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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS
NOVEMBER 2023
Discover a
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Creating A Better Tomorrow The global merger of Regal Rexnord and Altra Industrial Motion into Regal Rexnord IPS ushers in a new era in Industrial Powertrain Solutions. Renowned brands with world class powertrain products delivering end to end Powertrain Solutions to the Manufacturing industry.
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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS
NOVEMBER 2023
REVOLUTIONISING the hydrogen market
Official Industry Partners
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Welding automation
Elexon Electronics fire recovery
Management consulting with RSM
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CEO: John Murphy Chief Operating Officer: Christine Clancy Managing Editor: Syed Shah Editor: Josh Farrell joshua.farrell@primecreative.com.au Journalist: Phillip Hazell phillip.hazell@primecreative.com.au Production Coordinator: Michelle Weston michelle.weston@primecreative.com.au Art Director: Blake Storey Design: Tom Anderson, Caterina Zappia Sales/Advertising: Johnny Volwerk Ph: 0432 083 392 johnny.volwerk@primecreative.com.au Subscriptions Published 11 times a year Subscriptions $140.00 per annum (inc GST)
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Manufacturers’ Monthly Contents 6 Editor’s Note
36 Fire Recovery
10 Weld Comment
41 Management Consulting
12 News
44 Engineering Focus
24 Manufacturer Focus
48 Fastening Products
28 Business Combination
49 What’s New
30 Welding Automation
50 Last Word
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 the opinions of, or endorsed by the publisher unless otherwise stated. © Copyright Prime Creative Media, 2023
32 Vehicle Hoists
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34 Fluid Power
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The global merger of Regal Rexnord and Altra Industrial Motion into Regal Rexnord IPS ushers in a new era in Industrial Powertrain Solutions. Renowned brands with world class powertrain products delivering end to end Powertrain Solutions to the Manufacturing industry.
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NOVEMBER 2023
REVOLUTIONISING the hydrogen market
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The Manufacturer Focus for November looks at Hysata and its impressive new factory recently opened in Port Kembla. The company is making some of the most energy efficient electrolysers globally and have expanded to
the regional hub of Port Kembla to further expand the business. Further in the magazine we look at welding automation offered by Robotics Automation, a recent acquisition by Motion Australia and fasteners from United Fasteners.
30
36
41
Welding automation
Elexon Electronics fire recovery
Management consulting with RSM
>>
Get in contact to find out how Regal Rexnord IPS can help you with end to end Industrial Powertrain Solutions. 1300 258 726 Sydney
4 NOVEMBER 2023 Manufacturers’ Monthly
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1123 Atla
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Editor’s Note
JOSH FARRELL – Editor, Manufacturers’ Monthly
Resilience and growth
I
T has been another exciting month putting together the November edition of Manufacturers’ Monthly. I am consistently impressed by the resilience and the growth in Australia and find myself extremely buoyed by what the future can hold for the industry in Australia. The September manufacturing Purchasing Manager’s Index (PMI) indicates the overall economy grew globally after contracting for nine consecutive months. The PMI is an index of the prevailing direction of economic trends in the manufacturing and service sectors. It consists of a diffusion index that summarises whether market conditions are expanding, staying the same, or contracting as viewed by purchasing managers. While September saw activity contract for the 11th straight month,
6 NOVEMBER 2023 Manufacturers’ Monthly
September saw it register at 49 per cent, which is 1.4 percentage points higher than the figure reported in August. Timothy Fiore, chair of the ISM’s manufacturing business survey committee explained the results in greater detail. Fiore explained that this is the 11th month of contraction but we are seeing positive change from lower months earlier in the year. Both production and employment indexes were up for manufacturing after none were in August. Five industries reported growth which included: non-metallic mineral products, food, beverage and tobacco, textile mills, primary metals, and petroleum and coal products. Multiple survey respondents emphasised the importance of keeping an eye on the evolving supply chain, with one survey respondent in the
‘miscellaneous’ manufacturing category noting, “Overall, things continue to be very steady: Sales and revenue are as expected, and the supply environment has stabilised greatly versus 2021-22.” These numbers show positive growth for the industry. I believe these incremental steps are pivotal for Australia’s return to being an important cog in the global manufacturing space. Anectodal conversations that I have had with industry insiders show me that we are beginning to track in the right direction but the process is only just beginning. It has been a pleasure putting together this month’s stories. One that I took great joy in writing was Elexon Electronics article. The resilience the company has shown in the face of great adversity is incredibly commendable and I am so impressed by how quickly it has got its
production line back up and running. I was also incredibly touched to hear the fantastic support provided by the wider manufacturing industry: competitors and suppliers alike have all come together to throw their support behind the company to help them get back online. I would argue very few industries would show that type of support to competitors and it makes me incredibly proud to be a part of the manufacturing sector. This month we will also look at Hysata in our Manufacturer Focus, a company that has opened a new facility to improve its manufacturing capabilities for its hydrogen electrolysers. Also, be sure to check out our interview with Don Holley from RSM to learn about the company’s new management consultancy capabilities. Happy reading!
