Manufacturers Monthly Mar 2022

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MARCH 2022

Page 2. Discover 10 easy steps towards energy efficiency for your compressed air needs 0322 Atlas Copco Front Cover Man Monthly.indd 1

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1. Application 10. System Monitoring

2. Storage & Distribution

9. System Maintenance

3. Air Quality

8. Energy Recovery

4. Air Volume

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7. System Control

5. Core Technology 6. Equipment Control

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Air audits utilise data loggers to measure current (amps) and are are designed to provide a snapshot of the compressed air utilisation within a given system.

Results of such audits can provide a good understanding of the actual compressed air usage over a period of time, identify peaks and valleys in the air demand and help identify ways to improve the overall efficiency of the system.

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Manufacturers’ Monthly Contents 6 Editor’s Note

32 Software Management

42 Drive Systems

8 Comment

34 Manufacturing Excellence

43 Industrial Equipment

10 News@MM

36 Welding

46 What’s New

18 Manufacturer Focus

38 Events

47 The Last Word

22 Industry Focus

40 Materials Handling

26 Compressors

41 Servo Drives

Manufacturers’ Monthly is owned by Prime Creative Media and published by John Murphy. All material in Manufacturers’ Monthly is copyright and no part may be reproduced or copied in any form or by any means (graphic, electronic or mechanical including information and retrieval systems) without written permission of the publisher. The Editor welcomes contributions but reserves the right to accept or reject any material. While every effort has been made to ensure the accuracy of information, Prime Creative Media will not accept responsibility for errors or omissions or for any consequences arising from reliance on information published.

The opinions expressed in Manufacturers’ Monthly are not necessarily the opinions of, or endorsed by the publisher unless otherwise stated. © Copyright Prime Creative Media, 2021 Articles All articles submitted for publication become the property of the publisher. The Editor reserves the right to adjust any article to conform with the magazine format.

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During the COVID-19 pandemic, it has become clear how much Australia has relied on foreign imports, exposing the need for innovation and local production.

For the past two years local manufacturers have found ways through this challenging period pivoting and manufacturing, producing products that have served to combat COVID-19 directly, or helped alleviate the effects of the pandemic in other ways. In this

edition, we continue to feature local manufacturers who have come through this tough period and are continuing to thrive moving forward.

For one, we look into the amplified demand for implementing advanced robotics within the manufacturing process in many businesses, and how the robotic concrete moulding technique is removing all the labour and waste material associated with the traditional manual forming process.

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The cyber-physical in 2022

D

O you remember the Tesla Cybertruck? Reliabilitywise, everyone had their doubts, let alone the 80s comic book look which did leave a lot to be desired. Whether it was the unusually geometric design, or the failed testing of its “bulletproof” windows (video demonstration available on YouTube), there was definitely room for improvement in the vehicle’s presentation.

Still, despite having many detractors, there were some who came out and described Musk’s ute as “revolutionary”, and now, while it is still not the most popular vehicle in the market, like all great leaps forward in engineering, it did have its merits.

The finished product was a step into the future where software and hardware had been integrated in the process of manufacturing. For those who own Teslas, you would know

6 MARCH 2022 Manufacturers’ Monthly

that onboard software upgrades are delivered over-the-air. This means not only do you get your Stan or HBO to the onboard dashboard, but back in 2019, when there were wildfires in California, US, Tesla was able to unlock extra range through the software to guide drivers home safely.

Such a function is a two-way street for both the manufacturer and the user to get more out of the product.

Australian manufacturers have begun to use a lot more IoT-related products and services, and this has encouraged more quality providers to come to the market. In this issue, there are a few stories that feature developments in advanced manufacturing. These days, it is not only about making products last longer, but how manufacturers in different verticals are grappling with the challenges faced within their individual sectors.

Whether this is in the form of

skill shortages affecting the welding profession, which Lorch’s David Wilton speaks to us about how cobot welding helps alleviate such issues by taking away the stress of repetitive tasks, or the question of the realignment of advanced tasks for welders, who can then be more productive to the business. In this question and answer segment, we explore on how software and automation is becoming inseparable from hardware, but yet still dependable on “heartware”.

Also, this issue, we speak to Central Innovation who sources, builds and advises on world-class design process solutions to the manufacturing, architecture, engineering and construction industries. Managing director, Mike Russell explained that for a long time, there have been many Australian companies that have operated without a proper integrated

system but ever since the pandemic, he has seen the trend change with businesses starting to adopt these systems into their workflow and products.

And this is only natural because manufacturers have had to differentiate their products for the markets in which they serve.

Previously, the prospect of navigating the adoption of Industry 4.0 technologies such as cloud computing and cyber-physical systems might have been a complex and expensive journey for some, but not anymore.

With manufacturing now taking centre stage alongside other national priorities, it will be interesting to see the added investment into the area in the upcoming federal budget. Expect some cheers and groans but on the whole, as long as there is ample support given to move this industry forward, more than some would be relieved. manmonthly.com.au

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Comment

GEOFF CRITTENDEN – CEO, Weld Australia

Australia’s severe shortage of skilled people requires industry-led solutions supported by government

T

HIS time last year, when anyone asked me for an annual outlook, all I was prepared to say was that market conditions in 2021 would be uncertain. I was right. 2021 was just as unpredictable as 2020, with further lockdowns and border restrictions.

Unfortunately, I suspect that 2022 will be equally as uncertain—albeit for different reasons. The dominating issue may not be COVID-19. Instead, industry could be staring down the barrel of a severe shortage of skilled people.

A severe shortage of skilled people Prior to the outbreak of COVID-19, Australian industry was already facing a looming workforce crisis, including a severe shortage of skilled, qualified welders. According to feedback from Weld Australia’s members, the COVID-19 pandemic has only exacerbated this shortage.

The industry is facing a shortage of labour, from Welding Supervisors and Inspectors, right through to welders. Finding competent, skilled, experienced welders is becoming more and more difficult.

Welders are more in demand than

Australian industry has had a workforce crisis for quite a while, including a severe shortage of skilled, qualified welders.

8 MARCH 2022 Manufacturers’ Monthly

ever with several large-scale, highvalue projects on the horizon, from the Federal Government’s $90 billion Naval Shipbuilding Program, through to major infrastructure projects such as the $12 billion Sydney Metro project, and the $5 billion Melbourne Airport Rail Link.

And yet, the number of welding trade workers in Australia dropped by eight per cent in the course of just five years; from 75,800 in 2014 to 69,600 in 2019. In addition, completion rates of welding apprenticeships, including a Certificate III in Engineering (Fabrication Trade), continue to fall by as much as 23 per cent annually.

Australia is also home to a rapidly aging welding workforce, with approximately 30 per cent of Australia’s existing welding workforce aged over 45 years. This heavy proportion of older skilled trade workers, particularly welders, puts into focus the looming issues that sectors such as defence are likely to face when baby boomers finally reach retirement age. Welding positions will simply become impossible to fill, particularly given the projected increased demand with several large-scale, high-value projects on the horizon.

This shortage of welders has been

fuelled by a lack of short-term workers and immigrants, with our international borders closed due to COVID-19. Weld Australia members have reported that there simply isn’t the same labour pool available to complete work.

Industry training Initiatives Australian industry is not taking this skills shortage lying down. Industry is quickly coming to realise that they cannot continue to rely on Government to solve the problem. There must be a ‘pull’ strategy that engages students through close collaboration between schools and companies.

Weld Australia member, JRS Manufacturing is a strong advocate for this type of ‘pull’ strategy. Based in Toowoomba, JRS Manufacturing has recently established their own skills academy. The skills academy is not only training people to work in their own business, but also other businesses in Toowoomba. Weld Australia is set to work with JRS to help ensure the long-term success of this exceptional initiative, which will be launched later this year.

Similarly, another Weld Australia member, Precision Metal Group (PMG) began partnering with Parramatta Marist High School to develop a

metals and welding training program in 2020. The shared vision is to have more and more students exposed to the industry and certified as armoured vehicle welders before they graduate from Parramatta Marist, providing them with pathways supported by a skill set in demand by the Australian Defence Force. To begin, Year 10 iSTEM students rotate through fortnightly two-hour welding core skills workshops, while self-nominated students undertake intensive welding training at PMG’s facility in Wetherill Park.

Australian welding and fabrication businesses need to invest in the future of their own workforces and play an active role in the training of welders.

Australia will need an additional 28,000 welders by 2030 based on the existing pipeline of work. Industry has a vital part to play in filling these roles.

Innovative technological solutions Australian industry is also developing and investing in cutting-edge technology to help ameliorate looming skills shortages. Automation, robotics, and collaborative robots (also known as cobots) are changing the way the welding and manufacturing industries work.

According to a recent report by commissioned by Google, automation has the power to deliver a $2.2 trillion boost to Australia’s national income by 2030 from productivity gains.

This includes $1 trillion boost from accelerating the rate of automation and a $1.2 trillion boost from transitioning Australia’s workforce to higher skilled occupations.

Weld Australia members have demonstrated extraordinary innovation and invested in leadingedge technology in order to maintain production schedules and grow their businesses throughout what has been an incredibly difficult time over the last two years. It is this ability to innovative that has continued to manmonthly.com.au

ensure that Australian manufacturers are resilient, profitable and readily able to compete on the world stage.

Many of our local SMEs are at the cutting edge of research and development. For instance, the Artificial Intelligence (AI) and Industry 4.0 methodologies and technologies developed by Queensland-based Weld Australia member, IR4, are setting global benchmarks in efficiency. It is for this reason that IR4 (in partnership with Weld Australia and QUT) is engaging with global prime contractors to improve their welding cobot capabilities for major projects.

One industry program that is working to accelerate the pace of the adoption of cobots in Australian industry is the ARC Training Centre for Collaborative Robotics in Advanced Manufacturing. The Centre was established under the ARC Linkage Program – Industrial Transformation Training Centres.

Its aim is to unite manufacturing businesses and universities to develop

collaborative robotics applications.

Queensland University of Technology (QUT) is acting as the Administering Organisation and Weld Australia is a Centre Partner. Just some of the other Industry Partners involved include InfraBuild, IR4 and LA Services.

Government support – or lack thereof Clearly, Australian welding and manufacturing businesses are investing in the future of their own workforces and playing an active role in the training of welders. In tandem, local industry is leveraging the raft of benefits offered by advanced technology like cobots. Increasingly, advanced technology is becoming a critical factor in the success of globally competitive welders, fabricators, and manufacturers.

However, local industry needs the support of Federal and State Governments, as well as private industry. According to recent industry analysis, pre-fabricated imports continue to increase. As of

30 September 2021 (at the existing run rate), fabricated imports were expected to reach 950,000 tonnes for 2021, an increase of 15 per cent from the previous year.

This same industry analysis confirmed that China continues to be the significant import country for fabricated steel commodities. This is despite the fact that China has bans and significant import taxes on a whole raft of Australian products, from coal through to wine and seafood.

One does not have to look too hard to find examples of imported fabricated steel. The Cross River Rail Project in Brisbane called for two shoring tower systems, each of which consisted of 139t of steel. One of the towers was sourced locally, the other offshored. Similarly, the construction of the new 42,000 sqm Woolworths Distribution Centre in southeast Queensland relied upon 1,200t of imported steel.

These kind of short-sighted procurement decisions are making local market conditions impossible

for local fabricators. We need a commitment from Federal and State Governments to increase levels of local content for all procurement decisions.

We need the big corporates to award local contracts to local companies.

The strength of the sovereign capability of Australia depends on Australians investing in Australia. It might be cheaper in the short-term to buy from places like China, but all this does is weaken our economy.

If we do this, local companies will then be in a position to invest even more into their own businesses, and to strengthen our manufacturing industry from within. Business innovation encourages the creation of strong and lasting new businesses and the creation of new and better jobs, which together support a move to higher living standards. Innovation investment by business is crucial to our ongoing prosperity. But this can only be fully realised with the onshoring of fabrication work by federal and state governments, as well as big corporates.

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News @MM Commercialising 24 world-leading, Australian-made products

10 MARCH 2022 Manufacturers’ Monthly

Vaxxas’ clinical trials hope to deliver a COVID-19 vaccine with needle-free patches from mid-2022.

Image credit: AMGC.

The latest round of co-invested projects announced via the Advanced Manufacturing Growth Centre (AMGC) managed Commercialisation Fund will see Australia’s manufacturing industry contribute over $32.4 million, alongside the federal government’s $9.03 million to drive commercialisation of world-leading Australian-made products.

With $29 million of the $30 million Commercialisation Fund allocated to 55 projects just 10 months after the launch of the program, AMGC has revealed the spread of projects across the six National Manufacturing Priorities, with: • 34 per cent of projects spanning the NMP of Recycling and Clean Energy; • 23 per cent of projects spanning the NMP of Medical Products; • 18 per cent of projects spanning the NMP of Food and Beverage; and • 11 per cent of projects spanning the NMP of Resource Technology and Critical Mineral Processing.

The remaining 14 per cent is split equitably between the NMPs of Space and Defence. All 24 coinvested projects from tranches six, seven and eight are expected to create a substantial number of local jobs while driving additional revenues and export opportunities for the locally manufactured products.

“This latest tranche of coinvestment demonstrates the broad capability of Australian manufacturing and its ability to drive jobs growth across the entire spectrum of manufacturing roles, known as the Smiley Curve – that is jobs in R&D, Design through to production, distribution, and highlysought after sales and services positions,” AMGC managing director Dr Jens Goennemann said.

“The demand for targeted, well-managed, and appropriately sized co-investment has seen the Commercialisation Fund near

exhaustion after just ten months.

This demonstrates the appetite for co-capital investment and the manufacturing industry’s willingness to match or better federal investment to commercialise Australian ideas for domestic and international markets.”

The successful 24 co-invested manufacturing projects by National Manufacturing Priority include:

Recycling and clean energy: • Allthread Industries (NSW) – Recycling and Clean Energy – Develop and automate a new thermal arc spray line to manufacture corrosionresistant structural fasteners, which offer superior value and environmental performance when compared to imported hotdipped galvanised fasteners. Total project commitment $8.86 million

($367,860 from Commercialisation Fund) • Plantabl (VIC) – Recycling and Clean Energy – Commercialisation and manufacture of Great Wrap’s biopolymer resin (cling wrap) derived from organic waste, to produce a compostable stretch wrap that can replace plastic cling, silage, and pallet wraps.

