manager, Rod Press, it is essential that the process air pressure is maintained at 3.2bar. “We can’t use higher pressure air as it causes the geosynthetic fibre to rip. Conversely, if the pressure is too low, the fibre will block the tubes of the manufacturing line,” he says. “We need precise control over the air, to ensure we have access to it at 3.2bar – and lots of it. This is the optimum pressure at which the fibre can be drawn to maintain its structural integrity, while at the same time optimising the production rate.” Prior to the upgrade, a control valve was used to drop the compressed air pressure down from 7bar to 3.2bar. “This was obviously an area of inefficiency in the old production process, but a low-pressure compressor that met all of our criteria had always proved difficult to come by,” says

Geofabrics manufacturing and maintenance engineer, Wolfgang Huber. “We knew there had to be a better way.” Following the energy audit, Geofabrics engaged local automation company Remtron Automation to develop a solution designed to reduce power consumption. Together, the team was able to custom-design a low-pressure compressor with the ability to deliver at 4bar. “Other compressor manufacturers could only offer off-theshelf models incapable of meeting our operational requirements,” says Press.

Low pressure The customised Champion 160kW VOC160 variable output compressor (VOC) is complemented by a suite of Champion's ancillary air-treatment equipment, including a refrigerated air-dryer and a filtering system designed to remove contaminants down to 0.01 microns. After one year in operation,

the low-pressure air compressor has had a dramatic impact on Geofabrics’ bottom line, with the company reducing its power consumption by a staggering 12%. “The compressor has just about paid for itself after only a year,” says Press. “Now, that we only have to drop the pressure from 4bar to 3.2bar, there’s very little wasted compressed air.” Additional savings have been realised through the upgrade and replacement of the facility’s compressed-air reticulation pipe work. “Air leaks have been virtually eliminated,” says Huber. At present, the new low pressure unit handles the majority of the process air production. When additional air is required, one of the legacy 7bar compressors kicks in and provides the required top-up. This small remaining inefficiency is set to be remedied with the imminent delivery of a second low-pressure Champion compressor. However, this new unit will be equipped with variable speed drive (VSD) functionality. With a strong likelihood for further energy savings, the future looks bright for Geofabrics. In fact, once installed, the second low-pressure compressor will provide the company with the capacity to increase production. “We now have a major part of the infrastructure in place to boost throughput should we require,” says Press. With the upgraded compressed-air system already providing tangible economic returns, Press and his team have one less thing to worry about, allowing Geofabrics to get on with the real job at hand – producing innovative geosynthetic solutions. “The compressor-air system upgrade has enabled us to realise a range of operational and environmental benefits,” says Press. “We’re looking forward to further optimising and expanding our production process when the time is right, safe in the knowledge that our energy savings will also continue to increase.” Michael Knowles is Champion Compressors national marketing manager. Contact the company on 03 9703 9014 or www.championcompressors.com.au manmonthly.com.au

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Compressors &PNEUMATICS Hydraulic tube fittings PARKER Hannifin Corporation’s Tube Fittings Division (TFD) has released a range of fittings designed to stop hydraulic systems leaking. According to the company, the fittings provide leak-free capabilities and protect against red dust and corrosion due to their high-quality platings. The fittings are designed to withstand harsh operating environments, particularly those that promote the onset of red rust due to the formation of iron oxide, which signals oxidation and deterioration of the fitting base metal. In a recent salt spray test conducted by an independent test center, Parker TFD fittings remained free of red rust after 480 hours exposure, the company claims. This result is said to exceed both the current SAE requirement of 72 hours, and proposed new SAE requirement of 96 hours. According to Parker, its TFD fittings and fittings from five major competitors were exposed to a neutral salt spray test ASTM B117. All of the competitors’ fittings reportedly exhibited red rust after 240 hours, with the exception of the Parker fittings. It is possible that, in real-world applications, replacement of these competitor fittings would be necessary, the company says. Parker Hannifin 02 9842 5174, www.parker.com

36 OCTOBER 2010 Manufacturers’ Monthly

High-pressure hydraulic hoses ENERPAC’s new hydraulic hoses are engineered to provide ultimate safety in the workplace. The new hoses – featuring a MSHA-rated abrasion- and flame-resistant diffusion sleeve – are suitable for use with all 700bar (10,000 psi), high-pressure hydraulic equipment. They are also fully MDG41 Guideline compliant for fluid power system safety at mines, the company claims. Available in 1.8, 3.0 and 6.1m standard lengths (with other lengths available on request), the new hoses are designed to be teamed with Enerpac’s 700 series high-pressure hydraulic hoses, which reportedly give safety for demanding applications within

The hoses are designed for high-pressure hydraulic equipment.

the manufacturing, construction, civil engineering, metal fabrica-

tion, and mining workshops. Enerpac 02 9743 8988, www.enerpac.com.au

Compact cylinders for automation SMC Pneumatics series C55 compact cylinders are high-performance models conforming to ISO21287 standards. Designed to meet a broad range of automation machine applications, C55 compact cylin-

ders are said to achieve outstanding load performance thanks to their unique rubber bumpers, piston wear rings and rod bushing which are all used throughout the range. The units are available in bore sizes from

20 to 63mm with stroke lengths up to 150mm. Foot, flange and clevis mounts conform to both ISO21287 and 6431 standards. SMC Pneumatics 1800 763 862, www.smcaus.com.au

Compact, customisable pneumatic actuators AIR Springs Supply’s Firestone Airomatic pneumatic actuators stand 16mm high deflated but have a stroke of more than 12.5mm. According to the company, the polyactuators can exert forces of more than 45kN at just 3.5bar, but last for millions of cycles in

demanding industrial environments. The product was originally designed for the conveyor industry, but can be used in almost any actuation application requiring small pressure and stroke. Among the range is the 70-P13, the company’s most compact

pneumatic actuator, with a diameter of 76mm. Fabricated of moulded plastic elements welded together in a sealed unit, it is customisable to meet specific sizes and shapes for a variety of applications. Air Springs Supply 02 9807 4077, www.airspring.com.au

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The new range is designed for pneumatic tools with high torque.