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Comment Weld Australia
GEOFF CRITTENDEN – CEO, Weld Australia
im re B fa co fo
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a (w e to k re h
Australia’s Renewable Energy Revolution Challenge: Not Tech, But Trust
W
HILE in Canberra for the 2023 National Manufacturing Summit, Jim Sanford, Charlie Joyce (both from the Centre for Future Work), Adam Hersh (Senior Economist at the Economic Policy Institute in Washington and our keynote speaker), and I met with representatives of several Federal Government departments. During these meetings, I was surprised at how often Adam referred to the time, effort and money the Biden Government invested to bring the various interested parties onside prior to ratifying the Inflation Reduction Act (IRA). Adam made it clear that progress would have been impossible without the buy-in of all stakeholders from conservations and farmers, through to unions and planning departments. Initially, I thought this approach was a reflection of the divided and somewhat acrimonious political environment in the United States. I was convinced that meeting our climate goals was an issue of investment, partnering with the global supply chain and establishing a sovereign manufacturing capability—somewhat typical of ‘engineer thinking’. By the time the Summit concluded, I had made a complete about-face. Unless we achieve a social license—and quickly— Australia will fail to meet its renewable energy and net zero targets by 2050. 10 NOVEMBER 2023 Manufacturers’ Monthly
There is nothing difficult about achieving these targets from an engineering or manufacturing perspective, given the right incentives and investments. The challenge we must overcome is achieving a social license from the key interest groups of conservationists, farmers, unions, and planning departments. But, as we’ll explore below, the challenge is not insurmountable.
Conservationists Our continent is teeming with rare and unique flora and fauna. Since European settlement over 100 species have become extinct. As the planet warms it is envisaged that this number will increase and the rate of extinction accelerate. We therefore face the challenge of how to save the planet without destroying it. There is no question it can be done but, like so many parts to this puzzle, it requires us to radically change the way we think. The 400MW Willatook wind farm, north of Port Fairy in Victoria, exemplifies this challenge. Conceived in 2010, plans for the $1 billion Willatook wind farm encompass up to 59 turbines (with a maximum height of 250m), up to three 170m-high wind monitoring masts, a substation, battery storage, maintenance buildings, underground cables and
above-ground transmission lines. The site for Willatook wind farm is principally used for sheep grazing and lies within a zone designated by the Victorian Government as suitable for renewable energy, with easy access to an existing 500kV transmission line. The problem is, the site is also home to the nesting ground of the brolga, a threatened indigenous crane famed for its dancing rituals, and the 55mm-long, cave-dwelling southern bent-wing bat. It is worth noting that environmental reports state that just one pair of brolgas has regularly nested at the site between 2010 and 2021. After a decade of development work, including the two year environmental impact approval process, the planning conditions imposed to protect these species have effectively killed the Willatook project. The strict conditions cut the number of turbines that can be installed by two thirds and imposed a five month ban on construction work at the site every year. Similarly, in Queensland, the Pioneer Pumped Hydro scheme, regarded as essential for achieving net zero emissions in the state, is already receiving severe criticism from the Mackay Conservation Group. According to the Conservation Group, all of the water in the Pioneer
catchment is already fully allocated for farmers, drinking water, and environmental flows. There simply is no available unallocated water to operate a pumped hydro scheme. The Group is also concerned about the impacts on the Eungella National Park. Furthermore, the project is being politized by right wing parties whose alternative proposal is the introduction of modular nuclear power generation; a technology that does not yet exist. It is doubtful that there is a renewable energy project in Australia not being delayed by some form of environmental issue. So, we must implement a multifaceted approach to win the support of conservationists for major renewable energy projects like wind farms. This approach must reflect the delicate balance between promoting renewable energy development and addressing environmental concerns, and comprise adaptive management, mitigation strategies and collaborative partnerships.