Total project commitment $6.41 million ($534,760 from Commercialisation Fund) • 3RT (VIC) – Recycling and Clean Energy – Development of large-scale manufacturing capability for 3RT’s innovative and patented technology which converts low-value wood residue into a new hardwood with the same properties as 100-year-old timber. Total project commitment $3,326,840 ($698,420 from Commercialisation Fund)

• Sustinet (NSW) – Recycling and Clean Energy – Commercialisation of a scalable process utilising sugarcane waste to make value-add products such as mushroom grow bags. Once implemented, the Sustinent process will also be able to address problematic waste from cotton, rice, or wheat crops. Total project commitment $2.94 million ($499,500 from Commercialisation Fund) • Endua (QLD) – Recycling and Clean Energy – Development of onshore manufacturing capability for affordable hydrogen power banks that will deliver 100% renewable energy, on demand, as electricity. Total project commitment $2.94 million ($499,500 from Commercialisation Fund) • Solar Analytics (NSW) – Recycling manmonthly.com.au

News @MM

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•

•

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and Clean Energy – Manufacturer of SolarConnect product to manage energy generation and consumption from rooftop solar, inverters and batteries to achieve maximum benefit from rooftop solar systems. Total project commitment $1.44 million ($500,000 from Commercialisation Fund) Venlo (QLD) – Recycling and Clean Energy – Manufacture of a100 per cent recycled, repairable pallet, managed within a circular & closed-loop automated repair and remanufacturing system that is tracked/traced and serviced within a global network driving critical continual improvement in safety, security, providence and cost reduction outcomes. Total project commitment $710,900 ($450,000 from Commercialisation Fund) Geofabrics (NSW) – Recycling and Clean Energy – Integration of recycled materials into Geofabrics’ new and improved drainage products for infrastructure sector via a purpose-built manufacturing process to meet market demand for circular recycling solutions.

Total project commitment $607,000 ($252,000 from Commercialisation Fund) TomKat Global (QLD) – Recycling and Clean Energy – Manufacture of a new thermal container for the transportation of temperature sensitive and perishable produce.

The KoolPak has superior thermal performance to a polystyrene container, it is multi-use, fully traceable and recyclable. Total project commitment $555,000 ($267,500 from Commercialisation Fund) YOUC (VIC) – Recycling and Clean Energy – Commercialisation of a new ‘Smart Box’ system which will enable the tracking and tracing of boxes through the manufacturing process allowing for real-time restocking, reordering and waste reduction. Total project commitment $710,900 ($297,500 from Commercialisation Fund)

manmonthly.com.au

Medical products: • Ceramisphere (NSW) – Medical Products – Development of a manufacturing capability of transdermal (skin) drug delivery system using its unique nanocomposite patch technology for pain relief.

Total project commitment $2.17 million ($471,000 from Commercialisation Fund) • Elenium (VIC) – Medical Products – Develop a biometric device that can be deployed into a range of environments to automate biometric identification for access control, ticketing, contact tracing (requiring government integration), vaccination and antigen test status, and the capability to perform contactless fever detection once approved.

Total project commitment $1.35 million ($553,364 from Commercialisation Fund) • Examin (QLD) – Medical Products – Commercialisation of a 2-minute COVID-19 breath test using a novel electrochemical biosensor that detects viral load at a molecular level with a sensitivity and specificity of 97-98 per cent.

Total project commitment $1.3 million ($647,665 from Commercialisation Fund) • Vaxxas (QLD) – Medical Products – Scaling and automation of manufacturing capability to produce a novel, needle-free vaccination platform. The High-Density Micro-projection Array Patch (HD-MAP) aims to improve the efficacy, reach, safety and economics of vaccination.

Total project commitment $1.59 million ($600,000 from Commercialisation Fund) • Minomic Int (NSW) – Medical Products – Commercialisation of the MiCheck® Prostate test that is designed to detect life threatening aggressive prostate cancer in its early stages. MiCheck® Prostate overcomes the low accuracy of conventional screening tests to reduce unnecessary intervention

such as painful biopsies and improve overall management of the patient. Total project commitment $793,856 ($396,928 from Commercialisation Fund) • Reid Print Technologies (QLD) – Medical Products – Field trials and commercial certification of a novel ‘Smart Shoe Insole’ (Smart Orthotics Sensor Skin), used to monitor the onset of foot ulcers that commonly afflict diabetes sufferers. Total project commitment $690,000 ($300,000 from Commercialisation Fund)

Food and beverage: • TPS (QLD) – Food and Beverage – Commercialisation of advanced digital sensors for testing of water quality parameters in the food and beverage sector. Total project commitment $1.31 million ($444,875 from Commercialisation Fund) • ICEE (VIC) – Food and Beverage – Commercialisation of Bouncee, a reusable and collapsible insulated crate and coolant system for short transit perishable logistics, such as click and collect, and home delivery.

Total project commitment $1.31 million ($444,875 from Commercialisation Fund)

Defence: • Premcar (VIC) – Defence – Development of a manufacturing program to support the installation of a new, latesttechnology, powertrain into land-based defence vehicles for local and export applications.

Total project commitment $1.53 million ($699,931 from Commercialisation Fund) • Microbio (QLD) – Defence – Establish sovereign manufacturing of Microbio’s unique InfectID PCR testing technology that provides rapid, highly sensitive bacterial, fungal, and viral pathogen identification in clinical samples for defence and civilian use.

Total project commitment $1.11 million ($407,119 from Commercialisation Fund)

Resource technology and critical mineral processing: • EQ Resources (VIC) – Resource Technology and Critical Mineral Processing – Commercialisation and scaling of EQ Resources’ large-scale x-ray (XRT) and hyperspectral imaging (HIS) sensors for front-end loaders enabling the sorting of tungsten from historic mine waste stockpiles.

Total project commitment $2.17 million ($471,000 from Commercialisation Fund) • Technofast (QLD) – Resource Technology and Critical Mineral Processing – Commercialisation of Technofast’s Hydraulic Head Nut, which replaces original retaining nuts used to fasten the conical “mantle” in massive gyratory ore crushers.

Because crushers are subject to rapid wear and need regular replacement, the new fasteners allow for rapid replacement and maintenance, thereby reducing machine downtime and increasing operational safety for workers. Total project commitment $518,970 ($259,485 from Commercialisation Fund)

Space: • Spiral Blue (NSW) – Space – Commercialisation of Rainbow Python: a world-first integrated hyperspectral instrument and onboard computer that allows for the chemical analysis of any location on earth from space for use in agriculture, forestry, mining, and other sectors.

Total project commitment $2.97 million ($578,000 from Commercialisation Fund) • Black Sky Aero (QLD) – Space – Establish sovereign manufacture of vital precursor materials for solid rocket propellant not currently produced in Australia. This will lead to significant domestic and export market opportunities. Total project commitment $1.1 million ($497,750 from Commercialisation Fund) Manufacturers’ Monthly MARCH 2022 11

News @MM Twenty-two Australian entrepreneurs are supported to commercialise

The federal government is providing $12.2 million in funding for 22 Australian companies to commercialise their ideas.

As part of the latest Accelerating Commercialisation grants, 22 projects will share in $12.2 million in funding under the federal government’s Entrepreneurs’ Programme.

This will support Australian companies to commercialise their innovations and technologies, such as these medical start-ups with the potential to improve and save lives through their projects: • SDIP Innovations will use its $1,000,000 grant to commercialise a first-of-its-kind bone implant technology, enabling surgeons to treat complex and unpredictable bone defects using bone fillers to precisely address patient-specific needs • ResusRight will receive $419,799 grant to commercialise its ‘Juno’ clinical training and monitoring system and help train clinicians in newborn resuscitation • DetectED-X will further develop 12 MARCH 2022 Manufacturers’ Monthly

and pilot ImagED, which uses AI to help train clinicians and radiographers to better diagnose diseases such as breast cancer through its grant of $530,195 The grants will also help homegrown companies gain further investments to enter new domestic and international markets, minister for Industry, Energy and Emissions Reduction Angus Taylor said.

“We are proud to support Australian companies take their innovative technologies and products to the next level through the commercialisation process,” Taylor said.

“These latest projects are all great examples of Australian innovations – many across high-skilled manufacturing priorities – which have remarkable potential to improve the quality of our lives, create new jobs and support our economic recovery.”

Some of the other successful projects include: • Southern Ocean SubSea Pty Ltd (VIC) with a grant of $988,400 to develop a remotely operated vehicle capable of repairing aquaculture nets, which could significantly reduce costs and risks for the industry • Endua Pty Ltd (QLD) with a grant of $998,269 to commercialise its clean energy storage solutions for the off-grid diesel generation market, enabling customers to reliably generate electricity on demand without needing diesel generators • Anderson Horticulture Pty Ltd (NSW) with a grant of $403,558 to develop its micropropagation technology to cultivate more productive and efficient avocado farming practices and contribute to a more profitable and successful global avocado industry

• BIOCARBON (NSW) with a grant of $293,840 to commercialise its innovative technology to support green steel and help steelmakers to decrease their carbon footprint • Tribe Technology (WA) with a grant of $864,040 to commercialise its world-first automated Reverse Circulation drilling sampling system, to improve safety in the global mining industry The Accelerating Commercialisation Grant is part of the federal government’s Entrepreneurs’ Programme, which has provided 573 grants worth over $281 million to Australian businesses since it was established in 2014.

More information on the grant recipients, how to join the Entrepreneurs’ Programme and apply for an Accelerating Commercialisation grant is available to be look up on at the website at business.gov.au. manmonthly.com.au

News @MM Local AdBlue production ramps up to keep Australia moving Fertiliser manufacturer, Incitec Pivot, has ramped up its production of AdBlue by around 800 per cent as the federal government continues to work closely with industry to bolster diesel exhaust fluid (DEF) supplies for Australia’s transport sector.

Last week, Incitec Pivot produced over 3 million litres of AdBlue, representing around 75 per cent of Australia’s AdBlue needs. This locally produced AdBlue is already flowing through the domestic supply chain to wholesalers and service stations across the country.

Incitec Pivot has also commissioned a dedicated AdBlue distribution facility in Brisbane, which has the capacity to load the equivalent of three B Double trucks per hour.

The 24/7 operations will allow more AdBlue to get to market efficiently and help boost consumer confidence.

Temporarily securing Australia’s local capabilities through Incitec Pivot has been complemented by the federal government’s ongoing work to secure additional international supplies and working with industry to manage stock supplies nationally.

Other local AdBlue manufacturers continue to play an important role in the supply chain through production and distribution. The government is assisting these businesses by facilitating commercial supplies from overseas through the diplomatic network.

Since late 2021, the government has been working with AdBlue manufacturers, fuel retailers and transport and logistics bodies through the National Coordination Mechanism to replenish out-of-stock sites. As a result of these efforts, they have managed to largely overcome many localised stock-outs at priority sites across the country including the Hume Highway, the Riverina and South Coast of NSW. Although AdBlue users may continue to see a few sites occasionally stocked-out, they can be reassured that with the new AdBlue manmonthly.com.au

Incitec Pivot has locally produced over three million litres of AdBlue in one week, representing around 75 per cent of Australia’s needs. supply coming into the market these sites are now being progressively replenished.

“I thank Incitec Pivot for stepping up as we work together to keep our trucks fuelled and Australian diesel motorists on the road,” minister for Industry, Energy and Emissions Reduction Angus Taylor said.

“While Australia currently has sufficient volumes of AdBlue to meet its needs, this local production will help restore normal national stock levels. I also thank the broader AdBlue manufacturing, fuel distribution and transport sectors for their continued cooperation with the government on a weekly basis.

This open communication has meant sites have been replenished and disruptions have been minimised for AdBlue users during the holiday period.

“To ensure stocks can be replenished across the country, I continue to encourage industry to purchase stocks only when needed

and at normal levels,” Taylor said.

As part of the partnership with the government, Incitec Pivot will shortly begin trialling the production of technical grade urea (TGU), the active ingredient in AdBlue, with an additive sourced from Germany.

With a view to the longer-term future, the federal government continues to aid AdBlue manufacturers and suppliers to secure international supplies of TGU and AdBlue and assist with shipping and customs entry into Australia.

Manufacturers’ Monthly MARCH 2022 13

News @MM Lockheed Martin, Amazon and Cisco have teamed up to integrate unique human-machine interface technologies into NASA’s Orion spacecraft, providing an opportunity to learn how future astronauts could benefit from far-field voice technology, AI and tablet-based video collaboration.

The Callisto technology demonstration will be integrated into NASA’s Orion spacecraft for the agency’s Artemis I uncrewed mission around the moon and back to Earth. Callisto uses Amazon Alexa and Webex by Cisco to test and demonstrate commercial technology for deep space voice, video and whiteboarding communications.

Lockheed Martin, which designed and built the Orion spacecraft for NASA, is leading the development and integration of the payload.

“Callisto will demonstrate a firstof-its-kind technology that could be used in the future to enable astronauts to be more self-reliant as they explore deep space,” Lockheed Martin vice president and general manager of Commercial Civil Space Lisa Callahan said.

“Callisto is a shining example of how new partnerships with commercial technologies can be flown on Orion to benefit future human deep space missions.”

The Callisto payload features a custom hardware and software integration developed by engineers from Lockheed Martin, Amazon and Cisco. It includes innovative technology that allows Alexa to work without an internet connection, and Webex to run on a tablet using NASA’s Deep Space Network.

“The Star Trek computer was part of our original inspiration for Alexa, so it’s exciting and humbling to see our vision for ambient intelligence come to life on board Orion,” Amazon Alexa vice president Aaron Rubenson said.

“We’re proud to be working with Lockheed Martin to push the limits 14 MARCH 2022 Manufacturers’ Monthly

Image credit: Lockheed Martin.

Industry brings voice technology and video to the moon

An illustration of Callisto and how it will be used in the future with astronauts. of voice technology and AI, and we hope Alexa’s role in the mission helps inspire future scientists, astronauts and engineers who will define this next era of space exploration.”

Since Artemis I is an uncrewed mission, Callisto partners have worked with NASA to build a virtual crew experience at NASA’s Johnson Space Center in Houston, allowing operators to interact with Callisto from the Mission Control Center.

These remote interactions will test and demonstrate how voice and video collaboration technologies can help astronauts improve efficiency and situational awareness during their mission, providing access to flight status and telemetry, and the ability to control connected devices onboard Orion. Video and audio of the interactions will be transmitted back to Earth many times throughout the Artemis I mission, allowing engineers to analyse the performance of the onboard systems while also sharing interactions with the public.

“The future of technology is about igniting human potential

whenever and wherever that may be – which will soon extend to the depths of space,” Cisco executive vice president and general manager of Security and Collaboration Jeetu Patel said.

“Through Callisto, Webex is enabling boundless video communications and collaboration in deep space while helping to provide the next generation with inclusive and immersive technology.

This first-of-its-kind solution could one day support future crewed missions, providing face-to-face interaction between crew, command centre and loved ones.”

The Callisto technology demonstration will also allow students, families, space enthusiasts and the public to engage with and virtually “ride along” with the Artemis I mission. They can follow the mission on Alexa-enabled devices by saying “Alexa, take me to the Moon,” and the Webex video collaboration capabilities will offer opportunities for STEM education and remote classroom teaching events.

Artemis I is currently scheduled

to launch in early 2022 from NASA’s Kennedy Space Center in Cape Canaveral, Florida, for a multi-week journey around the moon and back. Artemis I will provide the foundation for future crewed missions to the moon and deep space and is part of NASA’s goal to land the first woman and first person of colour on the lunar surface.

According to Lockheed Martin, Callisto will demonstrate how voice technology, AI and portable tabletbased video conferencing can help improve efficiency and situational awareness for those on board the spacecraft, providing access to real-time mission information and a virtual connection to people and information back on Earth.