Ring and pin sets PROFESSIONAL tools supplier Kincrome has released a new range of accessories including

ring and pin sets for pneumatic and power tools, along with adaptors, universal joints, exten-

sion bars and clip rails. Designed to be used with pneumatic and power tools where higher torque and force is required, the impact sockets and accessories are manufactured from a high-grade Chrome Molybdenum steel (Cr-Mo), meeting ANSI & DIN standards. The company also distributes a ranfe of impact of sockets and accessories suitable for automotive, mining, industrial, building and construction applications. Kincrome 03 9730 7100, www.kincrome.com.au

Bent-axis hydraulic piston units PARKER Hannifin's new bentaxis hydraulic piston units are designed for open- and closedloop circuits in demanding industrial and offshore applications, including winches, pile drivers and cranes. Available in 150 and 250cc models, the F12 series motors are said to ensure lower loads of internal friction, reducing operating temperature and noise lev-

els, and improving reliability and productivity, according to the company. The units include a spherical piston design that offer high shaft speeds with the capability of operating at pressures of up to 480 bar, while producing high torque at start-up and low speeds. Piston-lock technology and a minimal number of moving parts are also features.

According to Parker, the use of laminated piston rings ensures low internal leakage, high thermal-shock resistance and a long operating life, while robust piston motors provide long service life with high reliability. The F12 Series bent-axis piston units are now available in 23, 30, 40, 60, 80, 90, 110, 125, 150 and 250cc sizes.

Hydraulic expansion toolholders SCHUNK’s TENDO E compact hydraulic expansion toolholders can reportedly transfer torques of up to 900 Nm (at a 20mm clamping diameter) safely and are perfect for volume cutting under dry clamping conditions. Even in case of oily tool shanks, the torques amount to 520 Nm, compared with conventional hydraulic expansion toolholders, Schunk claims. This capability over the company’s previous compact models hike performance by around 60%, the company says. The TENDO E can be used for rough machining, finish machining, drilling and reaming, making it a multi-purpose toolholder. It is also said to provide safe and precise tool clamping when milling with grooves. Schunk Group 03 9753 3588, www.schunk.com.au

Enerpac 02 9743 8988, www.enerpac.com.au

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manmonthly.com.au

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Manufacturers’ Monthly OCTOBER 2010 37

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Fasteners& ADHESIVES Another bonding technology which is rapidly gaining ground – and could have a range of industrial implications in the future – is a material which replicates the adhesion abilities of a gecko lizard.

Developments in adhesive and fastener technologies are tackling demanding environments.

Laws of attraction Lack of understanding of the latest bonding technologies could be jeopardising the quality and efficiency of your manufacturing process. Emily Mobbs writes.

T is hard to imagine a manufacturing application which does not require some sort of fastener or adhesive. The difference between the two may be clear, but industry experts say neglecting the latest bonding developments could mean missing out on a quicker, more cost-effective manufacturing practice. 3M Industrial Adhesives and Tapes product manager, Lauren Saltman, says there is still a perception among some manufacturers that adhesives lack the strength of a mechanical fastener. “This belief is generally held by those who have not used adhesives for their applications before. The only time an adhesive will not perform correctly is if it is not properly matched to 38 OCTOBER 2010 Manufacturers’ Monthly

the application,” Saltman told Manufacturers’ Monthly. She says when deciding on an adhesive, manufacturers should consider ease of application, impact on material choice, environmental factors and the strength and performance of the actual bond. “There are now many different adhesives which have been specifically designed to handle harsh environments such as high heat and UV and humid environments,” Saltman said. 3M has developed a specially formulated range of adhesives that resist harsh environments commonly found in aerospace, deep sea and space applications. Henkel Australia – Loctite division general manager, Eugene Robinson, says adhesives also offer a reduction in a product’s

physical weight. The company has worked closely with aircraft manufacturer Airbus on its A380 where one tonne of mechanical fasteners have been replaced with chemical adhesive solutions. “Making the aircraft one tonne lighter is a significant weight reduction in aviation language, resulting in energy efficiency, a reduction in fuel, and capability to hold more passengers,” Robinson said. In addition, he sees large business opportunities – an estimated double digit growth to be exact – in the wind and solar markets. “There are more people focusing on solar and renewable energy these days which has meant an increase in the manufacturing of windmills and solar power generation panels,” Robinson said. According to Robinson, adhesives are perfectly suited to the bonding applications in solar and blade panels. The joining of panels can be accomplished with high-strength structural bonds such as Methylmethacrylate (MMA) or Polyurethene (PU) technology. Another bonding technology which is rapidly gaining ground – and could have a range of industrial implications in the future – is a material which replicates the adhesion abilities of a gecko lizard. Researchers have taken a strong interest in geckos’ capacity to walk on walls and cling to the ceiling with their toes. This has inspired developments in self-cleaning adhesives and materials which are covered with carbon nanotube hairs just like the thousands of microscopic hairs found on the bottom of a gecko’s foot.

