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MAY 2021

INTRODUCING THE NEW

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INTRODUCING THE NEW

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Inside

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Manufacturers’ Monthly Contents 6

Editor’s Note

26 Manufacturing Strategies

37 Metalworking

Comment

28 Compressors

39 Endeavour Awards

10 News@MM

30 Metal Cutting

40 What’s New

20 Industry Focus

32 Sensors

42 The Last Word

24 Welding

36 Manufacturing Innovation

Copyright 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

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manmonthly.com.au INTRODUCING THE NEW

If you’re a business owner, there is a need to understand the risks that come with running a manufacturing business. In keeping team members safe, there needs to be an understanding what these risks there are and how they can pose a threat to them and what measures should be in place to mitigate them. In the industrial sector, it’s important to spend time researching, self-educating and reading up about the risks that your team faces daily so that you are able to keep the risk of accidents and injuries as low as possible. As we have explored in past issues of Manufacturers’ Monthly with

workplace accidents and injuries, is that in order to be able to mitigate risk, there needs to be an acute understanding and assessment of what these risks are. Taking the time to learn as much about The smart way to your business’s monitor process and systems is your equipment Efficient of time, Reliable and how definitely not a waste Flexible Clear you can significantly reduce the chance of any serious accidents taking place. Nothing is more important than health and safety in manufacturing. It’s vital that businesses take health and safety seriously from the moment when you first launch your business in order to reduce the risk of any serious safety issues that might lead to accidents and injuries. n

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4 MAY 2021 Manufacturers’ Monthly

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Comment

SYED SHAH – Managing Editor, Manufacturers’ Monthly

From the manufacturers’ standpoint

BOUT a year back, just when the world was beginning to come to terms with the impact of COVID-19, there had been talk for years about the opportunity that Australia, and the world, faces when it comes to the introduction of robotics and automation – and it is not one that is often understated. According to the Digital Innovation report, prepared for CSIRO’s Data61, in Australia alone, there is the potential to unlock $315 billion dollars of value over the next decade through the application of digital technologies. Jobs in aged care, education, health, and financial services have the potential to be radically transformed with digital technology. However, despite the economic potential, whether in improvements to productivity or cost savings, is measured in the billions, there are the perceived “negative” side effects which are layoffs, shortened hours, and reduced job satisfaction

6 MAY 2021 Manufacturers’ Monthly

– there is truth but not the whole truth in that. Since the first robot was introduced in Trenton, New Jersey 50 years ago, when other industries raise their concerns of the replacement of humans with robots, they should perhaps talk to a local manufacturer and listen to their story. Although the number of people employed by manufacturing businesses in Australia has fallen since the late 1980s, the past two years have seen an increase, just as manufacturing enters Industry 4.0, its next phase of technological innovation. Even after the pandemic hit, this looked to be the direction we are heading in, still. The workforce of Australia needs to grow its value through upskilling and the products they produce. This is because there is no simple binary of human robot replacement. When manufacturers adopt new technologies, they need a smarter workforce to power and control

those new technologies. This in turn spurs greater employment as dirty, dull, and dangerous tasks are automated, allowing people to take on higher value work. Australia has already been warming up to Industry 4.0 technologies thanks to the hard lobbying by industry associations like the AMGC, IMCRC and Weld Australia. They have been brutally honest with the state of manufacturing in the country and where we are at the moment, but at the same time have devoted endless energy into getting local manufacturing onboard. Despite the best efforts, the COVID-19 pandemic hit and economically, many areas of the country were affected, including manufacturing but that proved to be the silver lining. Companies took the effort to pivot. To understand what pivoting is, it means to shift to a new strategy, but in drastic times it could mean changing the

business direction of the whole company. Despite this, usually, companies have a few issues that needs addressing and requires certain aspects to be changed to remain profitable. The significant examples of successful pivoting in manufacturing include businesses like packaging manufacturer Detmold shifted their business strategy to produce PPEs. This set the scene for many other businesses to follow their act. However, pivoting in a business is not without its challenges. In this issue of Manufacturers’ Monthly, we speak to D&M Auto Industrial Spray Painting and Micro Precision Plastics who navigated through different turbulent periods in manufacturing in Australia – one during the departure of automotive passenger vehicle manufacturing in Australia and the other, the difficulty in getting an approved PPE despite passing all the safety protocols in the manufacture.

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Comment

GEOFF CRITTENDEN – CEO, Weld Australia

Manufacturing should lead COVID-19 recovery

USTRALIA’S jobs-driven COVID-19 recovery must be manufacturing led. Mandating compliance to Australian Standards – whether steel is fabricated in Australia or overseas – is the perfect first step to securing the future of the Australian welding and manufacturing industries. Given a level playing field, Australian welding is internationally price competitive, and of the highest quality. Without regulations that mandate compliance to Australian Standards for the manufacture, fabrication and erection of steel,

procurement decisions will continue to focus on the lowest common denominator: cost. Now more than ever, it is vital that action is taken to secure the future of Australia’s welding and manufacturing industries. Recent trade tensions with China illustrate just how important this is to our economy. Over the last 12 months, China has imposed trade strikes on half-a-dozen key industries including coal, wood, wine and seafood. Yet, China is still taking every opportunity to export their products to Australia, including fabricated

steel. Quite rightly, the federal government has not imposed reciprocal tariffs on China. With China’s capacity to inflict economic pain on us much greater than our own, reciprocal tariffs would likely do more harm than good. However, this situation can – and will – cost jobs in what is still quite a fragile industry. For instance, the jobs of 150 workers in regional south-west Victoria are under threat following the award of the wind turbine towers contract for the $360 million Ryan Corner wind farm to an overseas company.

Danish company Vestas has sent the contract for the manufacture of 52 wind towers offshore. This is despite the fact that Keppel Prince Engineering – the only manufacturer of wind turbines on mainland Australia – is located just 70km away from the project site. As a result, Keppel Prince will likely be forced to make 150 workers redundant. In a regional town with a population of just 10,000 people, the economic fall-out will be severe. The contract for the Ryan Corner wind farm comprises some 15,000 tonnes of steel. It is simply galling that a contract of this size has been

Quality assurance is guaranteed with local fabrication services.

8 MAY 2021 Manufacturers’ Monthly

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sent offshore. Local manufacturers like Keppel Prince cannot win jobs on their doorstep when multinational companies like Vestas place a premium on price over and above quality and safety. Nearly all locally manufactured steel used in Australian major projects is certified by the Australasian Certification Authority for Reinforcing and Structural Steels (ACRS). Local fabricators comply to internationally recognised Australian Standards and are certified by the relevant Australian authority. In this way, government and non-government clients can ensure the quality and safety of projects. Imported steelwork, which does not meet these requirements, is often of inferior quality and may not meet the Australian safety requirements. Weld Australia has been calling on the federal government for the last five years to mandate that all steelwork in Australia – both local and imported – is manufactured and erected according to Australian Standards. The federal government must act now to save jobs in regional areas and ensure public safety. The importance of our local manufacturing industry and the development of robust renewable energy sources cannot be underestimated when it comes to Australia’s post-COVID recovery. The federal government has asserted that job creation is vital to our economic recovery. And yet, it seems unwilling to protect existing jobs. Australia’s jobs-driven COVID-19 recovery must be manufacturing led. Overseas, investment in advanced manufacturing is prioritised by governments. Local industry and populations support manufacturing by buying locally made goods. As a result, manufacturing employs millions of people in overseas markets, contributing billions of dollars to their economies. Now is the time to make manufacturing a national manmonthly.com.au

Australian fabricators comply to internationally recognised Australian Standards and are certified by the relevant local authority.

priority. Government, at all levels, must support and invest in the manufacturing sector to aid its growth. Mandating compliance to Australian Standards is the logical first step. We are not suggesting the government impose tariffs on all imported fabricated steel. We are calling on both sides of government to amend the necessary regulations and mandate compliance to Australian Standards whether fabricated steel is manufactured in Australia or overseas. Given a level playing field, Australian welding is

internationally price competitive, and of the highest quality. Over the past three years, the number of Australian companies certified to ISO 3834 has grown exponentially, and the number of ISO 9606 qualified welders has grown in tandem. This growth has been largely driven by private clients (such as defence primes, and roads and transport authorities) specifying certification in tender documentation. While increased certification rates have substantially raised the quality of fabricated products

in Australia, it has come at a substantial cost, and it needs to be paid for. It is completely unreasonable for clients to buy cheap, uncertified products from offshore, and not support local fabrication. It appears that clients are still taking a very narrow view of project costs, allowing “cost to buy” to dominate the procurement process rather than whole of life costs. If this is the case, then they are not delivering value to their shareholders or tax-payers – merely concealing the true cost of the project. Manufacturers’ Monthly MAY 2021 9

News @MM Renewed support for Australian automotive R&D The federal government is driving the automotive sector forward by extending the automotive research and development tariff concession until 2025, keeping high-end research activities in Australia and supporting thousands of high-wage jobs. Minister for Industry, Science and Technology, Christian Porter, said vehicle research and development is vital to the nation’s prosperity with Australia being a significant competitor on the global stage. “By extending the automotive research and development tariff concession, the federal government is supporting the ongoing design and development of cars here at home and providing ongoing job opportunities for our highly-skilled workforce,” Porter said. “We’re supporting highly-skilled Australians such as engineers, designers, technical, automotive and other specialists to remain in these

important jobs. “It’s also evidence that while automotive manufacturing in Australia has changed over the past 10-15 years, we still have a healthy sector with well-paid jobs right along the value chain.” Ford Australia, which employs more than 2,500 staff, is a key beneficiary of the tariff concession, along with Toyota Motor Corporation Australia and Robert Bosch Australia. The tariff concession is demand driven and was worth more than $4 million on goods imported from 35 countries in 2018 and 2019. This extension significant investment in the automotive sector with programs such as the Automotive Transformation Scheme. “Extending the tariff concessions will also strengthen Australia’s engineering and design capability, which will have flow-on benefits to many other parts of the economy,

Vehicle research and development is vital to the nation’s prosperity with Australia being a significant competitor on the global stage. including manufacturing,” Porter said. “By retaining the tariff concession we’re also cutting red tape and reducing the administrative burden for businesses, making it easier

for them to remain competitive and contribute to Australia’s economic recovery.” The extension to the automotive research and development tariff concession is in effect.

Chilean-based manufacturer sets up shop in Cranbourne A Chilean-based international designer and manufacturer of mining equipment, Conymet Duratray, has chosen Cranbourne for its new manufacturing facility and global headquarters in a move that will create up to 100 new highlyskilled jobs. Minister for Economic Development Tim Pallas welcomed the decision by Conymet Duratray International to grow its current Victorian footprint by onshoring overseas manufacturing functions and establishing a new innovation division in West Cranbourne. “Conymet Duratray is relocating its global HQ to Victoria because of our highly skilled workforce, and our world-renowned capabilities in advanced manufacturing, innovation, and research and development,” Minister for Economic Development Tim Pallas said. “Attracting investment from companies such as Conymet 10 MAY 2021 Manufacturers’ Monthly

Conymet Duratray will also benefit from Victoria’s international logistics and distribution network to service its key export markets.

Duratray will help us grow highvalue jobs and boosts our economy.” “This is fantastic news for jobs and investment in the skilled workforce and we warmly welcome Conymet Duratray in calling West Cranbourne home,” Member for Cranbourne Pauline Richards said. The company intends to draw on Victoria’s highly skilled workforce and the state’s innovation, research and development capabilities, to

develop new specialties in the areas of mining data analytics, IoT, machine learning as well as advanced composite materials for its product line. Conymet Duratray will also benefit from Victoria’s international logistics and distribution network to service its key export markets, the state’s growing and dynamic mining equipment, technology and services sector.