Farmers Farmers were one of the first interest groups to be addressed by the US Federal Government in the drafting of the Inflation Reduction Act (IRA). Understandably, they are a powerful lobby group who will be significantly manmonthly.com.au
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CommentWeld Australia impacted by the construction of renewable energy infrastructure. The Biden Administration brought the farming lobby onside by agreeing a compensation plan and a set of guidelines for a construction approval process. In Willatook, the tough planning restrictions are supported by some local farmers who dispute the results of the environmental impact statement which assert that only one pair of brolga has been regularly nesting in the wetland area out of an estimated breeding community of 200 Australia wide. Whilst it would be wrong to question the sincerity of their support for the brolga, it is interesting to note this quote from one local farmer. “There’s a massive build-up in our area, they are just trying to put them (wind towers) everywhere, all on top of everybody down here,” he said, pointing to the drawcard for developers of the 500 kilovolt transmission line that crosses the region. “There are a lot of people not too happy about it.” Water allocation is a national hot spot that has been a running sore for nearly 20 years and did so again in September 2023 when the Murray Darling water plan again proved to be failing expectations. Clearly any pumped hydro project in affecting water will be a hot issue for local farmers which really should have been resolved before an announcement was made. Getting farmers onboard with the construction of renewable energy projects like wind farms on their land must encompass a combination of economic incentives, education, and addressing concerns specific to the agricultural community. We can look to the US where measures such as tax incentives and lease payments that provide farmers with an additional source of income have been implemented with success.
Unions A social contract with unions that paves the way for the transfer of jobs from the carbon economy to one based on renewable energy is essential. In discussing this issue with Senator Doug Cameron, just prior to his retirement in 2019, he suggested that this would need to be one of the first steps on the pathway to a renewable future. He emphasised that the crucial support required from regional communities reliant on coal mining and coal fired power generation would not be forthcoming unless some manmonthly.com.au
guarantees were put in place that offered a pathway to new and comparable jobs. The Queensland Government has recognised this, incorporating a Job Security Guarantee into its Energy and Jobs Plan. It states that: every energy industry worker is guaranteed a job within the Government owned energy sector as it transforms; and every energy industry worker will be offered agreed financial support and options to support transition to their new career. It is critical to note that the Queensland Government owns their state energy assets. As such, the government has a substantial financial and moral obligation to find jobs for its employees, as well as the obvious practical consideration of managing a pool of highly skilled labour in a critical shortage. While the Queensland Government has not yet resolved issues with the mining and transport sectors, the Job Security Guarantee is a promising start that should provide a model for other states and the Commonwealth.