Fastener developments The fastener industry is also in the midst of developing new technologies that meet demanding applications and environments. One such company is Alcoa Fastening Systems, which specialises in creating innovative fastener solutions designed to solve joining problems that cannot be resolved using traditional products. The company’s fasteners and installation tooling are primarily used in the aerospace, automotive and commercial transportation markets. According to an Alcoa Fastening Systems spokesperson, the company is currently testing its BobTail fastener for use in underwater applications such as clamping together oil pipelines. “It’s [underwater] not an easy environment to work in because it is hard to guarantee that you have a good clamp load or joint,” the spokesperson said. “We are in the testing stages right now and hope the technology will be commercialised in 2011.” The BobTail uses a swage design which works on the basis of crushing collar material into the lock in grooves so it cannot move. It does not have a thread or helical path, meaning higher clamp load can be achieved. The company is also working on new applications for its Huck 360, a traditional threaded fastener that has a special profile to protect against vibration. It is currently being used in North America by a wood chipping manufacturing company called MorBark. Huck 360 fasteners are used in the business’ tree shredding machines which are prone to strong vibrations. Alcoa Fastening Systems is currently working on developing the technology for the Australian market. 3M Australia 136 136, www.3M.com Alcoa Fastening Systems Australia 1300 363 049, www.alcoafasteningsystems.com.au Henkel Australia 1300 885 556, www.loctite.com.au manmonthly.com.au

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Always at work.

Innovation – built in. Fifty years ago we invented the ﬁrst liquid threadlocker. We’ve been the leading threadlocker technology ever since. From aircraft to medical equipment, engineers have relied on original Loctite® threadlockers to ensure the reliability of the most critical machinery ever produced. And now, we’ve made them work even harder for you. Introducing Loctite® 243 – it’s upgraded formulation provides even better performance with reliable cure on passive metals, increased oil tolerance and improved high-temperature performance. Loctite® 243, it’s the industry’s best medium strength threadlocker made even better.

Loctite is always at work innovating to improve product performance: both ours and yours. To learn more about how you can take advantage of the advanced research and development that supports Loctite® engineering adhesives, contact your local Loctite® representative on 1300 88 555 6 or visit www.iLoctite.com/innovation

Aust Mining AU light bulb 235x297.indd 1

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Fasteners &ADHESIVES Adhesives vending 3M and Control Vend have partnered to provide vending solutions to manufacturers. The solution involves stor- The vending machine ing and diswill be able to store pensing 3M the company's industrial conadhesive tapes. sumables including adhesive tapes as well as eyewear, hearing and respiratory protection in a Control Vend machine. According to the company, the vending machine will protect products from dust and damage and also assist with safety equipment compliance. The solution aims to control and reduce usage rates while maintaining ready access to the consumables. 3M Australia 136 136, solutions.3m.com.au

Fastener able to suspend 4,000kg ROBOTUNITS has recently showcased its fastening technology at the Automatica Tradeshow in Munich, suspending a 1.8tonne sports-car from a single standard fastener. The company, which has a production facility in Australia, claims its fastening technology is a form fitting, vibration safe and centrally-aligned connection of aluminium extrusions. The technology is said to provide a level of stability that was previously only possible with welding, and can be used for all possible connection between 50x50, 50x100 or 100x100 aluminium profiles. According to Robotunits, the standardisation of all its components allows savings in all stages of the engineering process, starting from the design stage to the onsite installation stage. Tests at different universities have reportedly all confirmed that Robotunits’ connection of 50x50 extrusions exceed break-

The fastening technology has breaking strengths of over 4000kg.

ing strengths of over 4000kg and are also 100% secure to vibration. The tests all used a standard fastener consisting of a connector plate as well as M10 and two M8 bolts. The company says these tests have shown that the connectors are perfectly bal-

anced in design, with these extreme strength capabilities only possible with the patented Robotunits extrusion and connection technology. Robotunits 03 9334 5182, www.robotunits.com.au Comment at manmonthly.com.au

Pneumatic-powered nailers

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

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

APPLIED FASTENER COATINGS • SPECIALISED PRECISION ENGINEERING 40 OCTOBER 2010 Manufacturers’ Monthly

The new Senco Fusion line of tools, from Airco Fasteners, has been designed to drive the DA and C1 series fasteners and also offers pneumatic power with cordless operation. The supplier claims the Senco Fusion technology eliminates the drawbacks normally associated with traditional gas and battery powered nailers including: fuel cell replacement costs; tool weight; and ramp up times. According to Airco Fasteners, the technology operates on the same principle as pneumatic tools but does not require a compressor or hose. An 18 volt lithium ion battery compresses air within a sealed aluminium chamber and releases it when the trigger is pulled. The battery can reportedly reach an 80% charge in 15 minutes and full charge in 45 minutes. Patented Reflex shot technology provides instant trigger

The series combines pneumatic power with cordless operation.

response and delivers up to 500600 drives between charges. The nailer line of tools includes the FN65DA 15-gauge DA Bradder and the FN55AX 18gauge C1 bradder. Airco Fasteners 02 9737 8377, www.aircofasteners.com.au manmonthly.com.au

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WE CAN TAKE THE

HEAT!