“We’re excited to embark on this new innovation journey in Victoria. We’re committed to supporting Victoria to become the mining tech hub of Australia, given its strengths in the METS, advanced manufacturing and technology,” Marcelo Medel, managing director, Conymet Duratray International said. Founded in 1974, Conymet Duratray specialises in the design and manufacturing of mining truck trays, spare parts, steel and rubber components for haulage equipment for the mining industry. The company operates facilities in Australia, Chile, US, South Africa and Russia and currently exports to more than 35 countries across five continents. Currently, there are more than 2,000 Duratray mining truck trays operating globally, ranging in size from 36 to 360 tonnes for all major truck manufacturers. manmonthly.com.au

News @MM Federal Labor announced $15 billion manufacturing fund Federal Labor leader Anthony Albanese has pledged to establish a $15 billion manufacturing fund if Labor wins the next election. The fund would operate in a similar way to the Clean Energy Finance Corporation, where an independent board would make pick projects and make investment decisions. Manufacturing jobs currently account for 6.7 per cent of all jobs, compared to 17 per cent in the 1980s. Director of the University of Sydney’s Core Research Facilities, Professor Simon Ringer believes Australia should invest more heavily in advanced and additive manufacturing to broaden export capabilities. “It is promising to see significant, bi-partisan support in boosting Australia’s manufacturing sector,”

he said. As we emerge from the COVID-19 pandemic, it is vital Australia invests in industries like advanced manufacturing.” “Advanced manufacturing is a major scientific and technological

disruption with the potential to transform Australia’s export economy and increase our country’s industrial sovereignty and resilience. “We now have processes allowing us to make things we could not have

Manufacturing jobs currently account for 6.7 per cent of all jobs, compared to 17 per cent in the 1980s.

previously made, using new materials made from remarkable combinations of properties derived from raw materials mined here in Australia. “We have already witnessed a great economic turn-around from the depths we found ourselves in last year. To ensure our future prosperity and opportunities for Australians, now is the right time for our country to capture the opportunity that this disruption offers. “A flourishing 21st century manufacturing sector in Australia needs a talent pipeline of scientists and engineers who are experts in advanced manufacturing with niche world-leading knowledge, world-class facilities and powerful academic and industrial networks. The sector is ready to do some heavy lifting here, now it’s time for our leaders to help carry this vision forward.”

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Manufacturers’ Monthly MAY 2021 11

News @MM CSIRO’s dish to support one of the first commercial moon landings

Image credit: CSIRO

The Parkes radio telescope played a crucial role in receiving signals during the Apollo 11 Moon landing in 1969.

The iconic Parkes radio telescope, owned and operated by Australia’s national science agency, CSIRO, will provide ground station support for one of the first commercial lunar landings later this year. CSIRO has signed a new fiveyear agreement with Houston-based aerospace company Intuitive Machines to support multiple lunar missions, including their first flight under NASA’s Commercial Lunar Payload Services (CLPS) initiative. The Parkes telescope, also known as Murriyang, is valuable for spacecraft tracking due to its large dish surface and advanced data acquisition systems, which are used primarily for astronomy research. The 64-metre telescope will be the largest and most sensitive receiving ground station for Intuitive Machines’ upcoming missions, maximising the return of the scientific and engineering data for the lunar exploration program. CSIRO CEO Dr Larry Marshall 12 MAY 2021 Manufacturers’ Monthly

said the partnership was an exciting new chapter for the iconic Dish, with the partnership tapping into CSIRO’s expertise and proven track record supporting spacecraft programs. “It was 50 years ago that Australia played a critical role in the original Moon mission, but innovation never sleeps, so we’re proud to support the latest innovations heading to the Moon’s surface,”Dr Marshall said. “Australia is growing a vibrant space industry, underpinned by our unique strengths in agriculture, mining, and materials, and because we know innovation thrives on collaboration, we’re supporting the entire international space community.” CSIRO’s Acting Chief Scientist Dr Sarah Pearce said CSIRO was proud to have its world class scientific facilities be part of the global team that will help Intuitive Machines and NASA deliver science instruments to the Moon. “Along with NASA’s Honeysuckle

Creek station near Canberra, the Parkes radio telescope helped share the Apollo 11 Moon landing with more than 600 million people around the world. And now we are proud to support the first companies extending their reach to the Moon’s surface, advancing knowledge that can benefit life both on Earth and, one day, on the Moon,” Dr Pearce said. “Australia is growing a vibrant and respected space industry, underpinned by world-class national infrastructure and a long history in enabling space exploration. This is another example of Australian capability supporting the international space community.” Intuitive Machines will launch its Nova-C Moon lander on a SpaceX Falcon 9 rocket towards the end of 2021, delivering commercial cargo and five NASA experiments to investigate the local geography and test technology required for future human exploration. CLPS initiative companies are responsible for all aspects of

delivering their cargo to the Moon, including spacecraft tracking and communication. NASA urged CLPS providers to utilise ground station capabilities outside of NASA’s Deep Space Network, the ground station network supporting the Agency’s many interplanetary space missions. Intuitive Machines Vice President for Control Centers Dr Troy LeBlanc said being the first commercial company to land on the Moon is a huge communications challenge. “We require the technical support and expertise of the team at CSIRO’s Parkes radio telescope to provide mission tracking and data downlink services,” Dr LeBlanc said. “CSIRO’s Parkes telescope adds significant data downlink capability to Intuitive Machines’ robust Lunar Telemetry, Tracking and Command Network. “The successful use of the Network for these initial missions will underpin the return of humans to the Moon and ultimately sustainable presence under the Artemis program.” Director of CSIRO Astronomy and Space Science Dr Douglas Bock said the agreement with Intuitive Machines recognises CSIRO’s experience operating large, complex spacecraft tracking and radio astronomy infrastructure. “Our Parkes radio telescope began supporting space missions in 1962, when it tracked the first interplanetary space mission, Mariner 2, as it flew by the planet Venus,” Dr Bock said. “Most recently, the telescope received data from Voyager 2 as it entered interstellar space, supporting the Canberra Deep Space Communication Complex – which we also manage for NASA. “Operating as a ground station for space missions complements the astronomy research conducted with the telescope and helps to maintain its capabilities as a world-class research instrument.” manmonthly.com.au

News @MM CSL manufactures AstraZeneca COVID-19 vaccine in Australia

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The COVID-19 vaccine is being manufactured at two CSL Australia facilities in Melbourne. The Therapeutic Goods Administration has approved the manufacture of the AstraZeneca COVID-19 Vaccine (ChAdOx1-S) in Australia. The Australian manufacture of COVID-19 Vaccine AstraZeneca, established by a Melbourne-based biotechnology company CSL, has involved extensive work by both industry and the TGA in the last six months. Manufacture of biological medicines, such as vaccines, is a highly-specialised process, and specific approval was required to ensure that the locallymanufactured vaccine had the same composition and performance as the overseas-manufactured vaccine. The vaccine is being manufactured at two sites in Melbourne. CSL-Behring Australia in Broadmeadows is manufacturing the active raw vaccine material, while the final vaccine doses, where vials are filled and packaged at CSL subsidiary Seqirus in Parkville. Quality control testing of the raw material and product is also taking place in these facilities. The final step for the Australianmanufactured vaccine is TGA batch release, which is required for every batch of any vaccine supplied in manmonthly.com.au

Australia. It involves a review of documents supplied by the commercial sponsor describing how the vaccine batch was made, tested, shipped and stored as well as TGA’s in-house laboratory testing to ensure the vaccine has been manufactured according to the required standards. The first batches of the vaccine are expected to be released in the next few days. The federal government has purchased 50 million doses of the AstraZeneca vaccine, to be manufactured on their behalf by CSL, and, subject to individual batches passing TGA batch release requirements. These will form the mainstay of Australia’s COVID-19 vaccination program over the coming months, and complement imported vaccine supplies. As part of Phase 1B of Australia’s COVID-19 vaccine program, more than 1,000 general practices will join the COVID-19 vaccination program. Clinics have initially been supplied with imported AstraZeneca vaccine, and will progressively increase in number to more than 4,000 by the end of April, along with over 100 Aboriginal Health Services and 130 Commonwealth operated GP-led Respiratory Clinics.

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Manufacturers’ Monthly MAY 2021 13

News @MM $2.4bn economic boost as government cuts red tape for tradies

The new AMR reform would automatically allow occupational licence holders to work outside of their home state or territory.

The federal government has announced it will cut red tape to allow a uniform scheme for automatic mutual recognition (AMR) of state and territorybased occupational licences and registrations. Under the new reform, builders, electricians, plumbers, architects, and other workers who hold an occupational licence in their home 14 MAY 2021 Manufacturers’ Monthly

state or territory, and wish to work in another state or territory, will automatically deemed to have the necessary licence. There will be no extra fees. More than 124,000 currently working across borders will benefit from the reform, as well as another projected 44,000 workers following the reform on July 1. In a statement, Treasurer Josh

Frydenberg said a uniform scheme means businesses can operate more seamlessly across Australia. It is also expected to help create jobs, increase competition and input, and lower prices for consumers. About 20 per cent of workers required to be licensed. The current mutual recognitions regime for licensed occupations is complex,

costly and deemed a regulatory burden for businesses operating across different jurisdictions. The National Cabinet endorsed a uniform national AMR scheme in November 2020, and an agreement was signed by the Prime Minister, State Premiers and the Northern Territory Chief Minister at the end of last year to establish and implement the scheme. manmonthly.com.au

News @MM Attack Class submarine project attracts more than 120 businesses More than 120 local companies have registered their interest with Naval Group to become tier-one capability partner of the Attack Class submarine project. The project has created almost 300 direct jobs in Australia, the company’s Australian subsidiary plans to double its local workforce in 2021 to prepare for building of a hull qualification section at Osborne in 2023, and construction of the first Attack Class submarine pressure hull in 2024. Naval Group Australia CEO, John Davis, said the response to the $900 million manufacturing package has been encouraging. “This program has already made great progress in creating jobs and designing the world’s most advanced conventionally-powered submarines,” he said. Naval Group and the federal government have committed to at least 60 per cent of the contract value for the 12 new Attack Class submarines will be spent in Australia, and included their joint commitment in the program’s Strategic Partnering Agreement. Inclusion in the Strategic Partnering Agreement follows Naval Group’s long-standing commitment to

manmonthly.com.au

maximise Australian content in the design and build of the Attack Class submarines, and its offer in 2020 that a local spend of at least 60 per cent be formally signed into the program contract. Naval Group global CEO Pierre Eric Pommellet visited Australia last month, and met with Commonwealth officials for talks on matters, including the joint 60 per cent agreement. “Naval Group is fully committed to supporting the development of Australia’s sovereign submarine capability,” he said. “I have been very impressed by the existing capacity of Australia’s manufacturing sector, and its enthusiasm for the Attack Class project. “This program will deliver to the Royal Australian Navy 12 regionallysuperior Attack Class submarines which are specially designed for Australia’s unique conditions. “But it will also create a new and sovereign submarine building industry in Australia. Strong local supply chains will ensure that Australia has new self-reliance in this critical defence capability.” Davis said his staff were already

The 12 Attack Class submarines manufactured in South Australia will have an increased number of locally-made parts.

working with hundreds of local businesses to build greater selfreliance and sovereignty in the Australian defence manufacturing sectors, and were proud of their commitment to local jobs and industry. “There will be increasing levels of local content in each of the 12 Attack Class submarines, as we continue working with local businesses to boost Australia’s sovereign

capability,” he said. “Ensuring that at least 60 per cent of the Attack Class contract value is spent locally will create hundreds of Australian jobs, for the long term, in new supply chains around the country.” Naval Group was selected by the federal in 2016 as the preferred international partner to build a new submarine fleet, which will defend the country’s borders.