Its goal is to explore how these commercial technologies can support astronauts on future deep space missions to the moon and beyond.

For more information on the Callisto technology demonstration payload, the Lockheed Martin website can provide more information about the project. manmonthly.com.au

News @MM Rheinmetall’s high voltage pyrofuse for safe e-Mobility wins award NEW full feature oil injected screw compressors 4-22kW

Rheinmetall has developed a pyrofuse that disconnects the battery or DC charger in EVs, in case of emergencies like accidents of short circuits.

NEW generation series-4 screw compressors up to 160kW

Oil free scroll compressors Medical, instrument, dental In the transition to electric vehicles, new safety systems are needed. To provide the growing market with advanced solutions, Rheinmetall has developed a pyrofuse that has won the 2021 China Automotive & Parts Industry Developing & Innovation Award.

The annual award ceremony was hosted by the distinguished magazine of the Chinese automobile industry, Automobile & Parts at the end of 2021.

The compact pyrofuse, a pyrotechnical safety switch system developed by the Sensors and Actuators division, won the prize in the domain of new energy.

Rheinmetall’s high voltage pyrofuse ensures safe operation of battery electric vehicles (BEV), plug-in hybrid electric vehicles (PHEV) and fuel cell electric vehicles (FCEV). The system disconnects the battery or the DC charger in case of emergency such as accidents, crashes or short circuits, manmonthly.com.au

reducing possible dangers and risks for passengers, rescue teams and first aiders. It has an ultrafast response speed below one millisecond and breaks the power supply immediately.

The operating voltage of the Rheinmetall innovation ranges from 450 to 1,000 VDC and it can break high currents of up to 30kA, operating at temperatures up to 120°C. The fuse system has the lowest best-in-class internal electrical resistance and reduces power losses and thermal selfheating.

Further benefits are the low weight and the cost-efficient design, and the ability to disconnect short circuit currents without outburst of conductive and hot gases. Additionally, the system is available with an integrated current sensor, saving costs, space and assembly efforts and simplifying component harmonisation.

With the ongoing transformation to e-mobility and new market demands,

pyrofuse systems will be widely used in electric vehicles and this technological segment will undergo rapid development.

Rheinmetall will continue to expand its advantages and drive further technological progress in the field of mobility and security.

Rheinmetall possesses a longstanding expertise in pyrotechnics. For customers in the automotive industry, the company has manufactured airbag igniters on a large scale.

Belt tensioners also feature sensor triggered Rheinmetall pyrotechnic solutions that react instantly in hazardous situations.

Law enforcement agencies and armies use pyrotechnic flash/bang munitions from Rheinmetall to disorient and disable opponents. Moreover, special smoke/obscurant and illumination rounds can be used to protect assets deployed in harm’s way and to give them a decisive tactical advantage in critical situations.

High pressure piston and booster up to 40 bar(g)

Refrigerated and Desiccant Air dryers from 15-6,000 cfm

For sales and service support contact your nearest BOGE partner www.boge.net.au or (03) 5940 5913

Manufacturers’ Monthly MARCH 2022 15

News @MM

ATSE’s program, Elevate, will award 500 undergraduate and postgraduate scholarships to women in STEM. ecosystem that can attract, retain and progress girls and women into STEM education and careers, ATSE CEO Kylie Walker said.

“The Australian Academy of Technology and Engineering is delighted to partner with the Australian government in implementing this game-changing and STEM workforce cultureshaping program,” Walker said.

“Elevate is designed around three pillars – education and impact designed and led by women; skills building, supported by mentoring

and networking; and leadership to increase the influence and profile of women in STEM. “As well as supporting a strong, thriving cohort of future women leaders and role models to enter and excel in Australian STEM jobs, Elevate will nurture a collaborative and innovative economy-building culture between Australian universities and Australian industry.”

ATSE’s goal is to immerse these scholars in a network of research and industry leaders to inspire and cultivate their future careers.

GenT device developed to convert waste into electricity for industry A thermovoltaic device that will convert infrared energy from waste heat sources into electricity is being developed by technology company, PhosEnergy, and the University of South Australia in collaboration with the Innovative Manufacturing Cooperative Research Centre (IMCRC).

The $314,000 research project, based at the University of South Australia’s Future Industries Institute (FII), will leverage PhosEnergy’s existing beta-voltaic technology and

16 MARCH 2022 Manufacturers’ Monthly

adapt it to create an efficient costeffective device known as “GenT.” Waste heat capture and utilisation technology has been identified as a growth area on the Recycling and Clean Energy National Manufacturing Priority roadmap. It represents a key strategy for improving energy efficiency across Australia.

“The GenT project epitomises PhosEnergy’s focus, which is to utilise innovative manufacturing and technology to convert underutilised or waste resources into valuable

products,” PhosEnergy managing director Bryn Jones said.

“The IMCRC funding will enable us to accelerate the commercialisation of our technology by providing the resources we need to construct prototypes and determine their suitability across a range of applications.”

University of South Australia’s Professor Drew Evans said: “The GenT project will utilise our expertise in materials R&D to help PhosEnergy develop a product of significant

The Elevate program will complement ATSE’s existing three high-profile STEM career pathway initiatives: • IMNIS: Industry Mentoring Network in STEM, an industry engagement, mentoring and internships initiative which will be integrated with the Elevate program • STELR: a schools-based, hands-on STEM education program • CS in Schools: a digital technology education program linking classrooms with industry.

“The Academy is ideally positioned to implement this transformational program given its track record of nurturing a diverse and inclusive STEM sector and its strong connections between academia, industry and government,” Walker said.

Elevate will be administered and delivered by ATSE as the lead organisation working with a diverse consortium of partners from industry and academia including ATSE’s Industry Mentoring Network in STEM (IMNIS), among others.

Image credit: University of South Australia.

The Australian Academy of Technology and Engineering (ATSE) has been named the sole implementing partner for the federal government’s 7-year $41.2 million “Boosting the Next Generation of Women in STEM” fund, through a transformational program named Elevate.

Elevate will award up to 500 undergraduate and postgraduate scholarships to women in science, technology, engineering and mathematics (STEM).

The program aims to address gender inequities in STEM through fostering more women-led industryacademia collaborations in applied research and business, growing skills of women in STEM and by propelling women into senior leadership.

ATSE and its partners will co-design a high-quality program spanning industry, academia and government to upskill women with STEM qualifications, research and business expertise, so they can lead and shape a dynamic and impactful Australian STEM sector.

The program will help create a diverse, inclusive and vibrant STEM

Image credit: ATSE.

ATSE to Elevate women’s leadership in STEM under new funding

Professor Drew Evans, who will lead the project in collaboration with PhosEnergy. benefit to Australia’s and the world’s energy sector.”

IMCRC deputy CEO Dr Jason Coonan said the project shows how industry can address global issues.

manmonthly.com.au

News @MM

Wisk, an Advanced Air Mobility (AAM) company that developed the first allelectric, self-flying air taxi in the US, has secured $450 million in funding from Boeing to further develop and certify its 6th generation eVTOL aircraft – an autonomous, all-electric passenger-carrying aircraft.

The funding will also support Wisk’s intensive growth phase over the next year, its preparations for scale manufacturing and its Go-to Market efforts.

Following the certification of its 6th generation aircraft within five years, Wisk intends to operate one of the industry’s largest fleets of AAM eVTOL aircrafts. This will be made possible via its autonomous technology.

Wisk anticipates close to 14 million annual flights, bringing time savings to over 40 million people across 20 cities – all with zero emissions.

“Wisk is extremely well-positioned

to deliver on our long-term strategy and commitment to safe, everyday flight for everyone. We are incredibly fortunate to have Boeing as not only an investor but a strategic partner, which provides us with access to a breadth of resources, industry-leading expertise, a global reach, extensive certification experience and more,” Wisk CEO Gary Gysin said.

According to Marc Allen, Boeing’s chief strategy officer, the investment reconfirms Boeing’s belief in the Wisk business.

“Autonomy is the key to unlocking scale across all AAM applications, from passenger to cargo and beyond,” Allen said. “That’s why straight-to-autonomy is a core first principle.”

Wisk began in 2010 as Zee Aero with a mission to deliver safe, everyday flight for everyone, later merging with Kitty Hawk Corporation. Upon recognising the commercial potential

Boeing has funded Advanced Air Mobility company, Wisk, to develop an autonomous, electric passenger aircraft.

of Wisk’s 5th generation aircraft, the aircraft and team formed Wisk with an investment from Boeing.

Previous undisclosed funding rounds were led by Boeing and Kitty Hawk Corporation through a joint

Image credit: Wisk.

Wisk secures $450 million from Boeing to advance eVTOL aircraft

venture, making Wisk one of the only AAM companies to be backed by two aviation leaders. Kitty Hawk remains an investor and has supported the development of Wisk’s previous generations of aircraft.

MCRI develop scalable test to screen rare genetic disorders in babies Researchers from the Murdoch Children’s Research Institute (MCRI) have developed a new screening method to identify three rare genetic disorders in babies, leading to earlier diagnosis and better treatment.

The screening method can identify Prader Willi, Angelman and Dup15q syndromes – which can lead to varying degrees of intellectual disability, autism, behavioural problems, seizures or severe obesity – via a “heel prick” test.

A sample taken from this simple test would show the number of chemical markers in affected genes that are not present at such high or low levels in children without these disorders.

manmonthly.com.au

The MCRI study has confirmed that the method could be delivered at large scale and at a low cost through standardised newborn heel prick tests.

“Victorian researchers are worldclass and changing lives every day with discoveries like this screening test that will help children reach their full potential,” Victorian minister for Innovation, Medical Research and the Digital Economy Jaala Pulford said.

The Prader Willi, Angelman and Dup15q syndromes affect about 135 babies each year in Australia, but the disorders are not included in newborn screening programs, and many go undiagnosed in a baby’s first year.

“Such early diagnosis, if available

through newborn screening, could prevent the diagnostic odyssey, reduce medical costs and the significant stress and anxiety currently experienced by the families while they await a diagnosis,” MCRI professor David Amor said.

A mother residing in Wollert in Victoria, Chrissy Cimino, said her son Elliott was diagnosed with Angelman syndrome when he was 14 months old. As a baby he couldn’t sit upright, never cried or babbled, and struggled to put on weight. If four-year-old Elliott had been diagnosed as a baby, specialists could have intervened earlier to help him develop his cognitive abilities and motor skills.

“We’ve missed out on years of

intensive physio and speech and occupational therapies and if Elliot was diagnosed earlier, we could have helped him a lot sooner,” Cimino said.

Researchers from the Royal Children’s Hospital, the University of Melbourne and international research institutes also contributed to the study.

The Victorian government provided a grant of $100,000 to MCRI as part of the 2018 Victorian Medical Research Acceleration Fund, supporting researchers to develop the new screening method. Since 2014, the Victorian government has committed $1.3 billion to medical research.

Manufacturers’ Monthly MARCH 2022 17

Manufacturer Focus Cast-in ferrule connection placement on a robotic mould for a lightweight curved panel.

Advancing the manufacture of curved concrete Alexandra Cooper speaks to Daniel Prohasky, co-founder and CEO of Curvecrete, about the new company’s bespoke, sustainable, curved concrete manufactured in Melbourne using advanced manufacturing.

O

NE of the main advantages of utilising industrial advanced robotic systems in the manufacturing industry lies in the improved security of the supply chain at large, according to The Action Plan for Critical Technologies report from the Australian Critical Technologies Policy Coordination Office (CTPCO). With the amplified demand for implementing advanced robotics within the manufacturing process in many businesses, this has become increasingly evident.

Established in 2019 through

18 MARCH 2022 Manufacturers’ Monthly

the support of the University of Melbourne and Swinburne University of Technology, the curved concrete and robotics manufacturing company, Curvecrete, was founded by CEO Daniel Prohasky and CFO Warren Rudd. Prohasky’s love for the idea of creating exciting architecture, to construct high quality buildings using low carbon, and less wasteful materials drove the creation of the new advanced manufacturing company.

The robotic concrete moulding technique was originally invented by

Paul Loh, David Legget, and Prohasky at the University of Melbourne. It produced bespoke curved concrete panels – making a simpler, faster, zero waste production process.

“I was doing my PhD at RMIT for Aerospace Engineering and was getting very involved with the digital fabrication space and trying to realise ways that we could build better by integrating architecture and engineering,” Prohasky said.

“Collaborating with researchers at the University of Melbourne eventuated in the core technology

that we use at Curvecrete. We started from a passion of trying to build higher quality buildings and even more so now with a strong focus on sustainable processes, Curvecrete is on a mission to accelerate the use of low carbon materials in construction.

Advanced manufacturing is an enabler of that.”

After negotiating a licensing agreement with the University of Melbourne, the founders then set off down the commercialisation route.

In October 2021, Curvecrete won an Accelerating Commercialisation manmonthly.com.au

ManufacturerFocus

Curvecrete co-founders, CEO Daniel Prohasky and CFO Warren Rudd.

Compared with the traditional manufacturing process of curved concrete and all of the waste associated with the formwork, by eradicating this formwork we save 35 per cent for nonstructural panels and up to 75 per cent for structural panels.

Grant from the federal government worth $325,158 to develop a pilot advanced manufacturing facility in Melbourne. This facility is enabling the scaled manufacture of low carbon construction materials, and using Curvecrete’s signature fit-for-purpose robotic systems to help deliver on manmonthly.com.au

new projects cost effectively and with high precision.

The manufacturing business’ pilot project, delivered as part of the Accelerating Commercialisation Grant, was the first step in proving the technology in the commercial space.

“For our first project, we created an extension of the fire escape for a multi-residential building in Melbourne,” Prohasky said. “It’s an existing 14-storey building, and we designed an access stairway to the rooftop and a curved concrete canopy to enclose that spiral staircase, for the residents to have access to the rooftop.”

This is just one example of a typical application for this new curved concrete moulding technique.

The Curvecrete panels can be used in: • Non-structural cladding applications such as curved sculptures, facades, rain screens, and non-combustible cladding replacement; • Structural applications such as modular curved homes, urban artwork, seating, and balustrading; and • Infrastructure including curved pedestrian bridges, highway sound barriers, and pylons.

A robotic, sustainable process The robotic concrete moulding technique works by using a parallel robotic system with several actuators.

As a completely fit-for-purpose actuated system, it is specifically designed as an adaptable mould that can manipulate its shape to form the curved concrete panel in a variety of different shapes, Prohasky explained.

“It’s got very minimal actuation,

there’s only three actuators, but there’s a lot of different moving parts that work in unison. We also developed some joinery that is like a triaxial joint,” he said. “The idea is that minimising the number of actuators significantly lowers the cost, time to manufacture, and reduces maintenance of the system; the next equivalent system is an order of magnitude more expensive, that uses an array of actuators. The output forms a series of curved concrete panels in a rapidly reusable process. Just today, we produced two panels on the same robotic mould with our rapid setting low-carbon concrete.”

The advantage of this is that it removes all the labour and waste material associated with the traditional manual forming process.