Planning During the 2023 National Manufacturing Summit, I was surprised that how often planning constraints were cited as one of the biggest hindrance to progress and investment. While it seems incredible that the bureaucracy and self-interest of one arm of government can confound another, it is clearly the case. In respect of the planning constraints placed on Willatook, Nic Aberle, policy director at the Clean Energy Council, noted: “If these are the types of restrictive conditions we are going to see on wind farms then there is no way we will meet the government’s targets for renewable energy or greenhouse gas emissions. This is a project that has had essentially two-thirds of the turbines cut out, and the consequence of that is we just keep burning more coal for longer.” Moyne Shire Council, which includes the wind farm site, has called for the Victorian Government to cease issuing planning permits for wind farms in the Shire until strategic land use planning in the state’s designated South West Renewable Energy Zone is completed in consultation with affected councils and communities. Danny Nielsen, vice president and Australian head of Vestas, one of the world’s biggest providers of wind turbines, described the slow progress
towards achieving the 2030 renewables target as “a cause for significant worry” and said the issue of development approvals stretched beyond Victoria, with no approvals in New South Wales for about two years. It is hard to describe the chaos in which our planning system finds itself. Unless this problem is quickly and sensibly rectified, Australia will not achieve its climate goals and will be relegated to even more of a ‘dig and ship’ economy. The current planning system not only stymies local development, but eradicates confidence in international investors. In the case of the Willatook wind farm, the site had already been designated by the Victorian Government as suitable for renewable energy. If investors cannot rely on this type of classification, they will simply choose to invest elsewhere. We need to solve this problem by drastically revising our environmental planning laws. We need to completely remove decision making from the political process, which is too easily influenced by our short term election cycle. We need to set time constraints and provide guidelines that reflect the situation in which we find ourselves rather than the one of just a few years ago. Decisions need to be made quickly and objectively by environmental and climate experts rather than lawyers and judges.
The wishful thinkers One group that cannot be overlooked in our analysis is the ‘Wishful Thinkers’. This group is identified by their promotion of rapid adoption of new (untried) technology to solve all our climate problems. Far be it from me to gainsay some of the wonderful and innovative technology currently being developed around the world—but let’s be realistic. Carbon capture technology has enjoyed some limited success in Norway and other gas fields. However, I can find no example of it being used successfully on a coal fired power station. This technology also relies upon suitable geotechnical conditions for CO2 storage. Despite some modest investment by the Federal Government, there is no industrial precedent in Australia. There are only two Small Scale Modular Nuclear Reactors (SMR) currently in operation in the world: one in Russia, and one in China. This technology is still a very (very) long way
from being commercially available. It is also worth keeping in mind that this technology is costly to build and maintain, slow to decommission and carry a range of safety concerns. Full Scale Nuclear Reactors are even more unsuitable. Australia has none of the expertise to design, build or operate a fission reactor; and we don’t just need one! Plus, if it takes 12 years only for planning permission to be denied for a wind farm such as a Willatook, how long would it take for a reactor? Commercial scale hydrogen technology is still 20 years away. For all the many advantages of hydrogen fuel cells, there are still a disadvantages and challenges to address, from regulatory issues and the huge investment required, through to complex storage and transportation. We need to focus on renewable energy sources that are available and achievable now—not in 20 years’ time.
The way forward We are now at the stage where even the most obtuse observer must realise that global warming is real and is coming at us much faster than we imagined it could. Last year, Australia experienced record floods, with countless people losing their homes. This year, we’re expecting a record bushfire season, with the Northern Hemisphere already experiencing some of its hottest temperatures on record. The climate crisis makes the renewable energy revolution an imperative. To make the renewable energy revolution a reality, Australia must: 1. Stick with the plan—wind, solar and hydro are our immediate solution. 2. Achieve a social license. All stakeholders must be brought onside with the plan, no matter the cost. It will be negligible in terms of the cost of doing nothing. 3. Resolve the bureaucracy, planning and legal constraints now—make the process efficient, simple and fast. 4. Partner with industry leaders and invest in manufacturing in Australia. There is no alternative. Global supply chains are already effectively empty. 5. Invest $200 billion into our own improved version of the Inflation Reduction Act. 6. Do all of the above yesterday. Tomorrow will be too late. Manufacturers’ Monthly NOVEMBER 2023 11
News @MM Australian Government invests $220 million in local munitions manufacturing The Australian Federal Government is investing $220 million dollars in munitions production at factories in Mulwala in New South Wales and Benalla in Victoria. The investment will significantly boost industrial capacity through infrastructure redevelopments at each site – ensuring they are equipped to support future production demands, such as 155mm artillery ammunition. New explosive mixers at Mulwala, and enhanced munition manufacturing
procedures, including nondestructive testing. Minister for Defence Industry, The Hon Pat Conroy MP, spoke about the importance of improving defence manufacturing. “Improving Australia’s ability to manufacture the munitions our defence force needs is not only critical to meeting the strategic challenges we face as a nation, it will also support local industry and well-paid, skilled local jobs,” he said.