Manufacturers’ Monthly MAY 2021 15

News @MM First private rocket test site launched in Queensland

The Helidon Rocket Test site is one of two professional astronomical research facilities in Queensland. The first privately-owned, static rocket testing site has been developed in a partnership between Rocket Technologies International and the University of Southern Queensland. A sandstone quarry is now the home of the Helidon Rocket Test Site, allowing developers to test rockets that are secured to the ground in a controlled environment. Executive director of the University of Southern Queensland’s Institute for Advanced Engineering and Space Sciences, Professor Schubel, said it was the only facility of its kind in Australia outside of the Defence Forces. “Rocket Technologies International and the University of Southern Queensland has partnered in order to build capacity for Australia, to develop the space industry and support fledgling rocket manufacturing companies so that they can enter the space race, advance technologies and sovereign capability,” Schubel said. “Through this partnership, we have been able to deliver this site for both 16 MAY 2021 Manufacturers’ Monthly

research purposes and for commercial testing.” The new precinct has one horizontal test bed, rated to 200kN, which is used to verify the functionality and performance of the rockets (tested while secured in a fixed position on the test pad). The fundamental data collected from these tests includes thrust, combustion pressure and casing temperature and provides critical information required for development of rocket technologies and trajectory modelling so that a launch test can be approved. Professor Schubel said it was a pivotal and important step in Australian space research. “We have entered what is being called The Space Race 2.0,” he said. “We have the Moon to Mars mission coming out of NASA and there is a lot of commercial interest around space exploration as well. “This is mainly around satellite communication systems, so there is a need for satellites to go up in the

next 5-10 years and Australia is in a very strong position to support that activity.” Owner of Rocket Technologies International and the Helidon quarry site, Allan Payne, is excited to be part of this next development. “I am investing in space research as it is the future. The opportunities are endless,” he said. “The relationship we have with the University of Southern Queensland is second to none and the most important thing is educating the future generation.” For University of Southern Queensland Senior Research Fellow, Dr Fabian Zander, who researches rockets and hypersonic flows, the new facility provides the opportunity for world-class testing. “It is unprecedented in Australia to have this type of access and we can bring ourselves, our fellow researchers and students down here to gain practical experience with the work that we are doing,” Zander said. “Internationally, the space industry

is booming. A large part of that is propulsion, including rocketry and high-speed flight, so we are looking at the fundamentals of that, constructing capability within Australia and educating a new generation of people to work in that field.” The facility is another component of the University of Southern Queensland’s expansive space research. The Helidon Rocket Test Site joins the University’s Mount Kent Observatory, the state’s only professional astronomical research facility. CEO of PFI Aerospace Nick Green is one of those space industry representatives already utilising the site. “This site is a purpose-built site, with excellent facilities and geographically ideal for the majority of Australia’s rocket manufacturing industry. Australia needs sites like this if we are going to get involved more in the space industry. It is a critical piece of infrastructure,” he said. manmonthly.com.au

News @MM 500 jobs secured at Portland aluminium smelter Victoria’s Portland aluminium smelter has been secured after an electricity deal struck with the nation’s biggest energy retailers backed by support from the federal government, announced in December. Alcoa will keep the smelter operating until 2026 will protect around 500 jobs and other workers in the region that rely on the plant’s continued operation. The smelter accounts for 14 percent of jobs in the Portland area. Prime Minister Scott Morrison said the announcement was welcome news not only for the 500 local employees and the region, but also for the Victorian electricity system. “Our support means keeping jobs and keeping the lights on,” he said. “This demonstrates the real confidence that industry, manufacturers and businesses have in Australia as we emerge from COVID 19. “The number one focus of my government’s National Economic Recovery Plan is jobs, and with Australia having restored the jobs lost during the COVID-19 recession, every one of our policies is focused on securing jobs like those at Portland and creating new ones.” Under the agreement with the federal government, the Alcoaoperated facility will see Portland

reduce its energy demand at peak times, making more electricity available to the grid and helping Victoria avoid blackouts. Minister for Energy and Emissions Reduction Angus Taylor said the agreement between the Commonwealth and Alcoa recognised the smelter’s important role in helping to stabilise the state’s electricity network and the jobs it supports. “The Portland smelter is Victoria’s largest energy consumer, and provides unique and valuable energy services to the grid” he said. “Securing its ongoing role will help Victoria keep the lights on during times of high demand, such as days of extremely hot weather and help Portland to be appropriately compensated for the grid services it provides.” The federal government will provide up to $76.8 million over four years to secure Portland’s participation in the Reliability and Emergency Reserve Trader (RERT) scheme. The smelter’s support from the RERT means Alcoa is compensated for the reliability services it provides to avoid shutdowns caused by intermittent energy supply in the Victorian grid. Local Member for Wannon, Dan Tehan, said the announcement was

The Alcoa-operated Portland smelter will provide more electricy to Victoria’s energy grid.

welcome news for the community. “This is fantastic news for not only the Alcoa Smelter workers but also the community of Portland as it keeps locals in jobs and builds the Portland economy,” he said. Under the agreement, Portland must participate in the RERT to the maximum extent possible to help ensure the stability of the electricity grid. The Portland facility represents around 10 per cent of Victoria’s electricity demand each year and

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produces almost 20 per cent of the nation’s aluminium output. The agreement will help strengthen the Victorian electricity grid which has been fragile following the closure of the Hazelwood coal-fired plant in 2017 and the rapid uptake of ntermittent renewables. The agreement is temporary and will end once post-2025 electricity market reforms are in place that better value the essential system services provided by large industrial loads.

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Manufacturers’ Monthly MAY 2021 17

News @MM Energy Renaissance, CSIRO and IMCRC to deliver defence-grade battery management system optimised for hot climates Australian lithium-ion battery manufacturer Energy Renaissance will develop a defence-grade, cybersecure Battery Management System (BMS), to be manufactured in Tomago, NSW. The $1.46 million BMS project is a joint venture by Energy Renaissance with the national science agency, CSIRO and the Innovative Manufacturing CRC (IMCRC). Energy Renaissance’s 4,500sqm purpose-built facility in Tomago, NSW will manufacture Australian

made batteries that are optimised to perform in hot climates. Technology and development director of Energy Renaissance, Brian Craighead said the collaboration will promote an Australian Battery Management System instead of relying on an overseas technology platform. “Software designed and developed in Australia has a strong global reputation and we’ve built a history and track record as an industry,” he said. “Through this project, we will

demonstrate the advantage that Australian intellectual property can bring to a highly competitive energy storage market where a superior Battery Management System is critical for the operating efficiency of a battery.” The batteries will power stationary (grid and microgrid, renewables, community storage, mining electrification, Defence SilentWatch applications) and transport (buses, light commercial and industrial vehicles) applications. Principal Research Scientist

The Energy Renaissance lithium-ion Battery Management System would demonstrate what Australian intellectual property can bring to a competitive storage market.

18 MAY 2021 Manufacturers’ Monthly

at CSIRO, Dr Adam Best, said the partnership with Energy Renaissance validates CSIRO’s capabilities to collaborate, train and transfer skills for the advanced manufacturing of batteries. “CSIRO is delighted to be working with Energy Renaissance to develop a Battery Management System that is the ‘nerve centre’ of a battery, and will make batteries safer, more affordable and optimised to operate in high temperature environments,” he said. The BMS will monitor and report on the battery’s usage, lifespan and faults through a mobile network to Energy Renaissance and their customers. Communicating through an inverter, the system will enable secure real time data, analytics and remote management to drive down the risk of battery failure and operating costs for grid-scale energy storage users. Managing director at IMCRC CEO and managing director David Chuter sees the research collaboration between Energy Renaissance and CSIRO as a catalyst for further establishing an Australian battery manufacturing sector. “The growing interest in renewable energy and thus demand for lithium-ion batteries provides a great opportunity for Australia. Through accessing local knowledge and expertise, this project will demonstrate how we can utilise Industry 4.0 technologies and principles to establish a viable Australian battery manufacturing sector for the benefit of all Australians, and as a national manufacturing priority. “The commitment from all involved in this project will help position and strengthen the value and influence of Australia’s role as a strategic partner in the global lithium-ion battery value chain.” manmonthly.com.au

News @MM Indigenous company NACP to build missile assembly and maintenance facility in NSW

The project would support the production, maintenance, sustainment and export of the Nulka decoy missile system. An Indigenous construction company has been awarded the head contract to build a $23.9 million missile assembly and maintenance facility in Western Sydney. National Aboriginal Construction Partners (NACP) Projects is expected to employ around 200 workers during construction of the Nulka Missile Assembly and Maintenance facilities, at the Defence Establishment Orchard Hills. Minister for Defence Industry Melissa Price said the federal government’s contract with NACP would provide a major boost for the Indigenous business and the Western Sydney community. “This contract exemplifies our strong commitment to the Closing the Gap initiative by providing dedicated opportunities for Indigenous companies,” she said. “The construction workforce will be about 50 to 80 workers onsite every day, with an estimated 200 workers being involved on the project over the 10-month construction period. “NACP Projects is committed to manmonthly.com.au

achieving 95 per cent local industry participation for the supply of goods and services for the project.” Price said the project would support the production, maintenance, sustainment and export of the Nulka decoy missile system. “The Nulka decoy missile is the world’s most sophisticated electronic defence system for the protection of warships against anti-ship missiles,” she said. “The system is currently deployed on more than 150 Australian, US and Canadian warships, making it one of Australia’s most successful export stories.” “The project will provide administration, assembly, maintenance and storage facilities to support the Nulka decoy missile.” “Nulka” is of Australian Aboriginal origin, meaning “be quick”. Member for Lindsay, Melissa McIntosh, said it highlighted the significant connection between the project, local indigenous

companies and the delivery of defence capability. “Backing our national defence industry creates and sustains more local jobs, and secures our sovereign capability,” she said. “From the construction phase through to the long-term support of the Nulka missile assembly and maintenance, this project demonstrates Western Sydney’s

potential to be deeply integrated into our defence industry and support a wide range of local jobs.” NACP Projects was procured under the federal government’s Indigenous Procurement Policy to support indigenous entrepreneurship and business development. Work on the project will start in April and is expected to finish in early 2022.

Manufacturers’ Monthly MAY 2021 19

Industry Focus Adapting to a fast changing manufacturing landscape

Manufacturers’ Monthly collaborated with the South East Melbourne Manufacturers Alliance (SEMMA) to find out how two small businesses have adapted to radical changes in the manufacturing landscape.

DAPTING to radical change is nothing out of the norm for Victorian manufacturer. With a strong background in panel beating and spray painting, Michael Van Dort and his business partner Darren King boldly took on the big names such as Holden HSV, Toyota, and Ford – but all that was about to change. The departure of automotive passenger vehicle manufacturing in Australia forced Van Dort, director of D&M Auto to overhaul his organisation when faced with the reality of losing 90 per cent of their work. Recently, the pandemic has forced many local manufacturers to evolve to a set of constantly changing conditions, ultimately highlighting the risks of our heavy reliance on offshore manufacturing. D&M Auto are an early example of a successful pivot, converting from spray painting small auto component parts to working with architects, designers, and artists. D&M Auto have a staggeringly diverse resume, from painting non-chip wheel rims for HSV, GH Mumm’s Bird Cage marquee at the Melbourne Cup, graffiti-resistant cladding for schools, 20 MAY 2021 Manufacturers’ Monthly

installation art for Pullman Hotels, to dresses for the Commonwealth Games and Australian Ballet. The company commenced operations in 1990 in Melbourne. In 25 years, it has built a reputation as a reliable and innovative quality 2 Pac finisher. Clients include builders, signage companies, factories, based predominantly in Melbourne. D&M Auto Industrial Spray Painting can paint any surface, including metal, plastic, composite panels and glass. Examples of products the company have spray painted are car parts, light switches and fittings, forklift and industrial machinery parts, road and train signs. “We take up the challenge to meet our clients’ needs with our network of local suppliers and chemists,” Van Dort said. “Using automation has helped us attain greater control and repeatability while reducing cost. If we had to return to the old ways, we simply wouldn’t be around.” Australian suppliers now work to close the price differential between local production and imports, with greater security, communication

and responsiveness giving the competitive edge. President of the South East Melbourne Manufacturers’ Alliance (SEMMA), Peter Angelico, said cost is a one-dimension aspect of a procurement. “Quality, environmental, and ethical considerations are increasingly shaping consumer choice,” he said. “They should also be a considerable influence on government procurement for major projects. “We want to promote better quality Australian products,” said Van Dort. “COVID reinforced onshoring for us and taking a collaborative approach to our work.” “We couldn’t have started without the auto industry, they were the seed – from there, we grew.” Van Dort explained that his company has two processing robotic lines. One is a smaller system, that it uses to paint smaller plastic components. And the larger one is more flexible with them being able to take a piece aluminium and turn it into a piece of cladding by coating it in any colour that the customer

wants. This, he said, can be done fairly quickly. “We are one of the only local providers of fire-proof cladding here in Australia,” he said. “We’re able to get the job done generally in a 7-day turnaround.” D&M Auto used to deal with the automotive segment, which had just in time (JIT) processes.