As a reusable system it produces zero waste in comparison to a traditional formwork process, whereby for every tonne of precast concrete that is made, 10-15 per cent of the material would be wasted.

Prohasky likens the unsustainable traditional formwork process to building a boat, then disposing of said boat on arriving at its destination.

Curvecrete’s robotic approach has also proven to be more cost-effective.

“Compared with the traditional manufacturing process of curved concrete and all of the waste associated with the formwork, by Manufacturers’ Monthly MARCH 2022 19

Manufacturer Focus

Curvecrete’s custom robotics components developed using FDM 3D printing. eradicating this formwork we save 35 per cent for non-structural panels and up to 75 per cent for structural panels,” Prohasky said.

The raw materials that Curvecrete use are concrete waste by-products from coal power and the steel manufacturing industry.

“The material itself uses waste by-products, and we use a proportion greater than 50 per cent within our material,” Prohasky said. “So, we’re only using slightly less than 50 per cent raw material for aggregates, as opposed to reused, and we’re going to be pushing even further to use recycled aggregates in the future as well. The mission really is to become negative waste, so we actually consume more waste than we use in raw material.”

The business is also trying to source their materials within Australia, where possible.

20 MARCH 2022 Manufacturers’ Monthly

“We use fly ash and slag – the fly ash is sourced in Australia and the slag is currently imported,” Prohasky said. “We’re trying to source slag locally before we consume high volumes, so we’re looking for slag suppliers locally. With the robotic systems, we manufacture everything locally that we can, but we do source a few components for the actuators from China. The rest is sourced locally and manufactured locally.”

Overcoming challenges There were several challenges that have confronted Curvecrete both as a manufacturer and as a business. The first sizeable hurdle was translating the research from the university into setting the business up for success. There have been some recent improvements on remedying this, including the federal government’s $5.8

million University Research Commercialisation Scheme that was introduced in the 2020-21 Budget and their $242.7 million Trailblazer Universities initiative, introduced in November 2021. However, Prohasky feels that a lot more still needs to be done in facilitating research translation.

“Research translation is really hard. The licence negotiation process was really strung out because it took us 20 months for us to negotiate that deal. It’s so hard to focus on actually succeeding as a company before it has even begun,” Prohasky said.

“There’s been a lot of good work that has happened to improve that process and streamline it, but there’s still a lot of work that needs to happen within Australia to really create a clear process across the board that every university

in Australia can operate under, that has a reliable and known low equity stake for the university.

For collaborations to occur across universities easily, a broad-brush approach is needed across all Australian universities; meaning the exact same benchmarked deal for every university in Australia matching or surpassing the most innovative countries in the world.

Then everyone can collaborate, and everyone knows the terms, so that they can commercialise really great research without being clouded by an unknown outcome during the research translation process.”

Upon embarking on the path to commercialising Curvecrete’s technology, the founders’ next challenge was upscaling the development of the product in a cost-effective way.

“The technology is quite manmonthly.com.au

ManufacturerFocus sophisticated, so the challenge was reaching scale cost effectively and making sure quality control is tight and that everything for the new product complied with the construction industry to sign off as structural, and fire engineering compliance requirements” Prohasky said.

“We’ve got our non-combustibility AS1530.1 compliance for material and we’ve just received our certificate of compliance for structural engineering for our first job. It was difficult, because we were effectively bringing the product to market, speeding up production, and delivering on a project at the same time. But, we did it!”

What’s next for Curvecrete?

In the aftermath of their first project, Curvecrete is aiming to further streamline their production process and implement more robust systems.

“From a systems and engineering approach, we’ve got the overall production, design and compliance system in place, but now it’s just about optimising the nodes within that system and making incremental improvements to the system on particular things in terms of efficiency, productivity rates and production yields. All to achieve really high valued beautiful sculptural architecture with zero waste!” Prohasky said.

In addition, the business is searching for further collaborations with other Australian manufacturers and suppliers in terms of implementing different products to deliver an effective internal development process. This would aid Curvecrete in reaching their shortand long-term goals.

“We have a goal to reach a 95 per cent success rate for our panels by achieving zero tolerance on our machines. We want to bring in at least over $1 million in revenue in 2022, or even in the first half of the year. I think we have the capability to do that, too. We’re looking for more opportunities to explore what’s possible with our technology. We are looking to be challenged!”

For the long term, the manmonthly.com.au

manufacturer’s overarching mission is to accelerate the construction industry towards a low carbon future, through their innovative robotic concrete moulding technology and low carbon material use.

in collaborating to develop robotic systems for construction. We’ve got a lot of knowledge in the space to share.”

Beyond these goals, Curvecrete has the potential to package their advanced manufactured technology

The technology is quite sophisticated, so the challenge was reaching scale cost effectively and making sure quality control is tight and that everything for the new product complied with the construction industry to sign off as structural, and fire engineering compliance requirements.

“We want to further enable the use of low carbon materials through efficient, elegant robotic systems that will enable that, and further implement those at scale,” Prohasky said. “We also aim to collaborate with pre-casters and other robotics manufacturers who are interested

as a more comprehensive, futureforward system to be used remotely – perhaps even in space.

“The goal is to create an automatic casting system – a robotic system which can manipulate itself based on backend database panels and churn out panel after panel

and include automated mixing, cleaning and setup,” Prohasky said. “We could package it up into a shipping container and then put it onsite in remote locations and then manufacture panels remotely.

The next step beyond that might be even to develop robotic systems that could build on other worlds as well, like on the Moon or on Mars.”

With such an increased availability for federal government funding and commercialisation opportunities around manufacturing technologies that are suitable for use in a space environment – such as the relevant streams that fall under the federal government’s $1.5 billion Modern Manufacturing Strategy – this aspiration is well within the realm of future possibility for Curvecrete.

“We’re always looking for new projects,” Prohasky said. “Anyone who wants to build something exciting with precision and high quality finishes, your next solution to do that can be curved, using a sustainable zero waste method. Get in touch through the Curvecrete website.”

Curvecrete’s low-carbon lightweight curved concrete canopy destined for Flinders Street.

Manufacturers’ Monthly MARCH 2022 21

Industry Focus Path to a collision-free autonomous robot Manufacturers’ Monthly speaks with the University of South Australia STEM program director and mechatronics engineering lecturer, Dr Habib Habibullah, about a new path planning algorithm that his team have developed to make autonomous mobile robots safer and more efficient.

The University of South Australia’s algorithm helps robots avoid incoming objects.

22 MARCH 2022 Manufacturers’ Monthly

manmonthly.com.au

IndustryFocus

I

N September 2021, the Australian team from CSIRO’s Data61 competed in the global DARPA Subterranean Challenge in the US – otherwise known as the “Robot Olympics” – and came second in the finals for pushing the boundaries in autonomous robotics.

Six autonomous robots were placed in real-world scenarios and awarded points for correctly locating items, maintaining autonomy, and mapping the terrain. These robots would have used a path planning algorithm to navigate their way to victory.

According to ScienceDirect, path planning (or motion planning) is defined as a computational problem that finds a geometrical path from the vehicle’s current location to its goal location, while avoiding obstacles.

Advanced robotic systems such as those displayed in the Subterranean

Challenge have been increasingly adopted in the manufacturing industry under the Industry 4.0 revolution, and have achieved great benefits. The Advanced Manufacturing Growth Centre’s Sector Competitiveness Plan 2017 stated that robotics and automated production processes enable “greater productivity, lower costs, improved workplace safety and higher production quality.”

One of the Plan’s priorities for improvement through research and development in this space begged the question: “How can robots better develop situational awareness to interact with workers and customers and in controlled environments?”

Investigating this question, a team led by Dr Habib Habibullah from the University of South Australia has created a path planning algorithm that addresses how autonomous

An in-house built weeding robot designed and developed at the University of South Australia by electrical and electronics engineering honours thesis students.

manmonthly.com.au

mobile robotic systems can work in harmony with humans, both safely and effectively.

How the algorithm works The concept behind the project was to design an autonomous robot with multiple objectives and uses, such as picking and placing objects based on an area tag or barcode in a warehouse setting. The robot would have the ability to operate where it may encounter dynamic obstacles such as human movement or other moving machines, like forklifts, as well as static obstacles in the environment, like shelves.

In the initial testing phase, the team achieved a high success rate in avoiding obstacles in a series of nine different simulations.

“It was not expected that it would reach the goal,” Habibullah said. “We restarted the scenario and implemented several other algorithms, but we only found a 50-60 per cent success rate. But in this special case, we succeeded in achieving obstacle avoidance at a higher rate, close to 100 per cent.”

The University of South Australia’s algorithm combines several common avoidance algorithms together, including Dynamic Window Approach (DWA) and an improved Follow the Gap Method (IFGM). According to Habibullah, the algorithm works by taking the dimensions of the robot and potential obstacles into account and calculating the distance between them. Using this data, it makes an arbitrary judgement on the potential speed of the oncoming obstacle.

“If a human obstacle is walking at one or two metres per second, we considered that the speed for the robot needs to be a little bit faster than the human’s movement,” Habibullah said. “When the obstacle’s speed increased, the algorithm was efficient in determining the distance between the obstacles and the robot itself, and also the relative velocity of the obstacle and the robot. And counting that towards hitting the goal, how much time it will have before colliding with the obstacle. If it calculates that it’s going to collide with the obstacle, then the robot will Manufacturers’ Monthly MARCH 2022 23

Industry Focus A TurtleBot project completed by a group of undergraduate students.

on GPS data will lose its location as it travels through a tunnel. Without the correct data coordinates, this could lead to an accident.

“By combining three different sources of sensor data, we can produce a better, more resilient map that will guide the vehicle, achieve better reliability and reduce the probability of committing an accident,” Habibullah said. “These are the considerations that we put in place to develop this algorithm, and our resource team are currently working on that to investigate any shortcomings it may have.”

Applying the algorithm in industry

a different line of operation, we can adapt an autonomous mobile robot to do that. So, we can reduce the set-up time and initial capital investment and also get a better return on that investment.”

When working in a collaborative workspace with humans and machines, there is a high level of safety that we have to ensure so that no major accident occurs. We came up with a solid, Striving for efficiency To make the University of South reliable calculation process that will support Australia’s path planning algorithm more efficient than others on the safe travelling. slow down at a speed that will let the obstacle pass and then the robot will continue on.”

In an instance where the obstacle is in line with the approaching robot and the robot cannot safely pass in time, the algorithm predicts a separate trajectory to reach its end goal.

TurtleBot test Upon confirming that the algorithm functioned at different levels of speed, Habibullah and his team transferred their tests to the Resource Lab, using a TurtleBot as a prototype. A TurtleBot is an entrylevel mobile robotics platform which can run Simultaneous Localisation and Mapping (SLAM) algorithms to build a map. It is controlled remotely from a laptop or smart phone.

“We used other mini robots as moving obstacles so that when the 24 MARCH 2022 Manufacturers’ Monthly

TurtleBot moves autonomously, the algorithm imported into its brain will readily apply and calculate parameters and uncertainties, the velocity and distance of obstacles and how to travel from the starting position to the goal position,” Habibullah said.

This allowed the team to optimise the algorithm within the TurtleBot system and publish the results in a report, “Local path planning for autonomous mobile robots by integrating modified dynamic-window approach and improved follow the gap method,” in the Journal of Field Robotics in December 2021.

“This has huge potential with respect to applications in the manufacturing industry,” Habibullah said. “From that point of view, if a robotic arm needs to be manoeuvred along the production line or support

market, Habibullah and his team used a sensor fusion approach. In this approach, data is extracted from multiple sources to form a single, highly accurate model of the robot’s surrounding environment. This helps the robot validate how it should act.

“We modified the algorithm so that we can validate this data in more than one source, so that it is definite and reliable,” Habibullah said. “When working in a collaborative workspace with humans and machines, there is a high level of safety that we have to ensure so that no major accident occurs. We came up with a solid, reliable calculation process that will support safe travelling.”

For example, a driverless vehicle currently on the market can track its location and the distance between itself and the vehicle in front of it using data from its GPS device, LIDAR sensors and camera. However, a driverless vehicle that relies solely

Habibullah has ambitions to help companies that are on the digitalisation route and are seeking to use autonomous mobile robots in human-machine collaborative workspaces, such as a manufacturing facility. To achieve this, the parameters of the algorithm need to be adjusted to become a fit-forpurpose model before it is ready for deployment.

This was the case with a recent project in which two of Habibullah’s undergraduate students designed and developed a weeding robot for vineyards.

“I had a client last year that works in the Riverland area, a threehour drive from Adelaide. He was looking to semi-automate or fully automate a device so that it can autonomously work in the orchard for weeding, spraying and crop monitoring,” he said. “It will move along the row, take images from different plants and then process the images live to see the condition of the trees or crops. From that, it can predict where it should spray and then directly take action. At the moment, we’re working to implement that as the first outdoor application of this algorithm for agricultural robotics.”

Recently, another four students at the University of South Australia worked to implement the algorithm into temperature sensor technology for SensorTec. In this instance, these temperature sensors were used in farms to determine the pH levels and manmonthly.com.au

IndustryFocus moisture levels at different depths of the soil.

“In doing this, we were working to automate the production line,” Habibullah said. “But we found some difficulties in doing that. The robotic arm, supplied by Omron, had a 1.3m reach but the length of the moisture sensor probe itself was only 120cm.

This meant that the robot was not able to reach up and move it from one tray to another tray.

“In that case, we recommended coming up with a mobile station for the robotic arm so that it can travel to the tray, or it can pick up and then take the probe to the testing station and then put it in either the faulty tray or success tray.”

The path planning algorithm can also be applied to rugged mobile vehicles used in the mining or welding industries.

“We had an email from a client who has a business in mining,” Habibullah said. “They are looking to perform welding tasks at different spots. They want a mobile vehicle so

that it can move to that particular point, with pre-set coordinates for the location of where it has to weld. Then the robot can move from station to station.”

The University of South Australia’s algorithm, used in conjunction with the robots within the Robotic and Automation Laboratory, could help to spark further change in the way that robotics is used in the manufacturing industry. An example of this is a potential application for car manufacturing.

“I have a plan in the near future to automate our robotic and automation station and make a prototype for other manufacturing systems. For example, in car manufacturing or other manufacturing systems where a different, more complex reach may be needed for the robot; meaning it has to travel to do that particular job,” Habibullah said. “For car manufacturing, even within the car body itself, the robotic arm would

have to move from the bottom to the top side, to the inside and so on. In that case, if we implement this kind of algorithm and find the safe distance between the nearest possible obstacles, we could make it a safer environment and produce a greater surface finish. We’re planning to enhance our capability to showcase this to our clients, both nationally and internationally.”

Skills of the future As Habibullah moves forward to identify new challenges and address them in order to attain the technology readiness level that is necessary for the new path planning algorithm, he is also preparing the next generation of skilled workers required to maintain the technology in the future.

“This is a rapidly changing technological platform – and whether it’s the manufacturing industry or the transport industry, including all robotic applications from warehouse problems to driverless vehicles, it’s

a rapidly changing publish or perish campaign,” he said. “We oversee that when these technologies become available to the masses in the near future, we are running out of the skilled people needed in Australia.