Developed by Defence, the new Resonant Acoustic Mixing technology in place at Mulwala will produce a broader range of advanced munitions, faster and more safely. This will increase the capacity for production of the BLU-111(AUS) aerial bombs, used by the Royal Australian Air Force. “The ability to bring the BLU-111(AUS) into operational service as an Australian manufactured munition is a significant milestone in boosting Australia’s defence
A m industry manufacturing capability,” Conroy said. “Our investment in these capabilities will accelerate the domestic manufacture of Australia’s Guided Weapons and Explosive Ordnance, such as 155mm artillery ammunition.” This is an example of the Australian Government delivering on the priorities of the Defence Strategic Review and establishing local manufacturing of guided weapons and explosive ordnance.
Made in Queensland grants growing good secure jobs in Cairns Round six of the made in Queensland grants has been released.
The Made in Queensland grants program is set to deliver more jobs across Queensland, with the release of the round six guidelines. Minister for Regional Development and Manufacturing Glenn Butcher was in Cairns recently to meet with local manufacturers and share the good news about the expansion of the Made in Queensland grants program. 12 NOVEMBER 2023 Manufacturers’ Monthly
Made in Queensland grants have already awarded $2.4 million in funding to Cairns manufacturing businesses, creating and supporting over 600 jobs. Those numbers are expected to grow further thanks to a further $20 million in funding becoming available through round six. Minister for Manufacturing, Glenn Butcher, said: “Thanks to our investment
in Made in Queensland grants, 136 projects have been supported so far.” “The results speak for themselves with 5,900 jobs supported and created from this job generating investment.” “It’s such an exciting time for Queensland’s manufacturing industry. From the Queensland Government’s Energy and Jobs Plan, our record $89 billion Big Build, or Queensland Train
Manufacturing Program right through to the 2032 Olympic and Paralympic Games,” Butcher continued. The Queensland Government’s support for manufacturers through this program has seen a total of $101.5 million committed to this program, creating and supporting 5,900 jobs and leveraging over $110 million in private sector investment. The Queensland government is showing strong support for manufacturing, with businesses across Queensland also benefitting from the $28.5 million Manufacturing Hubs Grants Program and the invaluable support provided through the Government’s $60 million investment in the six manufacturing hubs established in Cairns, Townsville, Mackay, Rockhampton, Gladstone and the Gold Coast. Manufacturers will also benefit from the $2.5 million that has been set aside in this round for projects that don’t involve the purchase of equipment. This can include, software, system improvements, lean manufacturing, professional advice, improvement planning and more. Engagement with manufacturers across previous rounds has shown that investment in these projects is crucial to business success. manmonthly.com.au
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News@MM Advanced Navigation unveils new robotics manufacturing facility at UTS Tech Lab Ed Husic was in attendance to open the new facility.
Advanced Navigation, a manufacturer of artificial intelligence for robotic and navigation technologies, has unveiled a new robotics facility for autonomous systems based at University of Technology Sydney (UTS) Tech Lab. Located in Botany, NSW, the facility will increase the manufacturing of Advanced Navigation’s world-first AI navigation systems for GPS-denied environments, including its digital
fibre-optic gyroscope (DFOG) technology, Boreas. Advanced Navigation CEO and co-founder, Xavier Orr, said there is a critical need to improve Australia’s economic complexity and sovereign capabilities. “A key step is to build our industrial capacity in high-tech, as well as drive knowledge exchange and propel collaborative initiatives between
government agencies, academic institutions and industry leaders,” he said. Advanced Navigation is one of only four companies in the world with the capability to manufacture strategic grade fibre-optic gyroscopes. This technology empowers reliable navigation for marine vessels, space missions, aerospace, defence, autonomous vehicles and flying taxis. The company deploys its unique
AI-based physics algorithms to solve complex challenges earth-bound and in space. In addition to the manufacturing capability, the facility will be home to extensive research collaborations between Advanced Navigation and the University of Technology Sydney (UTS). This will expedite the commercialisation of several socially impactful technologies, like Light Detection, Altimetry and Velocimetry (LiDAV) system, Cloud Ground Control, and Guiding visually impaired passengers. Vice-Chancellor and President of UTS, Professor Andrew Parfitt, said UTS is pleased to be working with Advanced Navigation to tap into critical growth areas. “The collaboration between UTS’s global research leaders in autonomous systems technology and Advanced Navigation’s exceptional team of scientists and engineers, utilising UTS Tech Lab’s cutting-edge facilities, highlights our commitment to developing sovereign capabilities for defence and space,” he said. “We look forward to deepening and expanding our collective capabilities with Advanced Navigation to accelerate the production of high-impact innovations.”