Customisation and service “The building industry, it’s like hand to mouth – they appear to have long lead times, so a lot of the time they don’t order material until the last minute,” Van Dort said. “If they have to order from China, it might take up to three months.” With D&M Auto, Van Dort said if customers needed something special, it is able react within a week. For example, customers can get whatever colour they want, and get it laminated and get the same warranty as they do from overseas – all from D&M Auto. According to him, what customers mainly look for is bespoke colour choice. Van Dort says the company’s main advantage is that it can formulate a colour and give customers manmonthly.com.au

Industry Focus the choice of anything they want – something they can’t get if they ordered from China. “They can get the colour they want, but they need to minimum order 700800 metres,” said Van Dort. “We’re able to put a PVC film on top of it, so it protects the coating from transport damage or anything like that and for lot of the add-on components, we can paint them.” D&M Auto services many cladding installers and suppliers in Melbourne. Van Dort said much of their work comes through word of mouth. “There’s plenty of powder coaters around, but there’s not many that can paint like we do, and we also do a lot of architectural products,” he said.

Pivoting after COVID-19 Micro Precision Plastics is another Melbourne-based manufacturer who pivoted during the COVID-19 pandemic. When the COVID-19 pandemic hit, only 15 per cent of their customers continued their business with the company. When JobKeeper came through, it enabled them to allocate money into the tooling of the masks. The company was established in 1977 and is an Australian familyowned business as a custom injection moulders to the plastics industry. Managing director Russell Lacy said the company realised at the end of last year the masks they had produced as protection against viruses were very suitable

for industrial purposes. “We ended up selling a lot of masks over the internet sales. We probably sold enough to cover off the cost with tooling, the R&D and the lab testing, cost of materials,” he said. “We developed a couple new tools and we put an exhalation valve in there. Some of the feedback we got from previous masks was that it was a bit small for a lot of people. “So, we made a larger mask and changed the profile of the mask, so it is more suitable for guys with bigger faces, who work in the building industry, and we just launched a new one.” Micro Precision Plastics is going out to the safety shops – one based in Melbourne and one based in

South Australia – who are pushing these out to stores, and Lacy said that they are starting to get some traction from that now. At the height of the pandemic, Lacey said most sales were generated from members of the public during the height of COVID-19, and mask wearing was mandated in Victoria and New South Wales. “We were having sales in Queensland and Tasmania when people were finding us and it was a combination of things that made us successful,” Lacy said. “It was an Australian Made product, and fully made in Melbourne, right down to the filters. Everything is made in our factory in Architects, designers and artists which has now become a large percentage of D&M Auto’s clientele.

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Manufacturers’ Monthly MAY 2021 21

Industry Focus Dandenong. People love that. “We had some good response through Facebook. Once we got the P2 certification, we couldn’t do any advertising. We had a shop MP Aussie Products, until Facebook pulled all of our advertising,” said Lacy. Micro Precision Plastics currently makes tens of thousands of face masks a week for customers. Lacy explained that any advertising they tried to do through Facebook or Google, because the product was rated as P2 (P2 is a respiratory filter rating), the product was rejected – the reason being those are essential PPEs that should only be used for hospitals. “It was very difficult for us,” Lacy explained. “We approached the government and said we think we’ve got this mask we think would be very good in areas you are looking for masks.” Lacy said the Victorian state

government made a decision to throw millions of dollars into the making of cloth masks. He believes the company missed out on every opportunity from the governments or Facebook advertising. “It was frustrating because you’re trying to do something that will help the COVID problem, and you end up being stopped because the product is good (has a P2 rating),” Lacy said. “None of the cloth masks produced for the Victorian government were P2 rated, but they threw a lot of money at those companies who were sewing together bits of material for the Victorian government.” “The federal government were really trying to pick the winners and losers,” Lacy said. “You might be a successful manufacturing company, but if you’re not in Defence, or food, or transport, you can’t get any funding to the manufacturing grants unless you’re in one of those industries.”

D&M Auto Industrial Spray Painting has branched out to serve other markets.

Rheinmetall Defence Australia Chooses Lorch Welding Technologies. “As the manufacturer of Australia’s future military defence vehicles and a leading global supplier of defence and security technology to armed forces around the world, it’s clear Rheinmetall needs the best Industry 4.0 welding solutions. We have standardised on Lorch welding technologies made in Germany. Lorch welding products are among the very best in the world. Their combined leading technologies and partnering approach from their German headquarters with local Australian subsidiary and distribution partner Global Welding Supplies in Queensland address our ongoing welding needs and set the standard for supplier partnerships”. Neil Fitzpatrick – Manager – GSC / AIC – Rheinmetall Defence Australia Rheinmetall Defence Australia uses the Lorch S Series, a digital Industry 4.0 pulse platform with advanced speed processes: SpeedPulse XT, SpeedArc XT, SpeedUP for all GMAW, GMAWP and FCAW processes. Lorch custom waveforms deliver the specific weld metal mechanical properties required by Rheinmetall to ensure the highest levels of quality and vehicle strength are achieved for the ultimate protection of Australia’s armed forces personnel.

For further information please contact David Wilton: LSP@lorch.eu Lorch South Pacific Pty Ltd is a subsidiary of Lorch Schweißtechnik GmbH, Germany. AD4485_ManMonthly_5.21

22 MAY 2021 Manufacturers’ Monthly

Photo credit: Rheinmetall press pictures

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Welding High speed, superior quality Manufacturers’ Monthly spoke with Lorch South-Pacific, Managing Director, David Wilton about high-speed processes, powered by a completely digital system.

ORCH Schweißtechnik GmbH is the clear master of speed, wielding advanced welding processes to increase welding speeds and optimise arc performance for specific applications. The company manufactures arc welding systems for industrial applications, demanding metal working, as well as for use in automation with robots and collaborative robot systems. With next generation inverter power technologies and digital control, Lorch delivers cutting-edge performance with faster welding speeds while producing a superior metallurgical weldment. Lorch latest generation S Series and MicorMIG platforms with “speed” technologies are more efficient, consume less power and can deliver faster welding speeds. Lorch South-Pacific Managing Director, David Wilton explains that speed translates to productivity and reduced operating costs. To achieve that, the welding processes needs to be optimised and that starts with a digital welding machine. “The Lorch platform, is a 100 per cent digital system, enabling advanced welding processes that are completely driven and controlled by

“Last but not least, is to actually make the task easier for the operator. The advanced manipulation – you can make it simpler and easier to weld with,” said Wilton.

The Lorch Speed Processes

The SpeedPulse XT is the cutting edge in pulsed MIG welding technology. software,” Wilton said. “That is the difference of a modern Industry 4.0 welding machine – it’s digitalised and it’s very high speed in its processing speed to be able to do advanced welding processes.” Wilton said the digital platform represents an evolution of welding processes that are optimised to a new level. “We can manipulate the welding arc to do different things when it’s controlled by software,” he said. “We’re doing this to drive productivity, and across the board that’s the main goal, do it faster, do it with superior quality, with superior weld integrity, which means the strength of the weld is literally optimised this way.

The Lorch Speed Processes are advanced processes which are suitable for Solid, Flux Cored and Metal Cored wire welding applications. Wilton shared with Manufacturers’ Monthly how they improve everything across the board – speed, quality and ultimately, cost savings. SpeedPulseXT With its advanced waveform control technology, SpeedPulse XT enables the quick mastering of pulsed welding. Pulse welding has been around for a long time, it’s ideal for welding thinner materials but it has a fundamental flaw in the fact that the process is slower than a conventional transfer mode and generates a lot of heat in the torch. “This is now being overcome by SpeedPulse XT, because what’s now happening is instead of one little droplet with each pulse, there’s multiple connected droplets followed by a molten metal flow

All the benefits of TwinPuls with the maximum of speed

No cold places The danger of cold places at the start of the weld is a thing of the past. Increased energy transfer ensures a completely fused start.

24 MAY 2021 Manufacturers’ Monthly

with each pulse,” said Wilton. “The days have gone for slow, single droplet pulsed welding. Today, SpeedPulse XT with its patented technology accelerates the entire welding process by depositing significantly more volume with each pulse.” The Lorch SpeedPulse XT is the cutting edge in Pulsed MIG (GMAWP) welding technology delivering extra fast welding speeds, reduced distortion and very low, insignificant levels of spatter, reducing any post weld clean-up time. “Every time we have a pulse, what that does is it deposits more molten material into the weld pool. When you put more molten material into the weld pool, you physically travel faster to produce the comparable weld size to a traditional single pulse system. This really speeds up the process of pulse welding. So, with the SpeedPulse XT you will get up to 48 per cent faster than traditional pulse welding,” said Wilton. “This also is a proprietary exclusive, owned IP by Lorch and the software enables that.” SpeedArc (MicorMIG) and SpeedArc XT (S Series) The SpeedArc is a better, evolved

TIG like appearance

Without end craters The welding current is automatically reduced at the end of the weld. So, end craters are now a thing of the past. And the automatic end pulse ensures that the wire end is finished without balling at the end – so the next ignition is performed perfectly.

manmonthly.com.au

Welding The SpeedArc process enables the welder to manipulate and control the arc.

process than the standard MIG (GMAW) or flux core welding (FCAW) because the user has the ability to manipulate the arc to have a much more focused and concentrated arc. This advanced process penetrates deeper, gives a better welded joint and thus provides better structural integrity. “With the Speed Arc process, we are manipulating and controlling the arc where we can really focus the arc,” said Wilton. “It has a

higher arc pressure and much more focused energy at the end of the wire that penetrates deeper into the steel compared to ordinary MIGMAG machines. “With the Speed Arc processes, welding can go up to 30 per cent faster than a standard process with the same wire and gas.” Wilton explained for a structural steel fabricator, one of the biggest costs in welding is the labour time. “If we can speed the process up and a welder can put down more kilos per hour, achieving higher deposition rates, the job gets done quicker and the cost comes down,” he said. TwinPulsXT Real-world applications that commonly used to be completed by TIG welding can now be welded with MIG-MAG processes up to seven times faster, with the groundbreaking capabilities of the new and improved TwinPuls XT. Its results are comparable to TIG.

“What we are producing with digital control is a TIG-like appearance,” said Wilton. “The fishscale like appearance is normally a visual appearance you get with the TIG process, which is associated with best quality.” “With an advanced digital machine, we are able to reproduce the TIG-like appearance but do it seven times faster and with an easier MIG (GMAWP) process for the operator, while still looking perfect.” SpeedUp Vertical up welding with MIG has always required a great amount of experience, skill and a steady hand to do the conventional “Christmas tree” style weld but the Speed Up option has made vertical up welding straightforward with no weaving required. “As you can see in the pictures, this weld has been done in a vertical position, so the welder is welding straight up. It’s again,

The weld has been done in a vertical position with the SpeedUp option.

a superior process that is now made much easier through the use of more advanced digital welding technologies to produce a consistent, premium quality result,” said Wilton. SpeedUp is also possible with Metal Cored wire, vertical seams can now also be produced quickly and easily. A wire change to rutile fluxcored wire is no longer necessary and saves time and money.

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Manufacturing Strategies

How working capital funding helped two manufacturers to grow their business Fintech lender Banjo Loans offers small businesses cutting edge technology with a personal approach to business, CEO Guy Callaghan tells Manufacturers’ Monthly.

Banjo Loans CEO, Guy Callaghan.