For additional information, call FEN_Flame_ad_297x235.indd FEN Flame ad 297x235 indd 1

1300 88 555 6 or visit www.loctite.com.au 8/07/10 3:49 PM

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Fasteners &ADHESIVES Pre-coated fasteners IN manufacturing processes, fasteners are often uncoated prior to use, and coated with a liquid product at point of assembly. According to coatings company Belmatic, uncoated fasteners add costs to the manufacturing process due to the fastener slowing down the assembly line and leaking under high pressure or temperature. The company provides a service to pre-coat fasteners, meaning they are dry to handle, don’t drip, and are free of fumes and mess. Belmatic applies a wide range of microencapsulated coatings to every type of threaded fastener, for various applications in manufacturing assembly processes. Pre-applied thread-locking adhesives, thread lubricants, thread sealants and anti-friction coatings are on offer. Belmatic Industries 03 9459 8097, www.belmatic.com.au

Adhesives versus fasteners HENKEL, the maker of Loctite, has worked with an Australia manufacturer of emergency response vehicles to build a trailer without a structural weld, bolt, screw or rivet, in a bid to demonstrate the time and cost savings of adhesives over traditional fasteners. According to the company’s business development manager, Treneau Joseph, the end result is a tougher, more reliable and better-looking trailer that cost less to build than a conventional model. Fixing the walls of the trailer to the aluminium frame involved a 5.25-hour, three-step process. Holes were drilled into the wall panels before they were riveted into place and a plastic rail was then installed to cover the rivets. The Loctite fast-fixturing structural acrylic that replaced the rivets and plastic rails reportedly shaved 1.25 hours off the emergency vehicle assembly process, and made the trailer more durable, according to

Henkel. Without rivets, the risk of corrosion associated with mechanical fixings has been eliminated and the more even distribution of joint stress has enhanced structural integrity. According to Henkel, the choice of adhesive was an important factor in the success of the trailer. Another emergency vehicle manufacturer was using a high VOC solvent-based cleaner in conjunction with a single part mix bonding technology to bond mild steel sheet metal panels to aluminium framework. The adhesive required substantial clamping for 24 hours and was, according to Henkel, tedious to apply and clean off. Reviewing the production system, Henkel's application engineers recommended Loctite ODC Free Cleaner & Degreaser that is said to rapidly clean substrates in a simple spray-on, wipe-off process. Loctite Structural Adhesive H8600 reportedly fixed the panel in 60 minutes, saving the manufacturer 22 hours.

"Selecting the right adhesive for the job can require some specialist knowledge," said Joseph. "You're not just buying a tube of adhesive or sealant when you choose Loctite, you're getting added value in the form of Henkel's technical clout – whether that's at the design, manufacturing or overhaul stage of the product lifecycle.” The company forms design partnerships with OEMs to streamline production processes and lower manufacturing costs with the use of adhesives and sealants. Trailer manufacturers with existing production lines can make use of Henkel's Application engineers who analyse production processes to identify time and cost savings associated with fasteners, sealants and adhesives. The company also often has training centres on-the-road. Henkel Australia 1300 885 556, www.loctite.com.au

Sidelock

Ground Engaging Tools TM

Sidelock adaptor and tooth systems increase nose strength integrity and operational life of the bucket. Models available for machine sizes from 100 to 550 tonnes, enabling quick and safe tooth changeover. Test-proven benefits of Sidelock G.E.T. system are: TM

Increased digging load capacity Extended operational life Increased nose strength Increased load bearing Increased safety margin

Sherval 10/172

• • • • •

For all the facts and figures call 1300 4 KEECH or visit our website www.keech.com.au Keech Australia 42 OCTOBER 2010 Manufacturers’ Monthly

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Preview

THE SAFETY SHOW SYDNEY/ SYDNEY MATERIALS HANDLING: 26-28 October 2010

Transport workshop

The Safety Show draws manufacturers hungry for safety answers.

Insider's view of workers comp premiums for manufacturers The Safety Show Sydney will host free workshops from 26 to 28 October.

N free workshops at The Safety Show Sydney, WorkCover NSW will present information on safety issues in manufacturing and how they affect premiums. Statistically one of Australia's most dangerous sectors, WorkCover records show manufacturing-related injuries in New South Wales cost $1.5 billion in 2008/09. In separate workshops, manufacturing employers can prepare for new Work Health and Safety laws. WorkCover will explain why the legislation is changing and summarise the new model law and key issues for New South Wales. The authority will also outline what to expect in the lead-up to implementation on 1 January 2012. The free 45-minute workshops will be held daily during The Safety Show and Sydney Materials Handling at the Sydney Showground from manmonthly.com.au