The Victorian Manufacturing Showcase is coming in November The Victorian Manufacturing Showcase 2023 (VMS2023) will take place on Tuesday 21 November at the Moonee Valley Racing Club hosted by the Victorian Government, in partnership with NORTH Link. The showcase will shine a spotlight on the future of advanced manufacturing in Victoria. The VMS2023 will bring manufacturers, thought leaders, government, educators, students and manmonthly.com.au
service providers together from all parts of Victoria to showcase their business, products and innovation. Key speakers and panellists will discuss the opportunities and challenges facing the industry including the circular economy, skills and training, finding and retaining talent, and the digital transformation of the sector. VMS2023 is free to attend, however registration is required as places are limited.
The Showcase will be held on 21 November at Moonee Valley Racing Club
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News @MM MaxiTRANS closes Queensland facility MaxiTRANS will be focusing on its operations in Ballarat.
MaxiTRANS has announced that it will be closing its trailer manufacturing facility in Carole Park, Queensland, following a decision to focus on centralising its trailer manufacturing business in Ballarat. Greg L’Estrange, MaxiTRANS Executive Chairman spoke about the decision to close the facility and what the future looks like for the manufacturer. “Since Australian Trailer Solutions Group (ATSG) purchased the MaxiTRANS trailer business in September 2021, our focus has been on setting the business up for long-term sustainability,” L’Estrange said. “This is to ensure that we can remain a viable Australian business to continue supporting our customers long into the future, as we have done so for over 75 years in the industry,” he said.
ATSG is coming into its third year of ownership of MaxiTRANS, and the business is preparing for the next phase of its expansion with the company investing significantly to grow and develop the Ballarat manufacturing site. “This investment is a demonstration of our total commitment to support local manufacturing, which will transform the trailer manufacturing industry in Australia to enable our business to continue delivering a high-quality product that continues to evolve with the changing needs of our industry,” said L’Estrange. Adding that its expanding capability will ensure MaxiTRANS is well positioned to help its customers to continue delivering industry excellence. MaxiTRANS officially opened the
Carole Park facility in February 2021, where it primarily produced tipper products under the Lusty EMS, Hamelex White and AZMEB brands. The business is set to close manufacturing at the site by the end of March 2024, with all existing and future orders for these products to be produced at its Ballarat facility. As the Carole Park site was establishing itself in the Queensland market, post pandemic pressures, including continual changes in the labour market and growing costs to run the 14,300m2 site, meant that it was no longer viable to hold two large trailer manufacturing sites for the business long term. We take this opportunity to thank everyone within the Carole Park manufacturing facility for their total commitment and extensive efforts to
try and boost the capability of the site, unfortunately this decision was needed so that our business remains here long into the future. Ahead of the announcement, MaxiTRANS has been gearing up to support the growth and expansion of its manufacturing capability at the Ballarat site, where it will now produce the full range of Lusty EMS, Hamelex White and AZMEB products alongside Freighter and Maxi-CUBE. Through the site upgrade, Ballarat has the capacity to take on the full production of these brands which will ensure there is no impact to our customers as we transition between the manufacturing acilities. As a business, MaxiTRANS has many employees with extensive experience under their belt, including several roles that were based at Carole Park. “Since ATSG purchased the business, our commitment has never strayed on supporting the needs of our people, which makes today’s decision an extremely difficult one. To ensure we retain as many people as possible and their experience, MaxiTRANS is in the process of discussions with reallocating roles to other areas of the business and supporting their relocation to other sites where applicable,” said L’Estrange. “While we are saddened by this decision, we are certainly excited for the long-term future of the business, as we forge ahead with our plans to expand the manufacturing capability at our Ballarat site and continue serving our customers and the transport industry.”