26 MAY 2021 Manufacturers’ Monthly

S one of the leading SME fintech alternative lenders in Australia, Banjo Loans has been helping to power small and medium businesses across the nation for over 6 years. Banjo’s clients include a wide range of businesses and industries. Banjo CEO Guy Callaghan said Banjo is a fintech with a difference. “We combine the rapid data analysis and technology you’d expect from a fintech, with an old school personalised relationship approach that is quite rare in our sector,” he said. “Our clients get the best of both worlds.” “More than 80 per cent of our clients come back to Banjo to reborrow. Those small and medium enterprises (SMEs) continue to look

to us to help them grow and build their enterprise.” Here’s how Banjo’s more holistic view helped to tailor better loans for a food manufacturer’s and a digital media manufacturer’s cashflow requirements. Cooee Foods is a manufacturer of specialist foods like condiments, packaged meats, and plant-based (vegan) foods such as vegan sausages. Founder and CEO Chris Egan and his multicultural staff of 80 are based at a plant in Moorabbin, Victoria. Cooee’s 8-year research & development (R&D) program is partly funded by the federal government, based on them manufacturing plantbased foods, and exporting their Redsun Pho product to Vietnam. Redsun products are also sold to manmonthly.com.au

Manufacturing Strategies Vietnamese restaurants in Australia. In 2020 Cooee secured a deal with Coles to sell several products in their plant-based, condiment and Redsun range.

Where Banjo’s expertise came in Because there was so much investment going into R&D, Cooee was operating with limited cashflow. The major bank they previously had a relationship with was only concerned with past performance and wouldn’t support Cooee’s plans based on their current position. Banjo took a more holistic view, including the company’s story and the research and development work they’d been doing. The Banjo team noted that, based on new supplier agreements including Coles, the company was forecast to have a $4.8 million increase in turnover. A member of the Banjo team visited the Cooee Foods factory to meet the directors and see the production facilities.

film studios and music businesses including Twentieth Century Fox, Icon, Madman, Warner Music, Hanabee, Acorn, EMI and most of the independent distributors. The company is currently the second largest independent manufacturer of CDs/DVDs and Blu Rays in Australia. By offering a full supply chain solution – manufacturing, warehousing, distribution and administration – Regency has established a sustainable competitive advantage. It has also acquired other businesses in recent years, including a children’s book publisher.

Banjo was able to review the application based on forward looking cashflow projections incorporating Cooee’s new sales agreements. Terms were agreed for an 18-month loan, tailored to Cooee’s cashflow requirements. Now in a strong cash position, CEO Chris Egan is delighted with the outcome. “Banjo is more nimble and have the technology that you’d expect from a fintech, but they’re also highly professional and focused on establishing a relationship,” he said. The Regency Media Group has expanded over its 50 years in business to become a diversified group working in digital media manufacturing and distribution, licensing and publishing. Fiona Horman is managing director of the privately owned company,and is one of Australia’s most experienced operators in the electronic media manufacturing sector. Regency’s manufacturing customers include the world’s largest

How Banjo helped The Banjo team noted that Regency has a proven operating and financial track record and a reputation for speed to market, just in time delivery, accuracy and quality of product. However, due to the wide range of payment terms of Regency’s clients, the company was experiencing a strain on its cashflow. Some of its distribution

clients have 7 to 14-day terms, while retail chains have between 60 and 90 days. Regency also exports to some American companies who have 120-day terms. The whole working capital cycle is about 120 days to 180 days depending on which debtor places a bigger order at the time. Regency often finds themselves in a scenario where suppliers are requesting payment before their clients have paid. Banjo was able to help with the working capital cycle of the business to fund the difference in cashflow needed. “I’ve found dealing with Banjo very refreshing,” Horman said. “They are very quick to process and authorise requests. They make themselves available to talk directly to me as a client promptly and resolve any queries very quickly. They seem to understand business requirements for growth far better than standard bankers. It has been a delight dealing with Banjo for our funding needs.”

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Compressors New variable speed drive: Brumby Compressor The CAPS Brumby range of rotary screw air compressors has been extended to include variable speed technology models to significantly increase efficiency.

HE CAPS Brumby range of rotary screw air compressors has now been extended to include variable speed compressors to compliment the current fixed speed range. With the option of choosing a tank mounted compressor or a complete solution including tank, dryer and filters, the CAPS Brumby range offers a solution for different air requirements. Both fixed speed and variable speed units are available in sizes ranging from 5 to 15 kW.

Fixed Speed vs VSD – which option is best for your need?

The CAPS Brumby range offers a solution for different air requirements.

Both kinds of compressors have differences in how they operate. On a fixed speed air compressor, the motor will run at one constant speed/fixed RPM. When air demand is placed on the system, the inlet valve will open, and then close again once the demand is removed. Therefore, due to the motor only running at one fixed speed, it will maintain a pressure of 0.7 bar

above the air demand at all time. A Variable Speed Drive compressor will use a variable speed, or VSD drive, which allows the motor to actually ramp up and down, allowing for power consumption savings. Properly sized for the same end use, a VSD compressor can yield power savings upwards of 35 per cent in some cases. Energy is always a significant cost to any business and reducing energy consumption can yield large savings. Aside from the variable motor speed when in operation, the inverter in the VSD system performs a “soft” start operation by ramping up the motor speed slowly, which reduce the high draw peaks that are typical when a fixed speed motor is started. This also helps protect electrical and mechanical components from the starting mechanical stresses that can shorten the life of an air compressor. So, overtime, choosing the variable speed option will save you up to 35 per cent in power cost but

Operators can get more savings using a VSD compressor.

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Compressors ...due to the motor only running at one fixed speed, it will maintain a pressure of 0.7 bar above the air demand at all time.

The integrated design prevents external damage to the machine. will also make your installation last longer and avoid downtimes.

Exploit your energy consumption CAPS Brumby direct driven variable speed range of compressors comes in two configurations, receiver mounted (VX Series) or receiver mounted fitted with oversized dryer and pre/

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post filtration (CSVX Series). This new design is tailor made for variable speed applications, providing energy efficiency and maximizing energy savings with a low cost of ownership.

Extra air storage capacity for spikes in air demand and longer cycle times Most machines of this size will sit

on a 300-litre receiver tank. Not the Brumby. Boasting a larger air tank ensures you have a consistent flow of compressed air. Not only does a large air tank provide you with consistent levels of compressed air, it also reduces the number of time the unit needs to load – saving you a lot in energy costs!

Integrated refrigerated air dryer and filtration package The Brumby Complete Solution package delivers the ultimate in air quality, featuring a refrigerated dryer with an electronic controller monitoring key parameters and a

filtration package, ensuring the efficient removal of contaminants. This integrated design saves your expensive air tools from damage and extends the overall life of your compressed air equipment.

National coverage, local support All of our equipment is supported by your local CAPS service team offering after sales support to enhance your energy efficiency, productivity and operations. Whatever you need, you’ll find that we’re just a phone call away for any technical advice, support, products or parts.

Manufacturers’ Monthly MAY 2021 29

Metal cutting

Bylaser has found that by offering security of supply, and the financial benefits of just in time (JIT) delivery, it has been a game changer for many its customers.

Adopting a philosophy of customer centricity Manufacturers’ Monthly speaks with Bylaser managing director, Michael Traynor, about the importance of putting the customer first.

HEN Michael Traynor took over Bylaser in November 2019, he saw a business that was weighed down by rules and regulations. The previous owners of the metal cutting business had been unwilling to invest. Poor systems and equipment were hampering growth, and the company had been competing on nothing but price. Staff were trained to pay homage to the business’ rules. Customers’ needs were met if they fit within “the way we’ve always done things” but this was more of a lucky by-product of the business approach than a conscious plan. It became increasingly obvious to Traynor that the one-size fits all

30 MAY 2021 Manufacturers’ Monthly

approach didn’t in fact fit anyone. And unless the business could be re-invigorated following the loss of a number of key customers, it would slowly fade into extinction. With this in mind, Traynor was charged by the board to inject new life into the business and grow and strengthen its operations. Traynor has always been of the view that only competing on price represents nothing but a race to the bottom. Instead, Traynor introduced the concept of “Customer Centricity”, where all decisions within a business are viewed within a context of putting the customer in the centre of the circle – a philosophy that is embraced by every area of the business. “We find out in detail what is

important to our customer, and how they define excellent customer service,” Traynor said. “This involves us identifying their tolerances, preferences, delivery requirements, problems with existing suppliers, headaches and generally what’s keeping them up at night.” “We then share this information with our department heads and together, we build a bespoke service to match the customer’s needs.”

Kanban – taking uncertainty out of lead times Traynor has found that for many customers – lead times can be a major issue. “Whether it’s in the construction industry, automotive parts, agricultural machinery or

indeed any business, the failure to have materials available on time can have big knock-on effects both for the project timetable as well as negative financial implications” he said. “In times like the present, with supply chains under increasing pressure, this has become even more critical than ever before”. To assist these customers, Bylaser has set up a “Kanban” solution. Expected parts and volumes are forecast in advance and agreed with the customer. Customer designs and parts are drawn and held in the system. Bylaser is then able secure the necessary materials and produce and maintain the volumes required in advance. The stock is held at Bylaser with the customer drawing upon manmonthly.com.au

Metal cutting them as required. This ensures the customer has immediate access to the stock they need at a moment’s notice, slashing what could otherwise involve extended turnaround times. “Customers also benefit from the freeing up of their working capital, with payments for the parts only being required when they have been used,” Traynor said. Since offering this service, Bylaser has found that this security of supply, together with the financial benefits of just in time (JIT) delivery, has been a game changer for many customers, particularly in the uncertainty accompanying a pandemic.

Creative solutions – just from listening “By listening to our customers and finding out what is important to them, we make it important to us,” Traynor said. Bylaser’s customer centricity focus has seen the development of service offerings as individual as their customers. The customer reward program was re-vamped to consider what the customer was interested in rather than the same old bottle of wine or a voucher. “When they were advised of meeting a sales milestone, one client requested we design and produce a metal sign for their new business premises. They were absolutely delighted with the result! Traynor has seen the team’s discussions with customers bring out a variety of wishes with respect to the packing of parts. “For some customers, we put tissue paper between parts to prevent scratching. Another customer requested that all parts we delivered to her should be ‘beautiful’. We designed a system where parts were individually wrapped and handled with white gloves to prevent not only scratches, but finger marks and smudges” said Traynor. He recalls one particular job for the Australian Navy being so delicate that the managing director, sales manager and the Tier 1 service manager could all be found on their hands and knees, individually wrapping and packing each item to ensure the paint work was not damaged in transit. A new freight manmonthly.com.au

The concept of Customer Centricity applies to all aspects of Bylaser’s business. company was also sourced that used trucks with an upper shelf so as to minimise the risk of damage if items moved in transit. Sometimes, it is just as simple as having the Bylaser team cook up a hearty BBQ for the client’s production crew.

Competing with China Based upon this 35 years’ involvement in manufacturing business, Traynor sees this individual approach a being a key strategy in remaining competitive in the Australian manufacturing environment and dealing with competition from cheaper Asian alternatives, particularly from China. According to Traynor, “By adopting a bespoke customer service offering we are tackling head-on some of the inherent weaknesses of the Chinese business systems”. “These include long lead times, quality variability, unreasonably large minimum order quantities and significant failures to meet agreed deadlines” he said. In his experience, these issues have only grown since the pandemic hit and there is unlikely to be any improvement in the foreseeable future. Traynor acknowledges that such individual customer service can come at an additional cost and compare unfavourably with the per

unit prices from Asia and indeed some other local competitors. “Although we are not always the cheapest in the market, by offering a service that exactly matches the needs of the customer, we were able to provide our customers with additional value by taking inefficient costs out of their business” Traynor said.

The results are in The results of the program have certainly paid off for the business. Since implementing the initiative, Bylaser’s turnover has increased by

more than 50 per cent. Traynor has also seen an increase in the amount of work won that would have traditionally been done in China. In his view, Australian businesses can compete with China when customers understand the real costs of being supplied from Asia. The Bylaser team members have also really gotten on board with the focus on the customer. Whereas previously it was all about working within the business rules, they are now encouraged to develop connections with their customer and are empowered to develop creative solutions that make for happy customers. “In this way, we are also able to develop genuine relationships with our customers which allows us to better deal with the bumps that can occur in any relationship.” Traynor has seen this have a positive effect on staff morale. “I’ve certainly seen an increase in team engagement and creativity since introducing our Customer Centricity strategy. There is a real buzz in the office and it’s a much more energised environment than when I first walked in the door”. “The impact of the pandemic on the business and the economy has required us to all rise to the challenge. I am very proud of our efforts and look forward to what’s around the corner.”