26 to 28 October. The two trade shows will host more than 300 suppliers of occupational health and safety solutions. Together, The Safety Show and Sydney Materials Handling normally attract around 10,000 visitors. The manufacturing sector was well-represented at last year's event, accounting for one in four visitors. The Safety Show Sydney and Sydney Materials Handling will run during Safe Work Australia Week from October 26 to 28 at the Sydney Showground. This safety trade show is one of Australia's leading events for OH&S and features the latest products and services pertaining to the safety manager role. These include: personal protective equipment; health and safety management software; risk management tools; safety signage; security and communication equipment; health and safety consultants; insurance products;

medical and rehabilitation services; first aid; ergonomics and office safety; vehicle safety; and hygiene services. The Safety Show Sydney features all the very latest safety products and services and in 2009 launched the Fire & Security feature; showcasing installation systems, fire and emergency training and fire retardant garments and attracting architects, facility managers, specifiers, security consultants and building managers. Other features include corporate health, building and height safety, training and technology, and electrical safety. Visitors also have the chance to see the latest in safety and materials handling solutions at the Live Demonstration Stage, including case studies and hands-on demonstrations. The Safety Show Sydney and Sydney Materials Handling 03 9654 7773, www.thesafetyshow.com.au www.sydmaterialshandling.com.au

IN free workshops at The Safety Show Sydney, WorkCover NSW will help visitors successfully navigate the biggest safety obstacles in the transport and storage industry. Statistically one of Australia's most dangerous sectors, WorkCover records show that NSW's transport drivers faced a greater risk of death than any other worker. In separate workshops, employers can prepare for new Work Health and Safety laws. WorkCover will explain why the legislation is changing and summarise the new model law and key issues for NSW. The authority will also outline what to expect in the lead up to implementation on 1 January 2012. The free 45-minute workshops will be held daily during The Safety Show and Sydney Materials Handling at the Sydney Showground from October 26 to 28.

Fast-track flooring SEAMLESS flooring that delivers a safe working environment underfoot in a matter of hours will be the main attraction of Flowcrete Australiaâ&#x20AC;&#x2122;s stand F34 at the show. The Flowfast flooring system can be ready to receive traffic just two hours after application enabling manufacturers, operators and commercial organisations to transform their working environment with minimum downtime, according to Flowcrete. Using resin technology, Flowfast is said to provide a joint-free, easily-cleaned finish with inherent anti-bacterial properties. The abrasion, wearand stain-resistance of Flowfast combines with its ability to withstand impact and thermal shocks to provide a highly durable floor finish. Flowcrete Australia 02 4651 1958, www.flowcreteaustralia.com.au

Manufacturersâ&#x20AC;&#x2122; Monthly OCTOBER 2010 43

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Preview Work Health and Safety Act explained LARGE shifts under the new national model Work Health and Safety Act demand immediate action from employers, prominent OHS lawyer Michael Tooma will tell The Safety Conference, which runs concurrently with The Safety Show Sydney. The Norton Rose partner will warn delegates at the Safety Institute's 26 to 28 October conference that company officers will be expected to "do much more and take responsibility for all sorts of things they've never had to before" when the laws are adopted on 1 January 2012. Tooma regards the positive, proactive duty of care on senior officers of companies and other organisations as one of the most signifi-

cant reforms of the model WHS Act. Current laws make officers liable for their companies' conduct rather than being allocated a duty in their own right. Under the new laws, officers must exercise due diligence to ensure corporate compliance. "Achieving due diligence is no simple thing: you have to show you've met a whole set of criteria," Tooma says. To begin with, Tooma says the need to acquire and maintain current knowledge of work health and safety matters mandates regular briefings on developments in safety. Due diligence also requires an understanding of the nature of the operations of the business or undertaking of

Tooma, a partner at the law firm Norton Rose, will be speaking at the conference.

the body. "Long gone are the days of sticking your head in the sand," he says. "You'll be expected to understand the hazards and risks within those operations. Due diligence means ensuring the company has appropriate resources and processes available to work safely. It means ensuring the company

uses those resources and processes and has appropriate processes for receiving and considering information regarding incidents, hazards and risks and responding in a timely way to that information. It also means verifying the implementation of those processes through regular audits and verifying legal compliance. "These are the quintessential features of safety leadership. These are the components of a due diligence system in operation. And from 1 January 2012, this is the law." Michael Tooma, a partner at the law firm Norton Rose, will be among 70 speakers at The Safety Conference presented by the Safety Institute of Australia.

Safety boot protects foot from steel cap THE Bootmate Pressure Protection Sock recently launched in the US and Europe will be the feature of Vasyli Medical’s stand number M3 at The Safety Show and Sydney Materials Handling this year. The Safety Boot Socks protect the foot from damage when the heel is lifted off the floor, bending the boot and allowing the steel cap edge to come into contact with the foot. According to Bootmate, this common and painful consequence of wearing safety boots is alieviated using the Book Socks. The Bootmate Socks incorporate a unique medical grade gel pad with the same flexibility and density as human flesh, so will conform to any foot type or shape without flattening. Bootmate Stand 07 5557 6555, www.bootmate.com.au

44 OCTOBER 2010 Manufacturers’ Monthly

The boot incorporates a gel pad to protect the foot from the steel cap.

Free height safety workshops THE Safety Show and Sydney Materials Handling will bring more than 300 specialist safety suppliers to the Sydney Showground from October 26 to 28. Occupational health and safety solutions from first aid through to forklifts and hoists will be among the thousands on show. One of the most lethal risks on Australian worksites – working at heights – will be addressed during a free workshop at The Safety Show by exhibitor, Workplace Access & Safety. Speaking ahead of the workshop, height safety expert Carl Sachs said NSW employers were likely to face the greatest changes under harmonised regulations. "Safe Work Australia plans to release draft national model height safety laws this year, which are expected to mirror the national code of practice published just last year," he said. "NSW employers need to reconsider their approach to height safety but the good news is that the code is clearer and more practical than the NSW regulations and it's a great guide to compliance in NSW and around Australia. While NSW offers only three levels of control, the national hierarchy specifies five more distinct levels. It's more prescriptive and easier to follow."

manmonthly.com.au

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The new webbing textile is self-cleaning.