We need to have the back-up and support for a driverless vehicle or for an autonomous manufacturing system, but we don’t have the capacity of those skilled people in Australia. So, we are targeting and developing our courses at the University of South Australia and related linear programs, so that we can produce the skilled students to take those challenges on in the future.”

In terms of producing and manufacturing technological solutions such as the path planning algorithm in Australia, and effectively integrating them into diverse robotic applications, Habibullah said it is paramount that we need to work hard to produce the skilled capabilities needed sooner rather than later.

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Manufacturers’ Monthly MARCH 2022 25

Compressors Go green with Atlas Copco’s latest oil-water separators Atlas Copco speaks with Manufacturers’ Monthly about its latest OSC oil-water separators and why they are a win-win solution both for oil-lubricated compressors and the environment.

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O make compressor condensate treatment effective and effortless – and make a positive impact on the environment – consider using the latest OSC oil-water separators from Atlas Copco.

The OSC oil-water separators filter the condensate from these compressors more effectively to meet and exceed the most stringent clean water standards. And their easy, no-mess maintenance drastically simplifies service.

When working with oil-lubricated compressors, condensate treatment is not just a must, in Australia it is the law.

An oil-water separator removes the oil from compressor condensate before it can enter the sewage system. However, too many oil-water separators offer poor quality and minimal ease of use. Atlas Copco’s new OSC series addresses these issues with unmatched filtration precision and zero-hassle maintenance.

Thanks to its ingenious multistage filtration technology with

Atlas Copco’s OSC’s removable filter bags and catridges make the oil-water seperation process fuss free.

polypropylene and activated carbon, the OSC removes a wider range of oil types. For stronger emulsions, organoclay can be used as the second stage filter material instead of activated carbon. This allows the OSC to achieve extremely clean wastewater with a purity as low as 5 ppm at outlet.

Compressor owners can meet and exceed the toughest current clean water regulations with Atlas Copco’s new solution.

26 MARCH 2022 Manufacturers’ Monthly

As a result, compressor owners can meet and exceed the toughest current clean water regulations.

In addition, the OSC’s removable filter bags and cartridges make the oil-water separation process considerably easier and a lot less messy. Customers also enjoy a long service interval of 4,000 hours.

To ensure optimal performance, the OSC comes with a test outlet that helps verify filtration quality and a service indicator for polypropylene filter saturation. An overflow indicator monitors correct water passage.

“Customers sometimes think any oil-water separator will do. But many offer subpar filtration and messy maintenance. Our new OSC resolves these issues,” said Jan Norz, global product manager for Air Treatment Equipment with Atlas Copco Industrial Air. “The OSC allows our customers to comply with current and future clean water regulations. Even better, its nomess filter bags and cartridges make maintenance much easier, which will be very welcome news to anybody

who has ever had to service an oilwater separator.”

The OSC series consists of 18 different types and sizes to give customers maximum flexibility. OSC 12 – 2500 can treat condensate from complete compressed air systems with nominal compressed air flow from 12 to 2,500 L/s FAD. Check now if your compressed air condensate system is complying with your local regulations. Contact Atlas Copco for more information and support in selecting the correct solution for your installations on 1800 023 469, or visit their website listed below.

At Atlas Copco, where great ideas accelerate innovation, industrial ideas have been turned into business critical benefits since 1873. By listening to their customers and knowing their needs, Atlas Copco delivers value and innovates with the future in mind.

For more information, visit www.atlascopco. com/en-au manmonthly.com.au

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Energy Generators CAPS’ new range of generators The Australian-owned business enters the European market to create an affordable generator while still using premium quality components. carrying the burden of a generator.

Thanks to its rigid structural design and anti-vibration mounts, it reduces vibration levels to a minimum. All chassis’ contain lifting lugs. In less than 1,600 kVA power generators, fuel tank is produced integrated into the chassis. In more than 1,600 kVA power generators, a rectangular type fuel tank is provided with the generator separately. In all types of fuel tank have its level and indicator.

Canopies

The CAPS Generator CP45-TB1.

F

OR over 41 years, CAPS has been Australia’s largest independent supplier of power generation and air compression products. With proven global engineering and export capabilities, the team of experts undertakes turnkey projects which include the design, supply, installation, commissioning, and provision of long term maintenance support to Australian industry standards (ISO 9001:2008).

As well as being a master distributor of KOHLER and AIRMAN generators, CAPS has partnered with a major manufacturer to the European market to create an affordable generator while still using premium quality components. Some of the components include LeRoy Somer alternators, Perkins, Doosan or Baudouin engines, ABB breakers and industry renown control systems.

CAPS fully supports and stands behind everything it sells – with a focus on guaranteeing generators will be high quality, dependable and

28 MARCH 2022 Manufacturers’ Monthly

suitable for your prime power or back-up power requirements.

Meeting tough industry testing and quality standards is the first step to the generator’s rapid response, powering up in seconds to deliver quality power during voltage and frequency changes.

Engines and alternators In all CAPS generators are leading engine and alternator brands that have state of the art technology and have compliance with international standard.

Engines with low fuel consumption provide accurate speed setting and order, mount to the fuel pump and have mechanic or electronic type governors. The alternators have bearing system which don’t need maintenance, with electronic a type voltage regulator providing voltage setting.

Chassis and fuel tank Chassis is manufactured from steel that has features and durability for

• Compatible with 2000/14/EC directives, certified noise emission level • 2 or 4 points transport possibility according to cabin size Hidden exhaust inside the canopy • Emergency stop button located on the canopy Improved air suction channel to ensure homogenous • cooling in the canopy • Radiator air outlet and exhaust with designed towards above • Lid on cab that provides to be filled up water and antifreeze easily to the radiator • Amplified paint system against corrosion and rusting • Improved performance in terms of sound insulation • Demounted parts that make transportation and maintenance easier • In accordance with customer requests, private canopy production with desired sound level/size

Control panels Standard control panel, that is used in CAPS generators, ensures comfortable and safe usage. All measured and statistical parameters, operating modes, notice and alarms and condition of generator, are monitored easily from the control panel. On the front of the panel’s metal body has electronic control

module and the emergency stop button and the panel’s metal body is made of steel sheet and is painted with electrostatic powder paint.

Options • Medium voltage alternator • Remote radiator applications automatic fuel filling system • Fuel tank, oil pan, dashboard, alternator, coil heaters • Alternator with double AVR and PMG synchronization systems • The generator output breaker, • Grid-generator transfer switches, accordance with the specific volume of demand-insulated cabins • Seismic solutions • Trailer • Remote monitoring

Back-up power solution Australian manufacturers need to consider the risks associated with a potentially unreliable power supply.

There are a multitude of processes critical to manufacturing plants and these processes could be adversely affected if there are any prolonged interruption due to an unscheduled grid failure. What would be the cost of losing production, plant, fridges, computers, lights, and staff not working for one hour, two hours or more?

Complete in-house solution – start to finish Delivering a back-up diesel generator, especially for the manufacturing segment, involves several challenges, such as real estate constraints, rapid start-up along with performance and emissions issues. This is why CAPS Australia’s complete solution provide; system design via our in-house engineers, build in our Australian ISO accredited manufacturing facility and commission a custombuilt system, perfectly matched to individual requirements. manmonthly.com.au

EnergyGenerators which sit mainly in the prime power generation space. AIRMAN are synonymous with bullet proof Japanese built quality.

Engines with low fuel consumption help contribute to further cost savings.

24/7 rapid response service

Our extended generator range CAPS Australia only supply quality generators, and outside of our own range, we also distribute other major OEM brands such as KOHLER and AIRMAN generators.

KOHLER has 100 years’

experience in the power generation segment. CAPS has also introduced its own newly released range of generators built in Europe.

Both are made to the highest standards and have built a solid reputation as dependable mains

backup generators. With sizes starting at 9kVA and going right up to 4,500kVA, CAPS can assist you with any backup generator requirement.

CAPS is also the Australian distributor for AIRMAN generators,

To ensure your back-up power equipment is always ready to perform when needed, CAPS offers a nationwide service network with the ability to service and repair your equipment.

Our highly trained technicians continually update their knowledge, and they have the model-by-model knowledge required to give you piece of mind.

Safety is a core value of CAPS, and our goal is never to put people, plant or the environment at risk. You can be confident that our technicians will be completely compliant to any site-specific safety requirements you have.

For more information, call your local CAPS Australia office on 1800 800 878 or visit www.caps.com.au

DataSuite: Central Innovation’s digital continuity solution Would you like to have an error free flow of data between CAD designs and your production systems? Central Innovation’s DataSuite may be the solution for your business to ensure digital continuity.

Moving data from one system to another is a complex, often manual task that is slow, monotonous, and prone to human error. The errors can be disastrous, causing significant losses in profits and productivity.

DataSuite automates this process, providing a common language between systems to allow data to flow seamlessly across platforms, removing the chance of human error and increasing the options for process automation.

DataSuite has many flexible options for robust, reliable automation of business rules, triggers, and standard data flows. Talk to us today to see how DataSuite may ensure that your business decisions are based on accurate information.

To find out more visit https://centralinnovation.com/datasuite/

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Manufacturers’ Monthly MARCH 2022 29

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Compressors BOGE prioritises product sustainability Manufacturers’ Monthly learns how BOGE is prioritising sustainability in its products to reduce carbon emissions.

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OWARDS a sustainable future – the new refrigerant dryers from BOGE’s DS-2 series are even more environmentally friendly than their predecessors.

They come with refrigerant R 513 A as standard, which has much lower global warming potential than the refrigerants previously used. But it is not just their remarkably low CO2 footprint that gives the new refrigerant dryers the edge; they also offer economic advantages. The smart control perfectly adjusts to the actual demand and reduces power consumption at a constant pressure dew point. Other components also ensure efficient operation.

Whether screw compressors, piston compressors, scroll compressors or turbo compressors, complete systems, or individual devices, BOGE Compressors meets the most diverse requirements and highest standards, with precision and quality always at the forefront.

BOGE is aware of the current environmental challenges, which is why the compressed air specialist has converted its DS-2 refrigerant dryer in the lower power range to refrigerant R 513A. This has much lower global warming potential than the refrigerant previously used but does not compromise on performance

in any way. The result: an extremely energy-efficient dryer series with the lowest CO2 footprint on the market.

Furthermore, BOGE refrigerant dryers generally require less refrigerant than similar models by other manufacturers, which also has a positive effect on the environment.

Another advantage of the DS-2 series: the refrigerant circuit is hermetically sealed. This means that the mandatory testing stipulated in F-Gas Regulation EU 517/2014 is not required. Which, in turn, means that the refrigerant dryer not only offers environmental benefits, but financial ones too.

Sustainability combined with high efficiency The heavy-duty aluminium heat exchanger is highly efficient. The coolant circuit is also designed to the highest quality standards. Low losses together with a low coolant requirement means low operating costs that are unmatched. This makes the refrigerant dryers from the DS-2 series the most energy-efficient on the market compared to systems with the same flow capacity by other manufacturers.

The approximately 60 per cent lower global warming potential of its DS 4-2 to DS 100-2 refrigerant dryers speaks for itself. Moreover,

operators will not have to compromise on performance. This means BOGE can guarantee the future supply of compressed air of the highest quality.

Outstanding performance at high delivery rates The BOGE Premium refrigerant dryer DS 460-2 to DS1800-2 is: • Energy efficient; • 4.3” touchscreen control; • Frequency-controlled fan; and • Lower CO2 footprint.

In addition to a high-efficiency heat exchanger with minimum pressure losses, all refrigerant dryers of the BOGE DS series come with energy-saving regulation as standard.

Thanks to the low differential pressure, the upstream compressor can have a lower positive pressure – another way of saving energy.

The intelligent 4.3’’ touchscreen control of the DS series ultimately guarantees truly cost-effective compressed air drying. All models of the DS series attain pressure dew points of up to 3°C and still function without restrictions even at ambient temperatures of up to 50°C.

Highly effective components All DS-2 dryers are designed for efficient drying: the heat exchanger has minimal pressure losses; the condensate drain with electronic level control drains off all condensate without any losses and the Scroll refrigerant compressor uses up to 20 per cent less energy compared to similar systems.

Energy saving controls as standard

Refrigerant compressed air dryer with sustainable, efficient and smart operation

manmonthly.com.au

If the dryer is run at partial load or in good environmental conditions, the intelligent control system automatically switches off the refrigerant compressor. The incoming compressed air is then cooled by the reserves in the heat exchanger, considerably reducing the energy input.

Touchscreen control All DS-2 dryers are fitted with a digital control as standard, which has a potential-free alarm contact and a ModBus RTU interface. The control enables visual monitoring of the dew point and display of the alarm messages. In addition, the control also takes over the energy saving control and informs, among other things, about the percentage energy saving.

Towards a sustainable future All models use the environmentally friendly and future-proof R-513A refrigerant as standard. With a low GWP (Global Warming Potential), it fulfils the requirements of f-gas regulation EU 517:2014 and ensures optimum service reliability. DS-2 models are the best choice for protecting your investment, the climate, and the environment.

A control that thinks for itself The new control – integrated as standard – further reduces consumption and costs and allows perfect adjustment to real operating conditions. It responds to temperature fluctuations immediately which minimises the power consumption.

The smart control also offers convenient and intuitive operation via a high quality 4.3”‘ touchscreen. It can even be easily incorporated into an existing infrastructure thanks to various interfaces. Communication takes place by Modbus RTU, USB ports or optionally by Modbus TCP/IP. Other new components, for example electronic hot gas bypass valves, in conjunction with the installed scroll compressors ensure efficient drying and reliable operation.

BOGE Compressors Australia import and distribute BOGE high-quality German machines, spare parts and all ancillary equipment through a comprehensive network of fullytrained sales and service partners throughout Australia, New Zealand, Papua New Guinea and Fiji.

Manufacturers’ Monthly MARCH 2022 31

Manufacturing Software Connecting software and people Manufacturers’ Monthly speaks with Mike Russell, managing director of Central Innovation, about how manufacturing businesses of all sizes are integrating data to save time and grow profits.

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ENTRAL Innovation has provided solutions for the Australian and New Zealand manufacturing industry for over 30 years.

Despite offering a range of software products and support, our people have been key to driving the company’s success over three decades, according to Mike Russell, managing director.

“Within organisations, typically the underestimation is in the implementation phase,” he says.

“Having the right experience to deploy the technology is often half the story.”

More than 100 Central Innovation staff across Australia and New Zealand provide technical support, training, and innovative products to thousands of big and small-tomedium enterprises.

“We are seeing key people leaving businesses, moving jobs because of the skills shortages in Australia caused by border closures,” he said.

“We’ve kept our team together and growing because we focus on the customers’ workflow and we don’t take shortcuts. The solutions we provide are built to provide resilience

and robustness. Anyone can promise to provide service, but you need the trained-people to deliver upon such a promise and not just the software.”

As well as some of the biggest manufacturing businesses in Australia, Central Innovation works with innovative, developing companies, providing solutions in which start-ups rely on.