Bylaser has set up a “Kanban” solution, where expected parts and volumes are forecast in advance and agreed with the customer.

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IIoT IIOT-Toolkit working to digitally empower smaller businesses ifm’s Freddie Coertze tells Manufacturers’ Monthly the importance of empowering businesses trying to digitalise systems, and how the IIoT-Toolkit can help.

TEPPING into the world of Industry 4.0 can be harrowing for businesses that don’t know where, or how, to start with digitalisation. With the Industrial Internet of Things (IIoT) developing in volume and complexity since the 1960s, it becomes increasingly difficult for companies, especially those with limited funding to know the right way to digitalise. “It’s difficult to start. There’s so many vendors that sometimes you don’t really know what you want until you’ve got some data,”

said Freddie Coertze, Australia’s ifm product manager of industrial communications National IoT Business Manager. Coertze also specialises in leading and growing IO-Link technology with ifm itself being one of the world’s largest sensor and automation companies. “We take an approach where we tell clients they should start small with just a starter kit, pick one area, and from there, make decisions based on the outcomes,” said Coertze. That’s why the introduction

of ifm efector’s IIoT-Toolkit is so important: simplifying digitalisation and empowering customers to be able to take control of their data and invest in predictive maintenance. In a sense, it’s allowing businesses to dip their toe in before fully immersing in process of automation.

How it works The toolkit empowers customers through combining data from the information technology level with the operational technology level.

“The advantages are actually owning that information and the solution,” said Coertze. “The biggest problem in the industry is because you have these two worlds – IT has been by themselves for so long and you’ve got operation technology running side-by -side with the production line, but you need information from both ends. We see this as the bridge between those two worlds to then get the data from either side and then make better decisions.” The toolkit utilises four main

The IIoT-Toolkit lets customers have control over their data.

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IIoT technologies to help identify production issues: IO-Link, Image processing, RFID and identification and vibration monitoring. The IO-Link provides consistent diagnostic information on the machine and its processes, while ifm’s software in the IIoT toolkit is able to sort and convert all this sensory data from the machines into qualified digital information. Simple plug-ins that come as part of the toolkit allow clients to access the data and make decisions based on the information they receive. The IIoT-Toolkit’s software, such as Sensor2Cloud, is able to automatically collect and directly send information to the cloud. Thus, the toolkit enables a flow of information that is constantly being sorted and logged. “We are really driving qualified data rather than just gathering information,” said Coertze. “That’s why all of our units, like the IO link and our vibration units, actually pre-process that raw data before it is converted into the qualified information that you can send to your data collector. We just want to make sure it’s the right information in there that makes sense.” With all this digital information being received from the machinery, the toolkit is able to create virtual factories in the cloud. The consistent stream of qualified information helps clients understand the best functioning of their production line that introduces intuitive data for on time decision making for production and machine maintenance.

Predictive maintenance According to Coertze, a key benefit of digitalising through the IIoTToolkit is the ability to identify conditions to predict machine condition and failures. “We want to move away from having to take the machine apart every six weeks and do something with it, basically only acting when the condition is deteriorating. That’s why we feel like predictive maintenance is part of making more informed decisions. In the long run this prevents breakdowns, increases efficiency and decreases downtime,” manmonthly.com.au

The ifm IIoT-Toolkit helps identify production issues.

he said. “We try help customers move to predictive maintenance.” Being able to detect damage early can also lead to avoiding unwanted spares, said Coertze. “It means you don’t need to keep spares of that machine around. It would be easier to order the spares when the machine is working, or about to fail, so you have time to act. Of course, that will increase efficiency, because you don’t need to stop the machine,” he said.

Empowering customers Using the IIoT-Toolkit also gives the obvious benefit of owning the data. “That means that they (the client) don’t need people to program a lot of things in the background,” said Coertze. “The biggest problem we have is most customers start with engineering teams, and these engineering teams don’t really have access to the IT side of the companies.” The problem is slow to get solved as every action the engineering team does requires approval by the IT teams, or requires an IT member to come in. “Now they can just buy this kit

The Sensor2Cloud software can automatically collect and directly send information to the cloud. and it comes with a PC and they can start and stop working on something,” said Coertze. “Because we need to empower the customer, or engineering team, to build a business case. Then they can say:

We’ve chosen this area in the business, we’ve got some data, we’ve got something to show, then we can get funding.” With the help of ifm, the toolkit enables end-users to run with Manufacturers’ Monthly MAY 2021 33

IIoT the process themselves, which makes it easier to begin the digitalisation process.

Customisation Part of customer empowerment is creating solutions specific to the companies individualised needs. This includes making integration easy and being able to scale up the technology. While a solution or process might work for the company next door, it might not necessarily work for everyone. “You’ve got to customise it to that extent, and that’s why we feel customers need to own the solution,” said Coertze. “The customer basically says, ‘Look, what issue have we got?’ If it’s vibration or any type of sensing,

That’s why the kit was initially developed: because it is really low in entry level pricing, so they don’t need capital for it they don’t need a lot of funding to start with the solution. for example, then we will configure that unit for them and then they will place the order,” said Coertze. “We get the solution delivered, (they) plug it in and log in online and start logging information.” By owning the data and the understanding the particular problem, clients are able to tailor solutions specific to the business. It’s also very handy, said Coertze, when there is no technical staff onboard.

Affordability A key issue with transitioning into Industry 4.0 is the cost of investment. “We saw that the small to medium customers would not normally have IT teams in house. For example, microbreweries – they would not necessarily have the ability to put software on site,” said Coertze. “That’s why the kit was initially

developed: because it is really low in entry level pricing, so they don’t need capital for it they don’t need a lot of funding to start with the solution,” said Coertze. “Other suppliers will go ‘Yes let’s digitalise everything’ but that’s not the message. That will cost millions, and they’ll (the customer) go ‘I don’t even know where we want to start.’ “You’ll see the way we set up our software is that they can really maintain it themselves, and it’s really self-taught. If you play around on the site, you can figure yourself out and you don’t really need a lot of training,” said Coertze. “I get a lot of customers are stuck in that mindset, ‘It’s too difficult for me, I don’t know what to do’. I think this (toolkit) is all about unlocking them to start with something.”

Engineering teams need acces to the IT side of the company.

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Manufacturing Innovation Making gaskets in Australia since 1940 Seal Innovations’ Raj Jadow explains how the company has modernised its technology.

LOT has changed in the world of gasket making over the past 80 years, but for Seal Innovations, one of Australia’s oldest gasket manufacturing companies, moving with the times has never been a challenge. Since its birth in early 1940s, Seal Innovations has gone through multiple name changes and expansions, but as Raj Jadow, Seal Innovations’ national key account executive explains, the company has also constantly modernised its machinery to offer the latest technologies in gasket production. “Like all manufacturing, gasket making has become more automated over time. Where previously over 80 per cent of production was done manually, today the proportion has been reversed in favour of automation,” says Jadow. An example, he says, is a fully automatic Kammprofile machine that enables Seal Innovations to produce Kammprofile gaskets in many shapes and sizes with continuous grooves. “Not many companies in Australia have the automatic Kammprofile machine,” he says. “With this machine, we can manufacture Kammprofile gaskets of different sections, without having to weld the end joints. This helps extend the life of the Kammprofile gaskets significantly. We also have a customdesigned automatic compression packing cutter that helps us process larger gland packing orders within minimum time.” But Jadow is also quick to note that Seal innovations has unique capabilities when it comes to the manual aspect of gasket making – something that he says is still crucial to manufacturing gaskets. “The manual skills are quite critical to gasket production as some precision metal working can only be conducted manually. We have highly skilled technicians with over 35 years of experience in gasket making.” manmonthly.com.au

Seal Innovations’ history Seal Innovations’ journey began as a business partnership between C.B. Byrne and E.C. Blackford in the early 1940s. At the time, the company had offices in Sydney and Melbourne and manufactured gaskets and washers at a 4600-square-metre facility in Brisbane’s Eagle Farm. Over the years, the company expanded, opening in both Adelaide and Perth and in 1947, formed an association with the UK-based Engineering Components. The company then became known as Payne, Byrne & Blackford and began its long association with Flexitallic. The business went through a few acquisition and mergers in the following years and was eventually split into two separate divisions: the Automotive Gasket division (ACL) and Industrial Gasket Division (Specialised Gaskets). Currently, the Industrial Gaskets Division of Seal Innovation is part of Industrial Solutions Australia’s group of businesses – which also includes CBC, BSC and WebsterBSC. Seal Innovations services its customer base through its eight branches nationally and supported by its state-of-the-art manufacturing facility headquartered in Eagle Farm, Brisbane.

Keeping industry moving Today, Seal Innovations manufactures specialised seals and gaskets for various industries like oil and gas, refineries, food and beverage and pharmaceuticals. Jadow says the company is regularly audited by major oil refineries and turbine manufacturers that purchase its products due to the sensitive nature of their applications. “Gaskets are critical components in industries like oil and gas. If a gasket fails, the resulting leak can be disastrous and even lead to explosions. That is why we are very strict with our production processes, complying with

Seal Innovations began a business partnership between C.B. Byrne and E.C. Blackford in the early 1940s. quality standards specified by ISO 9001, AS/NZ 4801 and ISO 140001,” he says. “We also take product traceability very seriously. Some of our customers expect precise traceability of the raw materials used in their gaskets in order to calculate the products’ shelf life accurately. We always keep well-organised records of all of our raw materials and their specifications in order to produce the required certificates when necessary,” he adds. Technologies in gasket production have undergone an evolution in the past decades. For example, asbestos, once heavily used in manufacturing sheet gaskets, was eliminated completely due to its health hazards. Jadow says Seal Innovations’ position as the exclusive licensee manufacturer and authorised distributor of Flexitallic Gaskets in Australia and PNG has enabled it to bring the latest gasket technologies to its customers. “Flexitallic was the first company in the world that invented spiral wound gaskets nearly 110 years ago. They also developed the patented Thermiculite material, which is a superior replacement to asbestos sheet seals compared to compressed fibre and tanged graphite sheets. As an exclusive licensee manufacturer for Flexitallic, we have introduced some of the most cutting-edge gasketing products in Australia, and we continue to support these

with our in-house manufacturing capabilities,” says Jadow. “Apart from the Kammprofile machine and the automated compression packing cutter, Seal Innovation’s Eagle Farm facility is also equipped with spiral winding machines, laser cutters, water jet cutters, knife cutters, three machined metal lathes, a paint station and a welding bay,” he adds.

Plans for future growth According to Jadow, Seal Innovation has plans to expand its capabilities further in the near future to offer even more traceability and automation in its production process. “We will soon be introducing innovative packaging with QR codes to facilitate even better traceability and access to product information for our customers. Further, Seal Innovations have just purchased a second laser, a laser etcher as well as an additional kammprofile machine and three additional spiral winding machines. A large investment displaying our strong commitment to manufacturing the highest of quality product in Australia efficiently and economically,” Jadow concludes. “This is how we aim to progress in the future: Building on the experience of our team and investing more in automation technologies to remain a leader in gasket manufacturing.” Manufacturers’ Monthly MAY 2021 35

Metalworking 3M Silver Wheels: combining performance with value 3M senior application engineer Nathan Bamford speaks about the Cubitron II products delivering speed and long life at a value price.