Fall protection range CAPITAL Safetyâ&#x20AC;&#x2122;s DBI-SALA fall protection brand has introduced a new webbing fall protection range called REPEL. The REPEL range is constructed from a specially-designed textile that forms a fine shell that is characterised by a high level of water resistance, a natural selfcleaning effect and a durable

protective function. Water or other substances such as oil or dirt simply run off its surface, Capital Safety claims. The range is made up of Delta REPEL full body harnesses, Force2 REPEL shock absorbing lanyards and REPEL pole straps.

IR windows

Management software

IR Windows are set to be the feature of Fluke Australia's stand G33 at The Safety Show when it returns to the Sydney Showground in October. Fluke IR Windows assist to increase: efficiency by cutting down the time needed to conduct regular inspections; safety by avoiding exposure to live equipment; and savings as fewer technicians are needed to conduct inspections. With a Kwik Twist cover that magnetically sticks to the panel when removed, Fluke IR Windows are designed to be easy to use and deliver image clarity through a CLIRVU crystal. Exclusive to Fluke IR Windows, CLIRVU crystal technology is impervious to both moisture and vibration.

SOFTWARE that emails due-date reminders, lets users drag and drop fields to create custom reports and takes just hours to implement will be featured at stand O08 at The Safety Show. The Mango compliance software was launched in Australia earlier this year by Global Strategies Group from New Zealand. The software reportedly takes an active rather than passive approach to compliance. Mango lets you know what's coming up and emails you to warn of missed deadlines. The internetbased system works in real time so managers can check the status of projects instantly. Mango's intuitive interface marks overdue items in red for easy reference and allows users to attach documents to milestones to demonstrate compliance.

Fluke Australia 02 8850 3333, www.fluke.com.au

Global Strategies Group 07 3870 8920, www.globalstrategiesgroup.com.au

manmonthly.com.au

Capital Safety 02 9748 0335, www.capitalsafety.com

Manufacturersâ&#x20AC;&#x2122; Monthly OCTOBER 2010 45

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CuttingTOOLS & CONSUMABLES Advances in metal cutting technology Developments in metal removal allow more productivity and a competitive edge. Hartley Henderson writes.

DVANCES in metal cutting have the potential to bring significant productivity benefits across a diverse range of manufacturing. Electro-chemical machining (ECM), for example, is an exciting new solution for de-burring requirements in machining operations developed by the EMAG Group in Germany. David James, national sales manager with local distributor Chiron Werke Asia Pacific, explains ECM is incorporated into the actual machining process and utilises a gentle electro-chemical metal removal

process that does not involve spark formations. “An electrode is connected to a dc or pulse source to act as a cathode (tool) whilst the workpiece represents the other electrode and is polled as an anode,” he told Manufacturers’ Monthly. “The charge in the electrode gap between cathode and anode flows in a watery electrolyte solution and dissolves metal ions on the work-piece. “Historically, de-burring has been put at the end of the machining process, requiring costly mechanical de-burring. Often, this has also resulted in a

The new coolant nozzle from MTI Qualos has been developed for A-series knurling tools.

secondary burr. “Alternatively, the pinpoint ECM process ensures that deburring occurs only at the point of the work-piece where it is necessary to remove material. “By utilising ECM, intricate components can be de-burred with great accuracy, cycle times can be reduced, and output rates increased.” James also points out that quality control is provided by ECM’s scalable power electronics which enable every individual cathode in a group of workpieces to be monitored separately, ensuring the size of the charge in the solution and the volume of metal removed by each cathode can be monitored.”

Near dry machining Near dry machining (NDM) is a technology that has been utilised in the US and Europe for some time. The process involves replacing flood coolants with the application of minute amounts of high grade vegetable oil lubricant in machining operations. According to Unist Australia’s 46 OCTOBER 2010 Manufacturers’ Monthly

MD, John Barker, local distributor of the technology, NDM can reduce heat generation, increase production speed, improve surface finish, extend tool life, and reduce housekeeping requirements by eliminating the collecting, treating, and disposal of flood coolants. “NDM can be used with ferrous and non-ferrous metals and is suitable for all metal cutting applications including milling, drilling, boring, tapping and sawing,” he said. “By using Coolube 2210, cost savings of up to 77% have been achieved when compared with traditional flood cooling methods. In addition, repeatable cost savings can be gained because this biodegradable and non-toxic fluid is consumed in the cutting operation resulting in no fluid disposal or recycling issues. “Not only does this method of metal cutting promote longer tool life and minimise cutting burrs, it also eliminates air-borne mist particles and related health issues.” manmonthly.com.au

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The unit provides precise movement of aluminium tubular gantry.

Plasma cutting machine The Vicon Elite is a rigid and versatile plasma cutting system with dual precision worm gear drives with digital motors. The unit is said to produce precise movement of the all aluminum tubular gantry. The gantry can accommodate multiple stations such as plasma torches, oxy torches, scribing tools and drill heads. Built-in material stops, clean out doors, and a machine status panel are some of the features the machine provides.