“A lot of the initiatives customers have been taking over the past 24 months have been supported by the architects, engineers and designers who are either trained by our people or we provide assistance with the software that they’re using which we’ve supplied.”

Integration solutions Central Innovation’s flagship solution, DataSuite, helps computeraided design data (CAD) flow seamlessly to production systems.

The software was developed by Central Innovation in Australia to enable businesses in the manufacturing industry to introduce a single process to their data management, using a common language to transform and merge data between systems, automate the Using DataSuite has saved Technopak more than 1,500 hours of manual work.

32 MARCH 2022 Manufacturers’ Monthly

business rules of the company.

“One example can be seen when we implement DataSuite for large or small companies to help them integrate the data that they’re putting in their design models across to their ERP systems to do things like create a bill of materials, for example,” Russell said.

“A lot of the software that companies buy is disparate. So, we integrate the business rules, the data from one point to another and the normalisation of all of those things.”

Moving data from one system to another can be a complicated, often manual task that is slow and exposed to human error. DataSuite automates the grunt work, but at its most complex can host a production workbench with business rules that check for the correct drawing numbers, part numbers, specifications, and standards.

“The customer can change these parameters so they’re not spending a fortune every time they want to change something,” Russell said.

Around seventy per cent of Australian manufacturing businesses operate without integrated systems, a trend Russell says is changing because of the supply chain and business resilience challenges that the Pandemic has again highlighted.

“A lot of companies have signed on to implement DataSuite because they are wanting to get the data that’s locked up in the design files available to other systems, processes and workflows within their business,” he said.

“People sometimes fail to recognise an integration problem. If you’re re-keying data, you’re making mistakes. In just about all cases, we do a statement of work which describes the workflow with the customer, the systems that they’re using to support that workflow, and the problems that they’re

encountering, and the capabilities they would like to develop.”

The solution to solve common problems for manufacturers isn’t a quick fix. Russell has seen SMEs suffer from trying to manage with software downloaded from the internet on their own – and says the impact of staff turnover is often underestimated when manufacturing businesses use DIY integration.

“With DIY, you have to have the expertise in house,” he said. “And we’ve seen what happens when DIY goes does not provide a sustainable, support solution. Particularly during the last couple of years with supply chain challenges and enormous amount of staff turnover. A lot of the experience and knowledge leaves the business when the people leave and so they end up swapping systems if favour of what their newcomers recommend – this can have mixed results. The point is that the systems that they’ve cobbled can’t run themselves once the local expert leaves the business. So, we are sometimes asked to help solve problems and help deliver capabilities.”

Technopak success story DataSuite has recently helped one of the world’s leading designer and developer of hygienic bulk packaging and powder handling systems eliminate data transfer errors and speed up delivery.

Technopak’s packing lines are currently composed of several thousand individual parts and many assemblies, designing everything in house with local and international companies to manufacture the parts.

However, the growing complexity of its SOLIDWORKS assemblies, along with changes in the data structure of its product data management (PDM) vault meant that Technopak was finding it increasingly manmonthly.com.au

ManufacturingSoftware

Mike Russell, managing director of Central Innovation.

difficult to export an accurate clean mechanical bill of materials (BOM) to its custom-built ERP. Luke Holmes, Technopak’s GM and operations manager, says attempts to overcome this data misalignment resulted in extensive manual rekeying of data and the need to constantly double and triple-check the information within the BOM.

“We had attempted to automate the process to save time, but we found instead that we were having to check every single line of data because we simply couldn’t trust its accuracy,” he recalls.

“Outdated information was being extracted, leading to downtime and work duplication, all of which was becoming increasingly timeconsuming and costly.”

The solution was to employ Central Innovation’s DataSuite software to deliver seamless data transfer between the PDM and ERP systems while eliminating the output inconsistences.

Luke estimates that using DataSuite to integrate Technopak’s custom ERP system with SOLIDWORKS PDM has saved the business more than 1,500 hours of manual work over the course of a year.

“We no longer have Procurement checking each and every line on the BOM once it’s released by

Engineering, saving us considerable time,” he adds. “And by removing this checking step, we’re also getting fewer double-ups and manual problems, which means we’re also saving the cost of procuring parts which turn out to be incorrect.”

The reduced occurrence of missing items in the assembly kits has also reduced downtime in the Workshop, and ensured a smoother workflow from Stores to Manufacturing.

“All these improvements mean we’re now saving a considerable amount of time and money, with a much-improved workflow,” Holmes said.

Solutions for big and small Mike Russell notes that SMEs often have big company problems on small company budgets. This disparity can lead to the search for an easy solution in the age of the pervasive internet, which can actually lead to more problems for businesses.

“The problem with people expecting a Google answer to complex or even basic workflows is a lack of forward thinking,” he said.

“We are happy to work with just about any brand of software, but I need to be convinced a business has the right people to implement the system and handle change management. This is very important because people are more mobile than companies. If all the expertise is tied up with one person who might leave half-way through implementation then you can experience problems.”

Central Innovation’s experience is allowing businesses to properly delegate tasks, not wasting engineer’s value on time-consuming assignments.

“This is what we do to improve business outcomes,” Russell added.

“Whatever design system, whether it’s cloud based or whether it’s desktop based, we can accommodate requirements. Flexibility and resilience are essential.”

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Manufacturers’ Monthly MARCH 2022 33

Manufacturing Excellence Keeping Australian manufacturing alive Laminex Australia executive general manager, Justin Burgess, and head of People and Performance, Laura Staples, tells Manufacturers’ Monthly about their goal to leave the company in a better shape than they found it, following over 85 years as an Australian manufacturer.

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STABLISHED in Melbourne in 1934, Laminex Australia manufactures high-pressure laminate, compact laminate and wetarea panelling, decorated MDF used for cabinetry doors, raw particleboard and MDF in their various sustainable plants across Australia. As a subsidiary of Fletcher Building, the business has expanded over more than 85 years to become one of the largest employers in their domain.

With an underlying focus on culture, the company is passionate about keeping Australian manufacturing alive.

“Our focus is to really innovate and be quite smart, and to lean in and think about how to compete in a global market,” Laminex Australia executive general manager Justin Burgess said. “I passionately believe we can do that and be successful.

I think that creates a unique proposition for us to challenge the status quo and not be afraid to reinvent ourselves, to stay relevant in Australian manufacturing.”

experiences and various initiatives across the business designed to make it a great place to work.”

In choosing a clear business model and strategy, then embedding that within the team’s growth mindset, the culture became more fluidly articulated and was able to evolve over time. This strategic direction created a natural progression in building the right team, as it became easier to integrate new people into the business.

Additionally, a mantra of “surprise and delight” in the HR team sparked initiatives with an innovative and fun approach.

“We wanted to make sure that we looked at things differently,” Staples said. “Whether it was teaching sales strategy through a board game called ‘Sales Experience’ – which we designed, created and rolled out across 250 sales leaders – through

to celebrating our internal thought leadership with our ‘Laminex Learning Bites’ podcast and recognising all the great leaders that we have internally that can teach our employees. We’ve made sure the things that we’ve done celebrate culture and were innovative and unique to our organisation.”

Another innovative employee experience that Laminex Australia introduced was “Laminex Live,” an internal TV show that has been successfully run for two seasons with an external host, following different themes. According to Staples, the last season was centred on better understanding strategy.

“We had Justin on for each episode to talk about each strategic pillar, and then we incorporated stories from across the business in the various segments,” she said. “This either highlighted various people

around the business, or we brought in external thought leaders to teach and educate on interesting topics.”

Work From Anywhere Another element of Laminex Australia’s success, both as a manufacturer and a business, was implementing a flexible work model called Work From Anywhere for nonoperational employees. While the COVID-19 pandemic played a role in fast-tracking this model, as it has done for many Australian businesses, Burgess said it resulted in a more stable environment.

“Ultimately, we started to unpack it and it offered a whole heap of other upsides for us,” he said. “It opened up the pool of talent across Australia; we weren’t necessarily thinking of a domicile in Melbourne, which enabled a lot of people to move and be comfortable, which we would

Workplace culture One of the strategies that Laminex Australia have implemented to secure a competitive edge as an Australian manufacturer was to transform their workplace culture.

This has led to achieving a place in the Australian Financial Review’s Best Places to Work in 2021 list, in the Manufacturing and Consumer Goods category.

“This has been about three or four years in the making, and the transformation journey has really been a result of defining what our culture was going to look like and creating an aspirational state for us to aim towards,” Laminex Australia head of People and Performance Laura Staples said. “Then we implemented a range of employee 34 MARCH 2022 Manufacturers’ Monthly

The HR team at Laminex Australia created and rolled out their own “Sales Experience” board game to teach sales strategy.

manmonthly.com.au

ManufacturingExcellence not have been able to do in a bricks and mortar workplace. It’s allowed us to explore new online tools of communication, such as Laminex Live, and work as effectively as we can.”

The Work From Anywhere model also meant that employees were able to spend more time with their families, they felt more healthy from being able to prioritise their health, were saving money by eliminating the daily commute to work. These subsets brought more value to the business.

In turn, this has transformed the organisation’s overarching mindset.

“The way people approach challenges and opportunities now are very different to the way we looked at it previously,” Staples said. “That puts us in good stead for all the things that are happening around the world at the moment. We certainly have that anti-fragile mindset where we see any challenge that comes our way as an opportunity to evolve as a business and change for the better.”

manmonthly.com.au

Growth above market For the future of Laminex Australia, growing above the market is paramount to increasing the value of the business and team as a whole. In the long term, the aim for them is to integrate a bigger focus on research and development and evolve into a building material science business.

“We want to start developing our own technologies and our own market-leading products and services, and become more solutions-based,” Burgess said. “We certainly see our future changing quite rapidly in the next five years. We are still really favoured towards product leadership, but really owning that with unique research and development.”

This product leadership is already being implemented in the manufacturing business. An example is Surround by Laminex – a modern range of pre-primed MDF wall panels which has featured on the TV show “The Block,” which has granted a new opportunity for Laminex Australia to grow.

Laminex Australia’s managing director Justin Burgess, with head of People and Performance Laura Staples.

“I think it’s another great example of our investment in Australian manufacturing and that’s something that is really important all of us as leaders,” Staples said of the opportunity. “Making sure that we continue to evolve as an Australian

manufacturer with a rich history, but also a great future ahead of us. If we can leave Laminex Australia in a better position than we found it, that would be an amazing outcome and put it in a great position for future leaders moving forward.”

Manufacturers’ Monthly MARCH 2022 35

Welding Cobots: An automated welding solution David Wilton, managing director of Lorch South-Pacific, speaks with Manufacturers’ Monthly on how the company is developing smarter solutions for tomorrow’s industrial challenges, such as the Lorch Cobot Welding system – a collaborative robot designed to take welding to the next level.

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ITH the demand far exceeding the supply of skilled welders in the market, smarter solutions where welding processes can be automated are needed. In the 2021 October edition of Manufacturer’s Monthly, managing director of Lorch SouthPacific, David Wilton, had shared with us about bringing together the art of high-level welding and cobot technology. Here, he gets down to the nitty gritty.

Manufacturers’ Monthly (MM): Cobots are great for replacing standard welding tasks. Where and how much of the human element is still a factor in the entire welding process, and why?

David: Let me break this down into a few parts. Any Automation is great for welding large amounts of repetitive parts, in the sense of never taking a break and working around the clock. Whether it be cobot, industrial robot or fixed automation, will achieve this. The fundamental difference with a cobot is its simplicity, speed of setup, flexibility to weld small batch quantities and ability to work in the general work environment closely with humans. So yes, a cobot can do large volumes of repetitive work, but also is highly flexible in performing very high-quality welding on a single part or small to medium batches of subassembly parts, like 20 to 40 parts.

Let’s be clear, no automated welding solution is going to take the place and skill of a highly trained, certified welding professional with the knowledge and experience for all welding applications. The problem is, we don’t have enough of these people – so why not use some of their skills in conjunction with cobot 36 MARCH 2022 Manufacturers’ Monthly

The Cobot can be used to offset the shortage in skilled labour.

technology? The best welders in a shop can still be welding, but they can also support a number of cobots to perform many of the mundane simple welding tasks. Taking this approach broadens our capabilities, drives productivity, improves welding quality and shop floor efficiencies.

Overall, makes the team stronger!

MM: How would a manufacturer or fabricator decide if a collaborative robot is right for the welding application?

David: Lorch Cobot Welding was released several years ago in Germany and now all across Europe, today growing at an exponential rate. Lorch Cobot Welding is new for Australia and New Zealand, but not for more progressive countries like Germany that have a very high

level of welding automation. Cobot welding has proven its place as a very good solution for small to medium enterprises that are looking for simplicity, flexibility, and a fast return on their investment (ROI).

In terms of welding, the purposebuilt, fully integrated Lorch cobot welding system has all the latest and most advanced “Masters of Speed” welding processes with hundreds of wire/gas and process combinations that are suitable for the vast majority of welding tasks in any position with solid, flux cored and metal cored wires on all types of materials including steel, stainless steel and aluminium. If it is not already standard, Lorch can develop specialised synergic lines with any wire/gas combinations if required.

MM: Could you share more about the ideal applications of using collaborative robots in a welding workspace and some advantages?

David: We have set up our Australian website at www.lorch.com.au, with testimonials and case studies featuring real customers that have invested in one or more cobots, where you can see the advantages that cobot welding can bring to the table.

MM: How do you save overall bottom-line costs in implementing an automated welding system, like the Lorch Cobot Welding System, on the factory floor? (e.g. manual worker redeployment, longer production hours for menial welding tasks) David: This is difficult – it really depends on the individual company manmonthly.com.au

Welding and the welding applications they are seeking to automate. I would add, cobots are not always the right choice; some applications will be more suited to an industrial robot if there is a highly repetitive production.

Our Lorch cobot partners are available for all enquiries and anyone who wants to see the Lorch cobot in action and then to look at their individual applications to really validate if cobots are the best choice and can deliver an acceptable ROI. Then, with our partners, codevelop suitable plans for finance, installation and training.

MM: In terms of ergonomics, how easy is it to deploy an automated welding system like the Lorch Cobot Welding system on the factory floor – sometimes there might be a need to move around machinery from time to time, especially in smaller businesses as they grow in size?

David: The cobot itself only weighs 30kg. Normally you would mount

David: With the Lorch Cobot system, the cobot is an Australian delivered Universal Robot (UR) that is warranted and fully supported in Australia. The welding system made

by Lorch in Germany has a 3-year warranty and is fully supported with trained and accredited service locations across Australia and New Zealand. Also, spare parts are stocked in volume in Australia and shipped anywhere in the South Pacific within 24 hours.

Lorch’s type of welding automation leaves the welder in full control.

the cobot on a suitable steel tool table that allows for simple jigs and fixtures. The table can be on wheels, highly manoeuvrable around a shop, while others will prefer a system more permanent, and the work can come to the cobot. This way, it is a bit easier to manage fume extraction.

MM: For large industrial scale robots, maintenance can be difficult with downtime taking weeks due to the availability of parts. What is the maintenance of cobots like and what kind of after care service can customers expect with Lorch and its Cobot Welding System?