PEED and efficiency are the most important parameters for any metal worker when selecting grinding wheels. But cutting metals faster and cleaner does not need to be more expensive. The new 3M Silver grinding wheels represent a class of cutting wheels that are both tough on metal and cost-effective. As Nathan Bamford, senior application engineer at 3M explains, the 3M Silver range use similar precision shaped grain technology as found in the premium 3M Cubitron II products to deliver speed and long life, but at a value price. “The 3M Silver range outperform conventional aluminium oxide wheels but sit just below our premium Cubitron II range. In our Right Choice Catalogue, we use a star rating, with the Cubitron II range having 5 stars and the Silver

range given a 4-star rating.” The Silver range by 3M includes both Depressed Centre Rigid Grinding Wheels and Cut-Off Wheels. With both of those models, Nathan says the secret to the high performance lies in the precision shaped grain technology. The service life in grinding wheels depends on many factors, but Bamford notes that abrasive products with precision shaped grain technology generally have significantly improved life compared to conventional discs. “When cutting steel and stainlesssteel tubing assemblies using 3M Silver Cut-Off Wheels, our customer reported 50 per cent less wear compared to their standard aluminium oxide wheel. For cutting structural metal sheet and plate, the 3M Silver Cut-Off Wheels demonstrated 40 per cent less wear than this customer’s usual AZ wheel.”

When using 3M Silver Cut-Off Wheels, customers have reported significant less wear.

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The Silver range by 3M includes both Depressed Centre Rigid Grinding Wheels and Cut-Off Wheels.

To further explain the technology used by 3M, Bamford draws a comparison between grinding wheels using conventional grains and those using precision-shaped grains. “In the conventional abrasive discs, the grains are randomly distributed in the coating covering an abrasive backing. This irregular cutting surface results in a “ploughing” effect as it cuts through the material. This ploughing causes heat to build up in the workpiece and the abrasive, which dulls the grain and eventually reduces the wheel’s service life,” says Bamford. “The precision-shaped grains, on the other hand, use the 3M microreplication technology to form sharp peaks that easily ‘slice’ through metal. This action prevents heat from building up in the workpiece and therefore prevent heat-related stress cracks and discolouration. Also, because the abrasive itself stays cooler and sharper, it lasts longer than conventional grain,” he adds. Selecting the right grinding wheel for each application can be complicated. They are available in a variety of sizes, shapes and grits. Bamford’s recommendation is to refer to 3M’s selection chart or to consult 3M abrasive specialists to recommend the best product for each application. BSC, a key supplier of industrial

abrasives and other industrial components in Australia, also actively supports customers with selection for their abrasive needs. BSC product manager Michael Rowe says BSC specialists are always available for assistance when needed. “Our team can facilitate to set up trainings or demonstration sessions for metal fabricators who want to assess the cost benefits of 3M grinding wheels. With our many years of experience working with almost every industry in Australia, we understand the customers’ grinding needs and we can recommend just the right product for their needs.” For maximum safety while grinding, follow these steps: 1. Elimination: Modify the task or workplace so that the hazard is no longer present. 2. Substitution: Replace the hazardous material, equipment or activity with a less hazardous one. 3. Engineering controls: Modify the design or specification of tools or equipment to isolate or reduce the exposure to the hazard. 4. Administrative controls: Introduce working practices and procedures that remove or lessen the risk. 5. Personal Protection Equipment (PPE): Protect the worker with suitable PPE. manmonthly.com.au

Sensors New laser profile scanner for OEM applications Bestech has supplied high performing laser profile scanners from Micro Epsilon on the Australian market for more than a decade. Manufacturers’ Monthly finds out the latest developments.

ESTECH Australia introduce the newest development for its laser profile scanner for advancing local manufacturing. The new scanCONTROL 2500 is ideally suited for high volume manufacturing applications, while the scanCONTROL 3000 offers a high-resolution scanning for challenging applications and measurement on difficult surface. The introduction of the entry level, compact scanCONTROL 2500 has made it possible for large scale manufacturing industry to consider integrate this high-tech system in their process. It provides measurement resolutions of 192,000 points per second, with a maximum measurement speed of 300 samples per second. The introduction of several new models means that scanCONTROL will be more economically feasible for applications that do not require high precision measurement such as for OEM clients.

High resolution profile scanning technology The new scanCONTROL LLT3000 scanner offers the highest performance scanning in terms of accuracy and measuring rate. It has a high-resolution sensor matrix that allows measurement of profile data up to 5.5 million points per profile to reliably detect the finest of details in an object. This advanced scanner is also available in high-speed version to offer a maximum sampling speed of 10kHz for dynamic measurement task. This new scanner can generate accurate results on surfaces with inhomogeneous structure as the exposure of its lens can be simultaneously adjustly without time offset. “The wide selection of range and capability of the scanCONTROL manmonthly.com.au

laser profile scanners open a possibility for integration in industrial manufacturing process, from mass production, 3D printing or research,” said Bestech’s national applications manager, Arend Wieringa. “The SMART version of the scanner can do automatic calculation of profile properties such as edge angle or gap and it can also be used to determine surface topology in 3D printing process.” The new scanCONTROL LLT3000 model is equipped with high dynamic range acquisition mode, which improves the exposure of the sensor matrix for measurement on difficult surface and for high-speed dynamic process. Therefore, it can reliably measure the profile of fastmoving object with high precision. “We have encountered an application where the end-users require a wide range profile scanner to measure on the conveyor belt,” said Wieringa. “Currently, our profile scanner has a maximum measurement range of 200mm. There is an ongoing R&D activity to improve the performance of the sensors, which we hope to introduce to our customer in 2021.”

Controlled intelligence There are two versions of the sensor: COMPACT and SMART. The SMART version of the sensor is integrated with intelligent controller to enable automated calculation of the profile without performing complicated analysis. When the customer enquires about a laser profile scanner, they will think about the sensor that are capable of detecting the object profile. The SMART profile scanner that we supply from Micro Epsilon provides additional measurement capability that can be interfaced

The entry level, compact scanCONTROL 2500 provides measurement resolutions of 192,000 points per second, with a maximum measurement speed of 300 samples per second. with PLC to streamline their production process. The laser profile scanner is particularly suitable for manufacturing applications that require automated calculation of profile properties such as gap, edge angle, groove or depth. “Edge angle detection is crucial in plasterboard manufacturing process to fit in the building specification,” said Wieringa. “The SMART version of the sensor can be mounted on the production line and automatically measure the edge angle which makes the production process more efficient.” The production of roof tiles requires high demand of measurement and testing to ensure the quality of the product. The demand for accurate profile measurement is crucial in roof tile applications as even a minor error in the tile sizing means that the tiles will not fit into the entire roofing section. The high precision measurement capability of the laser profile scanner enables reliable measurement of the surface roughness of the roof tile. In

addition, the advancement of 3D printing and additive manufacturing technology also requires a high precision profile sensor to reliably measure on the 3D-printed surface. “We have continuously improved the products with the introduction of new feature, ranges and measurement capability to meet the demand of the manufacturing industries,” said Wieringa.

About Bestech Bestech Australia specialises in supplying, designing and manufacturing sensors and instrumentation for measurement of physical parameters, data acquisition systems and technical teaching equipment. One of the fastest growing companies in Oceania, it provides efficient solutions in the form of an individual product or a complete turn-key system. Bestech provides full technical support, including consulting, design, implantation, test and commissioning as well as integration to support customers with high-end test and measurement requirement. Manufacturers’ Monthly MAY 2021 37

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Awards Endeavour Awards returns in 2021 Manufacturers’ Monthly is proud to announce the return of the Endeavour Awards ceremony this year.

RIME Creative Media is pleased to announce the launch of the annual Manufacturers’ Monthly Endeavour Awards – the premier night for recognising the industry’s successes – for 2021. While the venue is to be confirmed, the event will be held in Melbourne on September 30th. The Endeavour Awards are an event this magazine is immensely proud to be able to hold. They are a chance for all involved to celebrate the many successes within the industry, to help share these successes with a broader audience, to network, and to learn more about the many remarkable personalities and enterprises that make the industry great. This year, the Manufacturer of the Year Award will be supported by Bestech Australia. SEW Eurodrive will sponsor the Most Innovative Manufacturing Company Award. CEO and executive director of Weld Australia, Geoff Crittenden, said in the wake of a year where uncertainty was the only certainty, it is time now more than ever to celebrate the resilience of Australia’s manufacturers. “Weld Australia is delighted to take this opportunity, alongside our fellow sponsors, to spotlight those manufacturers excelling in their field, and to celebrate the Australian manufacturing industry across the board,” he said. “Weld Australia is proud to support the Endeavour Awards once again in 2021 by sponsoring the award for Best Industrial Internet of Things Application. “This award will recognise the most outstanding application used in a smart factory to improve the manufacturing process. Weld Australia is a champion of the Australian manufacturing industry, strongly advocating for the onshoring of manufacturing, and for state and federal governments to support local manufacturing. The Endeavour awards for VEGA is

manmonthly.com.au

The Endeavour Awards are an event this magazine is immensely proud to be able to hold.

an opportunity to demonstrate to the industry that we are serious about our commitment and ongoing support to the many clients within this sector. VEGA Australia managing director John Leadbetter said manufacturers will need to offer not only state-of-theart equipment, but also a competitive pricing bracket for their equipment. “VEGA recognises that for manufacturers to compete in a local and international market that strong and reliable partnerships are the cornerstone to making this venture a success,” he said. The Industry Capability Network (ICN) has a strong belief in companies that have made a difference with their supply chain networks and for this reason, have decided to sponsor this year’s Global Supply Chain Integration Award. As a business network, ICN has been helping bring together Australian and New Zealand companies on projects for over 30 years. “The Endeavour Awards provides an opportunity for manufacturers and industry to really showcase their capabilities and their innovative activities in the local marketplace to a wider audience,” said ICNL executive director, Warren Jansen. “Everything ICN does is guided by a clear vision to contribute to

increased economic activity and employment for Australia and New Zealand. by assisting industries to gain a greater share of domestic and international business opportunities.” Jansen said in these uncertain times, it has never been more important to support manufacturing in Australia. “The Endeavour Awards helps build awareness for the capability and capacity of Australian industry and manufacturing, putting Australian manufacturing on the global stage,” he said. BDO is proud to be sponsoring the Excellence in Growth Award at this year’s Endeavour Awards. BDO national manufacturing and wholesale Leader, Ryan Pollett, said over the past year, Australian manufacturers have shown resilience through a challenging period. “We are celebrating both the spirit and ingenuity of the manufacturing industry as it stands,” he said. “Each growth story brings a new perspective on the way they approach business and by sponsoring the Excellence in Growth award, we are helping to not only recognise those growth stories, but learn from them.” Pollett said the awards send a very positive message to the Australian manufacturing sector, Australian business and global markets that

Australian manufacture is innovative, cutting edge and ready to engage both locally and internationally. Innovation and Business Skills Australia (IBSA), as the national skills standards developer for the manufacturing sector, is part of the process for providing the industry with skilled workers. IBSA CEO Sharon Robertson, said the organisation is constantly engaging with employers and workers to understand industry needs and what skills are required for manufacturing to be successful going forward. “The awards provide us with opportunities to learn from industry best practice,” she said. “We use them to broaden our knowledge base and discuss the key, skills- related issues facing employers now and in the future. IBSA sees being involved in the awards as a fantastic opportunity to shine a spotlight on Excellence in Manufacturing Skills Development.”

The Manufacturer of the Year Award will be sponsored by Bestech Australia.