The Vicon Elite comes with a Standard 5’ by 10’ cutting area with options for up to 10’ X 40’ cutting area to accommodate various shop requirements. High-tech, precision dual linear guiding and worm gear drives with digital motors are said to produce precise movement of the machined ‘solid as a rock’ gantry. This results in precise cuts and superior round holes, the company claims.

Unist Australia recently fitted a NDM system to a horizontal band saw that is the workhorse for an engineering company that cuts steel on a daily basis. Barker says difficult solid tool steel up to 400mm diameter has been successfully cut, blade life has extended by 80% compared with the previous flood coolant system, and noise was reduced.

and the compact structure of the nozzle, ensures optimum flexibility of the knurling tools at all times while also preventing any impairment to longitudinal machining. “In addition, to ensure that the microchips contained in the coolant are cleaned from the nozzle, the coolant segment can be quickly released from the base plate and replaced as necessary.” Smith said. The Quick coolant nozzle is provided as standard with all Aseries tools and can also be retrofitted. Two versions of the nozzle are available: one with a slot for FL tools, and the other with three adjustable ball nozzles for KF tools.

Coolant nozzle From MTI Qualos comes an innovative coolant nozzle that has been developed for A-series knurling tools. Company GM, Andrew Smith, says the new Quick nozzle provides an adequate, even and precise flow of cooling lubricant, extends tool life, and is designed to substantially improve the knurl pattern. “Two options for connecting the hose to the coolant system, manmonthly.com.au

Power Machinery 02 9971 1755, www.powermachinery.com.au

Chiron 03 9575 0000, www.chiron.com.au MTI Qualos 03 9450 1900, www.mtiqualos.com.au Unist Australia 02 8850 2022, www.unist.com.au Manufacturers’ Monthly OCTOBER 2010 47

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Welding&PROFILE CUTTING

The ‘training workshop’ comes in the form of either a terminal or a mobile case.

Virtual welding saves risk Training welding apprentices can be both dangerous and costly on materials, which is why one company has developed a new virtual welding simulation system.

RONIUS has developed a new virtual welding machine designed to train apprentices; the virtual welder training tool system incorporates

48 OCTOBER 2010 Manufacturers’ Monthly

a helmet, torch and work piece which runs in conjunction with a PC and a screen. According to Fronius, virtual welding cuts down drastically on

the material-intensive sessions needed when training welders on ‘real’ welding equipment, resulting in considerable savings in time, space, materials, gas, filler

material and energy. Further, the virtual nature of the project is designed to be attractive to students brought up in the digital age. ‘Virtual welding’ is designed to create a safe environment for trainees to hone their abilities in the fundamental welding skills of hand movements and the ability to tune in to the sound made by the process. A magnetic tracking system detects even the slightest hand movements and transmits these to the virtual world, represented on a touchscreen or 3D glasses. A magnetic transducer underneath the work piece generates a spherical magnetic field and a sensor detects the position of the welding torch. The digitised signal containing the position data forms the input for the visualisation software, which evaluates the positions of the torch and work piece. An additional sensor on the welding helmet provides a ‘real’ view of the welding task, be it close up, from a distance or from different angles. The effect of gravity on the viscous weld metal and its solidification can be seen in detail as the position of the torch relative to the work piece changes. The typical weld seam characteristics resulting from the influence of different welding parameters are reproduced. In addition to the

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visual stimuli, the welder hears the typical welding noises accurately and in real time, Fronius says. As the trainees guide their torches along the sample work pieces, they mentally process the visual and audible analogue signals to determine whether the welding speed, torch distance and angle are all correct. They respond with the hand and ‘store’ what they've learned in their brain's motor function memory. The didactic virtual welding concept consists of training sessions and simulation sessions. In the training sessions, trainees first practice speed control by guiding the torch until they have accumulated the required number of points. Next, the trainees also practice achieving the optimum distance and the correct angle between torch and work piece. Virtual welding simulates different process conditions with instructive examples, which

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include setting the parameters. Progress in terms of the confident and safe handling of the torch is individually documented and evaluated. The ‘training workshop’ comes in the form of either a terminal (e.g. for colleges and training centres), or a mobile case that be can be taken to the training location. A structured database, similar to a server, can be used by the instructor to create, save and recall application-specific or trainee-specific teaching environments. As a result, creative teaching sessions pitched at the appropriate level can be put together to teach the skills needed at the various stages of the learning process. The work surface height is fully adjustable to accommodate all shapes and sizes. The trainer uses a scoring system to provide an objective assessment of the skills on display. Dave Smith is manager of Smenco. Contact 03 9466 4060 or www.smenco.com.au

Weld joint seam tracking Automation technology provider ABB’s new WeldGuide III is an adaptive sensing system that performs weld joint seam tracking during the robot arc welding process. The system identifies variations in the weld joints and corrects the robotic torch path while in motion. Using voltage and current sensors, the system takes real-time measurements through the welding arc to make any adjustments necessary to keep the robotic welding torch on the joint path, regardless of the path programming, ABB claims. WeldGuide III is a combination of hardware and software designed for ABB’s IRC5 robot controller, however it is half the price of ABB’s advance weld controller system and is said to be easier to use. ABB says WeldGuide III requires less initial programming

The system performs the weld joint seam tracking during robot arc welding.

than traditional robotic seam tracking systems and is ideal for applications on heavy weldments. The system is suitable for: heavy deposition welds where a 1 to 2mm weave pattern must be used to fill the gap between the parts; applications where the welding seam location moves from part to part, or during welding; and parts where multiple passes are required to complete the weld. ABB Australia www.abbaustralia.com.au, 08 9412 1095