MM: Despite being easy to use, there needs to be a certain level of training involved with automated welding. How much training does Lorch provide for its customers with the Lorch Cobot Welding system?

David: When a system is purchased, part of the cost includes full installation and training program over two days. Additional training is available if needed, but two days is really all you need – the rest is practice.

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The region’s largest international civil and defence maritime exposition, incorporating the Royal Australian Navy’s Sea Power Conference and the International Maritime Conference.

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manmonthly.com.au

Manufacturers’ Monthly MARCH 2022 37

Manufacturing Events Workplace Health and Safety Show returns in 2022 The only workplace health and safety show in Australasia is back in Melbourne to present safety professionals with a range of offerings where they can compare, buy and stay updated on the latest products and policies to keep their workplace safe.

Industry experts will gather to exhibit the latest safety innovations.

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FTER two years of frustrating COVID19 postponements, the manufacturing industry’s one-stop safety event is preparing to make up for lost time.

The two-day event from Wednesday 25- Thursday 26 May at the Melbourne Convention & Exhibition Centre offers free activities including live demonstrations, seminars, and round table discussions.

Marie Kinsella, CEO of International Exhibition & Conference Group, says the show was born out of a need for a more interactive business-to-business exhibition.

“It’s a place where all types of businesses and industry can come and learn about the latest

38 MARCH 2022 Manufacturers’ Monthly

in workplace health and safety,” she said. “We decided to offer a triple program with a major focus on education. The event runs concurrently with the Australian Institute of Health and Safety’s National Convention, where leaders in workplace safety talk about practices from around the world and introduce Australian businesses to the latest innovations in a whole range of safety areas.”

With Australian safety regulations seldom stagnant, technological advancements can help businesses comply with the latest rules. COVID-19 has pushed more manufacturers into automation, which requires different safety approaches in itself.

“Manufacturers are our major audience who attend the show,”

Kinsella said. “Safety technology is a big trend and there’s a lot of innovation in this space whether it’s wearable technologies or automation. The technologies are so varied across different sectors, but the innovations are effective in keeping workplaces safe.”

The event is free to attend, with a spotlight stage where companies demonstrate the latest products and services, in particular technologies in workplace safety. The focus is on it being a hands-on experience, with participants encouraged to choose from a whole range of discussions.

The spotlight stage’s first presentation on Wednesday 25 May will look at the challenges that businesses face when considering moving to safety software technology and the potential gains to be had

from the move. Later that morning, the group will hear about the missing links in creating wellbeing programs for employees. Over the two days, there will be many discussions covering a range of safety topics.

“Having the most experienced speakers share their knowledge about the full spectrum of safety is key to the success of the event,” Kinsella said. “There’s a number of levels of opportunity available; The first is coming to the trade fair, which is free to attend once you’ve registered online. Participants can pinpoint one or many of the free educational sessions on the show floor, which run for around 45 minutes. This supports discussions on the Spotlight Stage and learning sessions in the Knowledge Centre.” manmonthly.com.au

ManufacturingEvents Shifting to mental wellbeing COVID-19 has thrown up a multitude of challenges for the manufacturing industry, but it’s also changed our individual daily routines, financial security, and social activities. Mental health is always important, but Kinsella said more workplaces are taking the right steps to ensure the wellbeing of their workers.

“There’s a lot of new companies in this space who will be showcasing at our event,” she says. “There’s a real need to regularly check in and encourage open communication with employees if they’re struggling.”

Surveys are being introduced to more workplaces to simply gauge moods and anxiety levels. Developing on this, programs now exist to engage with workers who are feeling overwhelmed, sad, or anxious to encourage and present options to seek further health advice outside of work.

“I’ve been involved in workplace safety trade shows for over 20 years,” Kinsella said. “Within that time, the composition of safety events has

changed drastically. We are not only meeting about protective equipment and clothing anymore, there’s a wide spectrum of safety issues. Wellbeing is at the forefront of those, especially with the impact of COVID-19.”

A number of seminar streams are available to participants, including in the mental wellbeing space.

Knowledge centre seminars Brain chemistry: impact on health, safety, mental wellbeing and performance Greg McLoughlin, managing director, Health by Design, will examine how neurotransmitters and neural pathways impact health, safety choices, mental wellbeing, and performance in all aspects of our lives. The seminar will also examine COVID impacts such as ‘work from home’ and look at profiles that are better suited or less suited to working from home.

Do you know your OHS duties?

Cameron Hannebery, Special Counsel,

Lander & Rogers, will refresh knowledge of the Occupational Health and Safety Act 2004 (Vic), covering duties of employers, workplace managers and workers.

MSD risk analysis: a data driven approach David Bick, director of professional services, Joint Action Solutions, will explain how Physical and psychosocial factors contribute to musculoskeletal disorder (MSD) risks. The seminar will cover how to identify them with a ‘consequence score’ and make data-driven decisions to reduce the highest risks first with the least expenditure. It explains how task analysis can help you achieve compliance, keep your workers safe and your productivity high.

Practical guide to preventing workrelated back pain Mark Alexander, BPhty (Hons) MPhty (Sports) MBA will host the session so that businesses can understand

why their employees may suffer from work-related back pain and give practical strategies to prevent and manage the problem.

Psychosocial risk from the perspective of lived experience Stephanie Thompson, workplace health lead, Wayahead explores some unique risks for people who have lived experience of mental distress and mental illness and what accessibility in the workplace looks like.

Marie Kinsella says her team has done everything to ensure any attendees get the most out of the two-day experience. As organisations continue to look to boost productivity and profits, it’s essential safety isn’t left behind.

“It’s a cultural shift,” she said.

“It starts from the top and has to be reinforced from the boardroom level right to the shop floor.”

For more information, or to register online for the event, visit whsshow.com.au

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Manufacturers’ Monthly MARCH 2022 39

Modern Design

Materials Handling Boosting efficiency with Combilift Irish manufacturer Multihog has made its operations safer, quicker, and easier after implementing the Combilift Aisle Master Order Picker.

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OMBILIFT is not the only Irish manufacturer to enjoy success around the world with its engineering expertise and innovative products.

Around 30 miles away from its HQ in Monaghan, Dundalk-based Multihog designs and builds its range of multi-purpose vehicles which it supplies to global customers including contractors, airports and municipalities. Established 14 years ago, the company has enjoyed growing customer numbers thanks to its concept of one base vehicle that can be fitted with a wide array of attachments – front and rear – to carry out multiple tasks all year round, such as sweeping, snow clearing, grass mowing and pothole repair.

Multihog had been using an electric Aisle Master articulated forklift for four years to move pallets

of components from its warehousing area to the production facility. Due to expansion – yearly units number 350 and are still growing – the company was looking for a second truck to cope with the increased volume of goods handled. “Narrow aisle capability was one of the main initial reasons for choosing the Aisle Master, to make the most of the storage space we have available,” said Dallan McHugh, head of procurement and supply at Multihog.

“When we got in touch with Combilift about the second truck, we found out that they had just launched a new version of the Aisle Master in the form of an Order Picker – the AME-OP. When we had a closer look at this it was obvious that this would be the perfect fit for Multihog.”

The AME-OP is a stand-on electric powered model that combines the advantages of a narrow aisle

Its narrow aisle capability was a key reason why Multihog chose Combilift’s Aisle Master Order Picker.

40 MARCH 2022 Manufacturers’ Monthly

The AME-OP is a stand-on electric powered model that combines the advantages of a narrow aisle articulated forklift and an Order Picker for versatile operation. articulated forklift and an Order Picker for versatile operation. A main feature is the step-through operator compartment with a low floor height of just 280mm. This enables convenient single step access from both sides of the truck which speeds up order picking compared to the operator having to get in and out from a seated position.

It is available in a number of variants, with lift capacities from 1500kg to 2500kg, lift heights of

up to 12.1m, and can operate in aisles as narrow as 1650mm. The multifunctional programmable joystick control lever in the operator compartment, which includes controls for the hydraulics and traction, is adjustable to enable comfortable and ergonomic working conditions for operators of all sizes.

“It wasn’t until the truck was on site and operational that we realised how much we actually needed it,” McHugh said.

“The number of parts that need to be picked per kit can be 20 or 30 each, so with a conventional truck that means operators are climbing in and out of the cab 20 or 30 times – and that’s a pretty time-consuming process. By contrast, stepping off and on the Order Picker from the low step on either side is easier, quicker, and safer. Operators in the stores also found the transition from the original Aisle Master to the Order Picker very easy, and they were fully up to speed with the controls within just one or two hours. And when it’s not being used for order picking it has all the key advantages of our original Aisle Master such as indoor and outdoor operation for loading and offloading, and for stock replenishment at other times. So, it’s versatile – just like Multihog’s products.”

For more information on Combilift’s range of products, visit combilift.com For more information on Multihog, visit www.multihog.com manmonthly.com.au

Servo Drives Enhancing production with servo drive repairs Bob Crosse, the owner of RJ Crosse Steel Frame Constructions – a steel wall frame and truss manufacturer based in Victoria – tells Manufacturers’ Monthly how he found the right partner to repair the servo drives in his CNC machines.

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HAT do you do when a critical servo drive stops working and the original manufacturer only wants to sell you a brand new one, as your model is “no longer supported?”

That is the problem that faced Bob Crosse. Primarily manufacturing steel trusses and wall frames, he was experiencing an upsurge in demand. This was due to timber being in short supply across Australia and a surge in the house construction industry.

Based in rural Victoria, Crosse’s factory in Barnawartha has been operating for more than 15 years.

To improve his production, a CNC router using Okuma servo drives was brought into action. The models were an older VAC3 type; he had two D6s and a single D11. However these servo drives were no longer working properly – and this was having an impact on production.

“I first tried a number of electricians,” Crosse said.

“With no luck, I then sent it out to another mob and it came back even worse.” His next

DataFactory provided Crosse with a quote, expected timeline and advice on how to improve the protection of his CNC machines.

steps were to Okuma in Japan.

“They were really not interested in repairing or having anything to do with these older models,” Crosse was told. “They essentially only wanted to sell me the new models and that

Bob Crosse integrated a CNC router using older Okuma servo drives into his production cycle.

manmonthly.com.au

was just not economical in any way.”

After an evening on the internet, Crosse found Darius Kowalewski at the DataFactory in Nunawading.

“After a brief phone call,” Crosse continued. “I was impressed with Darius’ knowledge and felt confident that he could help.”

Sure enough, Kowalewski provided a comprehensive quote and expected timeline. These were all met, including advice on how to improve the protection of Crosse’s CNC machines as these utilised standalone motor generators, not from the power grid.

“I can certainly recommend DataFactory,” Crosse said.

“They helped us when it seemed no one else could.”

DataFactory is a highly qualified electrical engineering workshop, capable of repairing and re-building the most complex servo drives and circuit boards. They are time conscious and deliver their services on a national level. With more than

30 years of experience in this highly technical area, Darius Kowalewski is a professional electrical engineer with degrees in Power Electronics and Digital Communication Protocols.

Kowalewski has extensive knowledge of servo drives and complex control systems, many of which have been manufactured some years ago. He is fully equipped to test and repair a wide range of electrical equipment, even the re-building of the most complex servo drive units.

Generally, a first phone call will help to establish the essence of the problem and the quality and reliability of their work is testimonial of their many long term clients. Kowalewski understands the cost and time issues and as in many cases, a machine’s down time must be reduced as quickly as possible. Often the replacement parts are far more expensive than a DataFactory repair.

Manufacturers’ Monthly MARCH 2022 41

Drive Systems Final drives at a tailored price One of CRAMS key offerings – the O&K final drive system – is helping businesses ramp up production at a reduced price.

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COTT Johnstone has been with CRAM for more than five years, joining the company as its first mining employee when it opened a mining division half a decade back.

Scott oversees the provision of undercarriage components in WA – including final drive systems for excavators and other undercarriage components for drill and blast oil rigs.

CRAM has since been incorporated into Motion Australia’s group of businesses. Scott says one of the big benefits of this has been scale. “Since joining Motion Australia, we’ve had the ability to place larger orders, which means a greater ability to get stock out to our clients,” Scott says.

“That scale means greater flexibility.

We’re able to get larger items and larger volumes of stock.”

A key offering of CRAM’s is the O&K final drive system.

“O&K – originally a German brand, and still manufactured in Germany, although now owned by Bonfiglioli – is a renowned name in final drive systems,” he notes. “And CRAM has had the agency to sell O&K drives for more than 15 years – so we’ve been doing it a long time.”

Scott says that the primary benefit of opting for O&K is that it offers equal benefits to users at a reduced price.

“At the end of the day, we have an identical replacement final drive system,” he says. “So, it comes down to price and reliability. A customer should expect to get 25,000 hours – roughly three years – out of a final drive. They’re built to last a long time. But every mine site is different, and every mine site has different tramming policies and different transport methods on their site. Some sites will have low loaders – or trailers – to move their excavators, meaning they’ll last longer. Other sites don’t have that option, and so their excavators will have to tram between pits, which will increase the frequency of service intervals”.

42 MARCH 2022 Manufacturers’ Monthly

CRAM has had agency to sell O&K drives for more than 15 years.

Will Rogers, National Product Manager for CRAM Fluid Power, agrees with Scott that each mining site needs to be assessed on a case-by-case basis to ensure that our customers achieve their goals of a lowest cost per hour operation through various component programs that CRAM can offer.

“At CRAM we have a reasonable level of flexibility, though,” Will says.

“We can tailor the proposal to give the end user an equal fit component at a commercially competitive price.

We are also able to offer competitive advantages – if a particular site is interested in looking at a supply agreement – or can provide us with usage forecasting so we can plan the drive systems coming in, because that limits the effects on our local stock from fluctuations in demand.”

Will explains some of the final drive systems that CRAM offers for large mining class excavators.

F620 Final Drive “The F620 Final Drive is used on 296 tonne excavators,” Will says. “We don’t

currently stock this final drive incountry, although we do source them from the factory as needed. There is a limited install base for this machine in Australia, although there is still a few operating here and in Papua New Guinea. The typical lead time when ordering through CRAM would be four to five months’ production plus six to eight weeks’ shipping.”

F800 Final Drive “The F800 Final Drive is used on 407 tonne excavators,” he says. “The machines that utilise these systems are quite popular – there are plenty of these kicking around – so we actively stock the F800 in Australia.

We also offer component exchange programs for the F800 drives.”

F1100 Final Drive “The F1100 is for 537 tonne excavators. In Australia, there is a limited install base for this machine, so we don’t stock F1100s in Australia, although again we will source them from the factory for companies as needed.”

F1300 Final Drive “This drive system is used on 599 tonne excavators,” Will says. “Such machines are very popular in Australia and there are plenty of them operational in Australia.”

“Most sites will aspire to get 30,000 hours out of their final drives,” Will says. “There are different strategies that they will use to try and achieve this. Some sites will just take a chance and run them to destruction, while others will try and remove the final drive at between 15,000 and 20,000 hours to conduct a midlife rebuild to use it for a second turn. Although the second turn is never as long as the first.”