Nominations for the awards close on Friday 23 July 2021. Manufacturers’ Monthly MAY 2021 39

What’sNew Winmate’s W15IB3S-PTA3 15.6” PT Series HMI Panel PC Backplane Systems Technology presents Winmate’s W15IB3S-PTA3 15.6” PT Series HMI Panel PC. The W15IB3S-PTA3 is a 15.6” 1920 x 1080 resolution and PCAP Touchscreen HMI Panel PC with a low power consuming Intel Celeron N2930 processor. The true flat front panel is IP65 rated for protection against water and dust and a plastic enclosure. The HMI Panel PC has a fanless cooling system which can operate in temperatures from 0°C to 50°C. Multiple I/O interfaces include USB 2.0, one LAN port, serial interface RS-232/422/485 for machine-to-machine communications, USB 2.0, and USB 3.0 for data transfer. The W15IB3S-PTA3 HMI is an ultimate solution for Point-ofSale (POS) applications. Key features: • 15.6” 1920 x 1080 with P-CAP touchscreen; • Intel Celeron N2930 1.83 GHz; • Fanless cooling system and ultra-low power consumption; • Front IP65 for protection against water and dust; and • A true flat, easy-to-clean front surface with edge-to-edge design. Company: Backplane Systems Technology Phone: (02) 9457 6400 Web: www.backplane.com.au

Effective on-line condition monitoring for industrial machinery The vibration sensor of the VV family is a real-time vibration sensor specifically designed to monitor industrial machines under difficult operating conditions. The type VV sensor can detect and alert you to problems before they affect your production availability. The IO-Link technology simplifies the setup and automates monitoring using the industrial network of your plant being either Ethernet, Profinet, Modbus or EtherCat. The continuous monitoring is realised in four categories of machine failure: impact, fatigue, friction and temperature. With the vibration sensor VV you increase the equipment availability, decrease the maintenance costs and ensure the quality of the machine. Raw signal capture for real-time advanced analytics or simple indicators for automated alerts. Industrial grade machine protection integrates directly into your existing control platform without the need for control cabinets or extensive wiring thanks to IO-Link. This allows the timely and predictable scheduling of maintenance before major damage or failure and production downtime. Machines are continuously and permanently protected unlike intermittent monitoring systems. The industrial proven IO-Link system simplifies integrating Industry 4.0 technology directly into your existing control platform. Expensive secondary networks, gateways, and IT support is not needed. IO-Link masters send status signals to the controls and has the ability to send calculated and raw vibration signals to higher level systems for advanced analytics. The vibration sensor internally acquires and analyses various process values that are used to detect machine errors. Critical points such as: - v-RMS (Machine looseness conditions) Effective value of the vibration velocity, identifies component fatigue. - a-RMS (Machine friction conditions) Effective value of the acceleration, identifies mechanical rubbing. - a-Peak (Machine impact conditions) Maximum acceleration, identifies mechanical impacts.

40 MAY 2021 Manufacturers’ Monthly

- Crest-Factor a-Peak/a-RMS, is one of the important measures of overall machine condition. - Temperature Identifies a rising temperature caused by excessive friction or other effects (e.g. electrical causes). - Raw data For detailed analysis or cause analysis in case of damage, the sensor also provides raw data of the acceleration recording. These are issued on request as a BLOB (Binary Large Object) and transmitted using IO-Link. The system can record the operating condition at 4 second intervals and transmit the data during several minutes to higher level systems. Company: ifm efector Phone: 1300 365 088 Web: www.ifm.com/au/en

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AVS-500 Series Embedded Machine Vision Systems System performance plus reliability are critical factors for Vision-based systems. In order to detect defects, Vision Systems need to perform fast and accurate analysis of objects. The AVS-500 Series are powered by 6th/7th Gen. Intel processors to provide a state-of-the-art multi-core processing platform. In addition, high-speed PCIe x16 expansion allows high bandwidth GPU data access which is essential for reliable image processing performance. The AVS-500 Series is equipped with two SODIMM sockets supporting up to 32GB of DDR4 system memory, two Gigabit RJ-45 Ethernet connectors, four USB 3.0 ports, two USB 2.0 ports, four digital inputs, four digital outputs, two RS-232 ports and one RS-232/422/485 and one RS-422/485 port for communication. Two easily accessible 2.5” SATA hard drives can be internally mounted for operating system and data storage. While two full-size Mini-PCIe slots are provided on the motherboard, AVS-500 Series models are also available with two or four expansions card slots. Various PCIe x16, PCIe x4, PCIe x1 and PCI slot combinations are available. The on-board Intel HD graphics engine provides VGA and HDMI output with support for 4K UHD high resolution displays. The AVS-500 Series is capable of connecting to multiple GigE and USB 3.0 cameras for machine vision applications and also supports light source control, ensuring that objects are correctly exposed during the imaging process. Possible applications include: Automation Control, 2D/3D Measurement, Surface Inspection, PCBA Inspection, Robotics Arm Guiding, Textile Auto-inspection and Label/Barcode Scanning.

• Extensive I/O support; • PCI/PCIe expansion slots; • Fanless design with integrated chassis heatsink; • Easily accessible hard drive enclosure; and • DC 9~36V wide-ranging power input. For more information contact Interworld Electronics. Company Name: Interworld Electronics Web: ieci.com.au Telephone: 03 9593 7555

The AVS-500 Series features include: • Intel 6th/7th Gen. Core i7/i5/i3 processor support; • Up to 32GB DDR4 memory;

igus roller e-chain for targeted irrigation with savings potential New precision irrigation carriage reduces water and fertiliser consumption by 75 per cent – e-chain in a trough guides hoses with additional energy saving. The aim of the precision irrigation carriage from Rathmakers Gartenbautechnik is to use water resources sensibly whilst protecting the groundwater at the same time. With the new automatic irrigation system, the water reaches exactly where it should: directly to the plants. For the safe and compact guidance of hoses and cables, the developers rely on an igus energy chain system consisting of roller chain and guide trough. Water shortage is a major problem worldwide, which is why solutions are needed, especially in agriculture, which bring water in a targeted manner to the plant. For this purpose, Rathmakers Gartenbautechnik has developed a precision irrigation carriage together with Landwirtschaftskammer NRW. Whereas conventional irrigation carriages with a continuous jet stream waste a lot of water, the precision watering carriage irrigates and fertilises in a stipulated way. The unique system is especially suitable for outdoor potted plant cultivation and ensures that water is delivered precisely into the middle of the plant’s growing pot. By using this new technology, savings of 50 to 75 per cent are possible in irrigation water, plant protection and fertiliser, depending on the pot size. This also reduces the nitrogen input into the groundwater. The precision irrigation carriage has a span of 40m and a travel of 208m. The cables and hoses for the water supply were pulled behind the carriages until now. A loop was created, which required about 2m of space between the carriage guide and the plants. A safe and space-saving hose with cable guidance was required. Therefore, Ralf Hormes, CEO at Rathmakers Gartenbautechnik, contacted igus.

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343 sqm of more usable space The main advantage of the system: by guiding the hoses and cables, the usable area is increased by 343 sqm. It also increases the service life of the supply components in the system. A 3500R series roller chain with a width of only 35cm is used in a guidelite guide trough. The technical basis of the energy chain is the integration of rollers into the chain links to reduce the coefficient of friction on long travels. Thereby, up to 57 per cent of the required drive energy can be saved while moving the energy chain system. The guidelite guide trough is a cost-effective and quickly installable solution made of corrosion-resistant and durable high-performance polymer. The igus energy chain systems are available for custom solutions from Treotham Automation. Company: Treotham Automation Pty Ltd Phone: 1300 65 75 64 Website: www.treotham.com.au

Manufacturers’ Monthly MAY 2021 41

The Last Word

INNES WILLOX – Chief Executive, Ai Group

New National Cadetship Program needed to help businesses rise from COVID-19

HILHEN the COVIDpandemic struck a little over a year ago apprenticeship commencements fell through the floor and young trainees were among the first to have their jobs cut or training cancelled. Ai Group advocated hard for a program to support apprentices and the Federal Government responded with the Boosting Apprenticeship Commencements program. That program, which has now been extended, provided support for businesses to retain or take on new apprentices. It has been an overwhelming success which has benefitted more than 100,000 apprentices and trainees. The new funding announced recently will consolidate the gains and enable more employers to take on their usual annual intake of apprentices and trainees and in many instances increase apprenticeship numbers. Another Ai Group proposal which will support the creation of a strong pipeline of skills to help lift the economy out of the COVID downturn is a National Cadet Program Ai Group has urged the Federal Government to use the May budget to fund national wage subsidies to assist employers to engage VET and higher education students as cadets and interns. The rapidly changing work environments and skill needs thrown up by COVID-19 are best served by learning that is connected to the workplace and closely reflects workplace skill needs, such as work-based and work integrated learning models. Apprenticeships are a typical employment-based learning model but work-based learning includes internships and cadetships, where formal education and training is supplemented by actually doing the work on the job and support from other skilled co-workers. There is much evidence that combining an employment contract

42 MAY 2021 Manufacturers’ Monthly

with formal education and training results in better employment outcomes. Benefits of work-based learning include a stronger connection to current workforce needs and better linkages with labour market demand. For employers, such programs create potential long-term employees in addition to benefits gained through the productive work completed during placements. The proposed national program, designed and proposed by Peter Dawkins (Victoria University) and David Lloyd (University South Australia), would require substantial wage subsides in order to provide incentives to employers to take on cadets at scale in the height of exceptionally high youth unemployment and poor labour market prospects. The program could be developed through Commonwealth/ State and Territory partnerships, as well as with Commonwealth Higher Education funding. Existing infrastructure that administers employer incentives and wage subsidies could be expanded. Another area which could benefit from Federal budget support concerns the need for higher level skills programs to meet the demands of a transforming economy. Digital transformation has been fast-tracked by the pandemic and it is vital for the recovery that higher level skills programs are introduced across industry to meet the need for skill levels that are creeping ever higher. Prior to the pandemic, automation was already disrupting skills, reallocating employment between tasks, sectors and regions. Labour demand is shifting towards higher level, more cognitive skills for which many workers are not adequately trained. Ai Group’s pre-pandemic research had shown that employers were prioritising managers for digital technology training. This need for management development is likely to have been heightened by the acceleration into digital systems

Ai Group’s chief executive, Innes Willox. by many companies. Businesses are now even more likely to develop new digital strategies which have implications for their workforce development. The transforming economy will continue to rely heavily on higher education to develop higher critical enquiry. Formal work-based learning programs at higher levels, are gaining interest from both industry and potential apprentices/cadets. These approaches have the twin benefit of extending the level of qualification awarded for apprenticeships as well as expanding the scope to non-trade and more para-professional occupations. There have been two pilots to trial higher apprenticeships. The Ai Group pilot focused on high-level technical skills in engineering and digital technology. The other was developed by PricewaterhouseCoopers, who piloted an 18-month Diploma of Business in apprenticeship mode for professional, business, information technology and financial services. In South Australia at the start of 2021, a group of about 20 school leavers are commencing formal training contracts to undertake the Diploma with a range of companies including manufacturers and water

and energy transmission companies. One large Defence industry manufacturer intends to offer apprenticeships at the Bachelor level once approvals have been obtained. It is clear that higher education, advanced apprenticeships will greatly assist the needs of industry. However, there are challenges in making higher apprenticeships more broadly available. State Training Authorities currently recognise only VET-level qualifications as apprenticeships or traineeships. Universities in Australia are not familiar with the model. Industrial awards generally do not make provision for them. Ai Group’s own advocacy on education and training is soon to be given a big boost with imminent launch of our own Centre for Education and Training. This will be a new research and advocacy body designed to better connect skills development with the needs of industry and the community. We are working hard to ensure that there is a strong pool of skilled workers ready to contribute to growth and provide meaningful and well targeted jobs and careers as our economy emerges from this pandemic. manmonthly.com.au

JULY 2021 – FABRICATIONS SPECIALIST SHOWCASE One of the biggest contributors of Australia’s manufacturing sector are the specialists in material fabrication. This is a showcase of the capabilities of fabrication specialists that service Australia’s largest manufacturers across both heavy and light industries. This July 2021, we will be featuring a showcase listing of Australia’s best fabrication specialists and their machine capacities and verticals they serve. 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: 09 June 2021

To book contact DANILO CORTUCCI now danilo.cortucci@primecreative.com.au | 0434 419 663

“Laser Profile Scanning serves as effective inline measurement system to ensure uniformity of roof tiles during production”

PRECISION SENSOR SOLUTIONS FOR QUALITY MANUFACTURING Manufacturing demands on increasing productivity while ensuring satisfactory quality of the product. Bestech offers the highly precise non-contact profile scanning system with high-speed capability up to 10kHz. The intelligent controller can automatically calculate profile properties and feedback the results to industrial communication interfaces. Its compact and robust design are specifically for ensuring long lasting application in industrial environment • Accurate on inhomegenous surface • Intelligent tracking and profile correction • Adapted to rapidly changing surface Email: enquiry@bestech.com.au

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Phone: (03) 9540 5100