Gas Stream Torches Mig welding just took a giant leap forward! New Patented gas-streaming technology speciﬁcally developed for high quality MIG welding. HannaMig® have just launched their new Mig Torch T-Series which includes the patent HannaMig® Gas Lens Diffuser and Flexeneck™. Say good-bye to weld imperfections, porosity, and gas pours; the HannaMig® Gas Diffuser and HannaMig® T-Series Mig Torch range has the answers! The patented design of the HannaMig® Gas Lens ensures an uncontaminated gas ﬂow from the torch, especially important when welding stainless steel heat exchangers & process equipment, where oxygen contamination from the atmosphere is to be eliminated.

www.hannamig.com.au manmonthly.com.au

Manufacturers’ Monthly OCTOBER 2010 49

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Welding & PROFILE CUTTING The product is available in a range of sizes and configurations.

Heavy-duty roller beds THE new ESAB CD and CI roller beds are designed to simplify the handling of pressure vessels, pipes and wind towers during fabrication work like welding. The range is suitable for difficult work environments and is grit-blasted and coated with abrasion-resistant polyurethane. The roller beds feature oversized bearings, a double worm gear arrangement for smooth rotations and are housed in a

cast steel gearbox. Using solid state inverter technology, speed control is said to be extremely precise, allowing for the most particular fabricating requirements. The product is available in a range of sizes and configurations to cater for differing uses including variants with motorised and idler rail bogies. ESAB Australasia 03 9383 7652, www.esabasia.com.

Lathe offers highquality batches

ESAB Falcon Fully Integrated power supply, software and hardware. The ESAB Falcon is a remarkably versatile cutting machine for plate processing that can meet the needs of your current production with the option of upgrading in the future if your cutting demands change. The ESAB Falcon can be used for Oxy-fuel, Plasma or combined Oxy-fuel and Plasma cutting. Extensive control functions, interfaces and an integrated cutting database with 65 fixed programs deliver a high degree of cut quality.

Two tool carriages, Oxy-fuel and Plasma for wider variety of cutting options.

Low level outboard rail allows for easy loading and unloading of the table with forklifts.

Backlash free cutting accuracy.

Solid reinforced main beam.

IN STOC K

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Options for

• Cutting tables • Fume extraction

This versatile heavy-duty water-cooled plasma cutting and gouging system is ideal for mechanized applications.

Precise setting of the cutting torch height is achieved automatically ensuring optimum cutting quality at all times.

Each tool carriage is provided with a reliable automatic ignition device.

Ask for a “No obligation demonstration” at the Westgate Hi-Tech Machinery ESAB Centre of Excellence.

Tel: (03) 9391 1133 Fax: (03) 9391 1244 sales@westgatehitech.com.au www.westgatehitech.com.au 5 Sutton Street, Sth. Kingsville, 3015, Victoria ABN 37 395 752 411

50 OCTOBER 2010 Manufacturers’ Monthly

Monfort Engineering is reportedly offering its customers more accuracy and repeatability after purchasing a Colchester-Harrison Alpha XT 1460 lathe from 600 Machine Tools. Seeking a brand-new automatic lathe for the company’s workshops, Monfort Engineering managing director, Mike Kumar, chose an Alpha XT 1460 with indexing turret. “We have four manual lathes, mainly engaged on producing individual components of high quality. However, our accuracy and fast turnaround in the jobbing market is attracting batchwork from local and inter-state customers,” Kumar said. “It is our most expensive machine to date, but it is an investment in the company’s future. In addition to producing prototypes and one-off components in the general jobbing market, the Alpha will enable Monfort to offer accuracy and repeatability to such major industries as mining and processing,” said Kumar. Managing director of 600 Machine Tools, Cliff Purser, said the Alpha 1460XT boasts a 11 kW main spindle motor, a swing-over bed of 460mm, swing-in gap of 730mm, and a 1500mm distance between centres. “It offers a line-up of optional equipment, including a choice between a manual Parat 40-position hand indexing 4-station tool-post with quick-change tool-holder facility, or an automatic bi-directional, multistation VDI 30 turret mounted on the front of the cross slide,” he said. 600 Machine Tools 02 9674 4738, www.600machinery.com.au

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BUILT TO PERFORM WELDMATIC 270 BIG ON POWER. BIG ON PERFORMANCE. With the highest output in its class, a feature packed wirefeeder and reliability that is second to none, the Weldmatic 270 has been designed to deliver professional results every time. This is one investment that wonâ&#x20AC;&#x2122;t let you down.

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lence l e c x e uring t c a f u n r ma o f m a r prog s d r a w nal a o i t a n r remie p s ’ a i l Austra

The 2011 Endeavour Awards is the pinnacle event where the best of Australia’s manufacturing industry get the recognition they deserve! All ﬁnalists will receive free publicity in Manufacturers’ Monthly and two free tickets to the gala dinner on 26 May 2011 in Melbourne where the winners will be announced.

Award Categories Technology Application of the Year Environmental Solution of the Year Safety Scheme of the Year Consumer/Trade Product of the Year

Industrial Product of the Year Australian Steel Innovation Award Global Integration Award Exporter of the Year

Young Manufacturer of the Year Lifetime Achievement Award Manufacturer of the Year

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