Ultimately, Will says, the strategy chosen will be dependent on the walking rates and machine utilisation of any one site.

“The typical time frame between final drive change-outs is every three to five years. CRAM offers opportunities to pick up the rebuilds as well as supplying new final drives.” manmonthly.com.au

Industrial Equipment Siemens SIRIUS ACT Push Buttons from APS Industrial APS Industrial, a locally owned and managed company formed by experienced leaders in the industry, tells Manufacturers’ Monthly about Siemens’ powerful SIRIUS ACT Push Buttons – the best choice for Australian industry.

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OWERFUL machines and plants need powerful push buttons, switches, and indicators: SIRIUS ACT offers you a unique portfolio of elegantly designed push buttons, indicator lights and switches that are the perfect embodiment of style, intelligence, and physical toughness.

Constructed with genuine metal and high-grade plastics, and engineered with smart functions and communication capabilities, these new push buttons, indicator lights and switches have been tested for the most extreme environments to ensure reliability for your most critical operations. With various intelligent features, Siemens SIRIUS ACT Push Buttons are the choice for Australian industry.

Easy to use Easy handling also means easy

installation. An innovative snap-on concept makes the task of installing a unit so effortless that it can be done with one hand. And because everything is so simple, SIRIUS ACT further reduces the risk of incorrect installation.

Extremely rugged Push button functionality is preserved even when dust or water is involved under high pressure. Even oils, caustic solutions and extreme environmental influences cannot disrupt reliable operation. Thus, SIRIUS ACT is the perfect solution for a host of applications.

Flexible communication The various communication interfacing options provided

by SIRIUS ACT enable simple combinations of push buttons and signalling devices, HMI touch screens

and industrial PCs, which means that complex input stations can be set up without extensive wiring and engineering time and effort.

Integration into the TIA Portal enables them to be visually displayed for better harmonisation with the hardware, thus simplifying and speeding up hardware configuration.

Further advantages are uniform data management (intelligent system), time savings thanks to intuitive hardware configuration and lower downtimes resulting from faster fault diagnostics. The option handling feature enables flexible systems to be designed and individually adapted – even during ongoing operation.

Modern design The flat, round metal and plastic elements combine unparalleled functionality with a timelessly

aesthetic look. The new SIRIUS ACT push buttons and signalling devices offer the right answer for every application, taste, and budget.

With Siemens push buttons, switches and signalling devices you opt for a completely different system design: choose from four design lines and diverse options for combining.

In partnering with the world’s leading technology companies, APS Industrial offers Australian customers the broadest portfolio of industrial low and medium voltage electrical and automation products within the region. Central to this is APS Industrial’s exclusive master distribution agreement with Siemens.

As the master distribution partner for Siemens in Australia, APS Industrial are proud to bring the full range of SIRIUS ACT push buttons and signalling devices to the local industry.

Siemens’ SIRIUS ACT range have been tested in the most extreme environments to ensure reliability in critical operations.

manmonthly.com.au

Manufacturers’ Monthly MARCH 2022 43

MARITIME & DEFENCE MANUFACTURING For the first time since 2019, the INDO PACIFIC 2022 International Maritime Exposition will bring together Australian and International industry, government, defence and academia to explore the sector’s biggest issues, innovations and technologies.

In May 2022 – as the official media partner of the event – we will showcase businesses in the defence and maritime manufacturing space.

In every edition of Manufacturers’ Monthly, we’re proud to work with our commercial partners on content that helps connect you with your future customers.

Booking deadline: 30 MARCH 2022

To book contact DANNY HERNANDEZ now danny.hernandez@primecreative.com.au | 0431 330 232

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What’sNew

Qorvo’s CMD328K3 Low-Noise Amplifier for X-Band and Ku-Band Satellite Comms Mouser Electronics Inc, the industry’s leading New Product Introduction (NPI) distributor with the widest selection of semiconductors and electronic components, is now stocking the CMD328K3 6 GHz – 18 GHz low-noise amplifier (LNA) from Qorvo. The device is ideally suited for electronic defense and communications systems where small size and low power consumption are needed.

The Qorvo CMD328K3, available from Mouser Electronics, is a broadband MMIC LNA that operates between 6 GHz and 18 GHz with a noise figure of just 1.4 dB. The CMD328K3 amplifier delivers greater than 27 dB of gain with a corresponding output 1 dB compression point of +12 dBm. The broadband device is a 50-ohm matched design, which eliminates the need for external DC blocks and RF port matching.

Housed in a leadless 3 mm × 3 mm plastic surface-mount air cavity package, the CMD328K3 amplifier is an ideal alternative to hybrid amplifiers. Applications for the CMD328K3 LNA include X-band and Ku-band radar, satellite communications, and electronic defense receivers.

As a global authorised distributor, Mouser offers the world’s widest selection of the newest semiconductors and electronic components — in stock and ready to ship. Mouser’s customers can expect 100 per cent certified, genuine products that are fully traceable from each of its manufacturer partners.

Company: Mouser Electronics Phone: (852) 3756 4700 Website: www.mouser.com/new/qorvo

Innodisk’s InnoAGE 2.5” SATA SSD 3TI7 Industrial Grade SSD Backplane Systems Technology is proud to present Innodisk’s InnoAGE 2.5” SATA SSD 3TI7 Industrial Grade SSD. The InnoAGE SSD comes with a Microsoft Azure Sphere inside and is further integrated with Innodisk’s customised firmware, software and hardware technology.

This new solution enables multifunctional management: smart data analysis and updates, data security, and remote control through the cloud, while benefitting from the power of the Azure Sphere to guarantee secured communications between the SSD and the cloud.

The InnoAGE SSD delivers an easy-to-use interface with its customised cloud management platform. In technical terms, the Innodisk-developed firmware receives commands from the Azure Sphere via a second connection to Azure. Therefore, it can execute SSD debugging messages as well as monitor read/write behaviour patterns to increase the storage device’s lifespan. Most importantly, system operators can quickly revert to the default settings from the cloud-based dashboard in the case of a device or system crash.

Hence, the InnoAGE Industrial Grade SSD is designed for both in-band and out-of-band network management, providing full recovery even when the operating system has crashed or is severely impaired to the extent that in-band management would be of little help.

Key features: • The world’s first Hybrid SSD with an Azure Sphere inside • Encripted end-to-end security from edge to cloud • Hardware level allows easy and simple development • Supports out-of-band network management and diverse platforms • Supports wireless 2.4/5GHz Dual-Band 802.11 a/b/g/n Wi-Fi • Supports ethernet.

Company: Backplane Systems Technology Phone: (02) 9457 6400 Website: www.backplane.com.au

manmonthly.com.au

Manufacturers’ Monthly MARCH 2022 45

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ATDC’s heavy duty RS3 commercial roller shutter The Australian Trellis Door Co. (ATDC) has recently installed its heavy duty extruded RS3 commercial roller shutter at Toymate’s new store at Watergardens Shopping Centre at Taylors Lake, a suburb north west of Melbourne.

Finished in a striking bright Blaze Blue powder coat from the standard dulux duralloy powder coat range, these electric operated shutters each spanned a width of 4m wide x 3m high.

The installation required battery back-up facilities to prevent any down time in trading in the event of a future power failure in the shopping centre.

Extra security was provided by the installation of key switches which restricts the number of persons able to operate the shutters.

Project manager for the installation was Red Box Displays.

Company: The Australian Trellis Door Co. Phone: 1800 657 435 Website: www.trellisdoors.com.au/products/commercial-security/roller-shutters

Compressed air for laser cutting industry Chicago Pneumatic are proud to introduce the new 16 bar compressor for the laser cutting industry. Our brand-new cut through technology, so you can cut through the competition.

Laser cutting, one of the thermal cutting methods, is to use the focused high power and high-density laser beam to irradiate the workpiece, so that the material at the irradiated place will melt, vaporise, or blown away.

From many practices, the main factors affecting the metal laser cutting thickness and cutting efficiency are the power of the laser cutting machine, the type of auxiliary gas, the pressure, and the flow rate of auxiliary gas.

Air compressors, as the auxiliary gas provider, plays a critical role in laser cutting.

When choosing air compressors for laser cutting machines, those factors should be considered comprehensively.

The quality of compressed air has a very direct impact on the quality of laser cutting. The compressed air contains water mist and oil. If not cleaned high-pressure

jet to the protective mirror of the laser cutting head will seriously affect the transmission of the laser beam, disperse the focus, and cause the product to be cut incompletely and produce waste products.

Therefore, the air compressor must be equipped with a good dryer to remove the moisture in the compressed air as much as possible, and the high-precision filters must be installed after the dryer to fully filter oil and dust particles.

Also, once the compressed air is dried, the temperature returns to normal, which can effectively avoid condensation. Such high-quality compressed air can sustain the long-term stable operation of laser cutting machines.

With the development of laser cutting machines from small power to high power, the pressure requirement of the air compressor supporting the laser cutting has also increased from the initial 8 bar to 13 bar in the past two years, and now to 16 bar.

Higher air pressure brings better cutting quality and higher cutting efficiency.

How can we help you?

With high outlet pressure we ensure • Cutting speed and thickness; • Blow away metal debris; and • High efficiency in cutting.

With stable free air delivery, we can ensure the quality of the surface (smooth like a mirror) and with less water and oil in the air, we can ensure the lifetime of the laser heads.

Key features: • 16bar outlet pressure; • Dew Point Controlled Dry Air; • High Efficiency Coalescence Filtration; and • Activated Carbon filter for clean oil less Air. Company: Chicago Pneumatic Compressors Phone: 1300 555 284 Website: www.cpcompressors.com.au

46 MARCH 2022 Manufacturers’ Monthly

manmonthly.com.au

The Last Word

INNES WILLOX – Chief Executive of the national employer association, Ai Group

What are Australian CEOs expecting from 2022?

A

FTER two years of dealing with the unexpected and ever-changing challenges presented by the global pandemic, on balance Australia’s business leaders are cautiously hopeful that 2022 will be a year of improved business conditions, moderate growth, and further employment creation.

That’s what Ai Group’s annual survey of CEO expectations and plans for 2022 has told us. There is, as always, a wide range of views among CEOs about how the year ahead might pan out and 2022 is certainly not looking any easier to predict than is usually the case.

It is clear from the survey responses that business leaders are expecting their organisations to face fresh disruptions from COVID-19 in 2022 – 79% of CEOs are anticipating further disruption from COVID-19, with almost half of respondents ranking the pandemic as the leading inhibitor to growth in 2022.

Businesses are moving to a ‘living with COVID’ footing after two years during which, as a nation, we bought time by insulating and then vaccinating ourselves. Just as there was no playbook for the initial two years, we will again be learning on the run during this new phase.

Business leaders expect to face additional supply chain interruptions and challenges – only 17% expect improvements to supply chain impacts relative to 2021 and a further 31% anticipate no change from the turmoil of 2021.

Skills shortages ranked as the third most commonly nominated inhibitor of business growth in 2022 with almost three quarters (73%) of business leaders anticipating difficulties in finding and retaining skilled staff over the course of 2022.

Input cost pressures experienced in 2021 are tipped to continue with 79% anticipating further cost pressures and only 1% of CEOs expecting input prices to abate in 2022. As we discuss in our report, expectations of being able to pass manmonthly.com.au

some of these higher costs on to customers puts business leaders at odds with the relatively benign inflation outlook anticipated by the official economic agencies.

Our report indicates that CEOs have firm expectations about further input price pressures and about their selling prices over the year ahead. In contrast, the RBA is expecting the Consumer Price Index (CPI) to moderate to an annual rate of 2.25% in 2022 from its expected rate of 3.25% in calendar 2021. With inflation outcomes and inflationary expectations key factors in the ability of the authorities to maintain accommodative monetary policy settings, this is a critical point of difference and will be keenly watched over coming months.

Despite the challenges foreseen in 2022, there is a sense of measured hopefulness about the year ahead: • Compared with their experiences in 2021, distinctly more business leaders are expecting improved business conditions in the year ahead than are anticipating an erosion of business conditions.

• The proportion of CEOs expecting an increase in their turnover

(57%) is almost three times higher than the proportion anticipating a drop in their turnover (20%) in the coming year.

• The proportion of business leaders expecting to increase their workforce is more than two and a half times larger than the share expecting employee numbers to fall in the year ahead.

This cautious hopefulness comes despite the seriousness of the disruptions anticipated to characterise 2022, and the prospect of an impending federal election and the policy uncertainties it will bring.

This is a vote of confidence in the strategies and investment priorities business leaders anticipate deploying. Our report identifies that CEOs are particularly focused on five interrelated areas: • Addressing supply chain disruptions by changes in inventory practices and supply arrangements; • Introducing new products and services; • Ameliorating skill shortages by investing in staff training and development; • Continuing to introduce new

technologies – with a particular focus on information and communication technologies; and, • Raising investments in physical capital.

Business leaders are deploying these strategies to fortify their businesses in the face of current and anticipated near-term challenges but also with an eye to the importance of laying some of the foundations for more substantial gains over the longer-term.

As we suggest in our report, these strategies and investment priorities are critical to our success as a country in transitioning to living with COVID and they are also positive directions for our nation’s successes in the longer-term.

However, in view of the magnitude of the longer-term challenges – in particular, the well-entrenched deficiencies in productivity growth and business investment – it is clear that much needs to be done. In a federal election year, it is timely to point to the importance that our political leaders give these underlying challenges the attention they deserve.

More business leaders are expecting improved business conditions in the year ahead.

Manufacturers’ Monthly MARCH 2022 47

INTRODUCING THE NEW CAPS GENERATOR RANGE! CAPS is excited to launch its brand new range of generators to the market, complementing our existing range of AIRMAN and KOHLER generators.

CAPS wanted to be able to offer our own range of generators, that through our 41 years of experience has allowed us to specify. A range with the right quality, the right features and that are more than up to the challenges of the Australian conditions. We have partnered with one of the world’s leading European manufacturers of power generators to bring to you our new range suitable for both prime or back-up power. Highly specified and a competitive price.

POWER GENERATORS (PRIME OR BACKUP) CAPS will be initially offering generator sizes of 9kVA right through to 794kVA. CAPS generators featuring world class componentry and the brands you know and trust such as; Perkins engines, Leroy Somer alternators, Deepsea controllers and many more.

They all come with high quality super-quiet acoustic enclosures, double-wall bunded fuel tanks and a myriad of safety features such as Earth leakage, electric fuel level sensor, low fuel alarm, fuel gauge, battery isolator, rain cap, lifting points and emergency stop button.

IN STOCK AND AVAILABLE NOW

AUTOMATIC TRANSFER SWITCHES

For a complete backup solution, you will need to add an Automatic Transfer Switch. This facilitates management between your generator supply and mains supply to automatically start and stop the generator when power is lost or restored. All CAPS standby power generators can be equipped with Verso automatic transfer switches in the range of 35A – 630A

At CAPS, we’re the experts in the supply and installation of industrial diesel generators in Australia. Whatever your power industrial generator needs are, we’ll make it happen.

CALL 1800 800 878 OR VISIT CAPS.COM.AU Manufacturing Monthly March 2022.indd 1

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