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Boeing Defence Australia’s largest apprentice intake boosts trades workforce Boeing Defence Australia (BDA) has welcomed eight apprentices in the largest single intake to the company’s trades workforce. The apprentices, who have graduated from Aviation Australia’s (AA) 80-day Certificate II in Aircraft Line Maintenance, will join BDA’s F/A-18F Super Hornet and EA-18G Growler maintenance program at RAAF Base Amberley. 14 NOVEMBER 2023 Manufacturers’ Monthly
They take apprentice numbers across all of Boeing Australia to 44. BDA’s director of Product Support, Training & Maintenance, Mike Prior, says Boeing is building stronger trades workforce to support increases in fleet sizes. “As the sustainment provider for the Australian Defence Force (ADF) platforms, we’re building a stronger sovereign trades workforce to support fleet
upgrades, increased fleet sizes, and the introduction of the Apache,” he said. “Through this investment in apprentices and our long-standing partnership with AA, we’ll have the right people with the right qualifications ready to ensure mission readiness for the ADF.” Graduate Daniel Gaskin spent 12 years in automotive mechanics before
being accepted into the apprentice program. “This opportunity has allowed me to meld my mechanical background with a genuine interest in aircraft mechanics and engineering,” Gaskin said. “I’m immensely proud to now be part of Boeing and excited to work on fighter jets for a global aircraft manufacturer,” Gaskin said. manmonthly.com.au
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News@MM NASA chooses Australia as strategic partner to design and build lunar rover for moon-landing The National Aeronautics and Space Administration (NASA) has chosen Australia as its strategic partner to design and build the Trailblazer lunar rover due to proven expertise in remote operations, developed through resources industry. The Australian Space Agency has tasked the AROSE consortium with developing the preliminary design of the Trailblazer lunar rover by the middle of 2024. If successful, the AROSE team – led by Fugro and Nova Systems – will then build, test, deploy and operate the rover on a future moon mission for NASA as part of the Artemis program. Fugro Space Systems Director, Dawn McIntosh, said that Australia is well positioned to be a world leader in remote operations in space. “Australia is already the world leader
in remote operations for the mining sector,” she said. “Now we are well positioned to become a leading provider of remote operations technology and expertise for Space.” AROSE Director of Space Programs, Dr Newton Campbell, said the extreme environmental conditions on the Moon’s surface create specific challenges for the rover design. “Lunar regolith is pretty nasty stuff,” he said. “It’s not like digging up normal dirt here on Earth. Since the Moon has no atmospheric or liquid erosion properties it’s much sharper than soil particulates here on Earth. We’re just not used to dealing with that, even with what we deal with in the Pilbara.” Dr Campbell said there would be a
Australia continues to be heavily involved in developments for space.
significant amount of advanced tech in the rover design. “Everything you’re building for Trailblazer is almost entirely new because you have to make these technologies Space-grade,” he said.
“That means they must withstand extreme temperature variations. Not just built for the hot, not just built for the cold, but built to deal with both of those things, with new forms of shielding for example.”
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News @MM Tasmanian defence industry goes from strength to strength Tasmania’s manufacturing and defence industries continue to innovate and provide cutting-edge technology and world-leading defence products to Australia and the globe. Minister for Advanced Manufacturing and Defence Industries, Madeleine Ogilvie, said that the Tasmanian Government is the strongest supporter of these businesses and is committed to supporting this critical sector so they can continue to stamp their mark as world leaders. “We have released the Advanced Manufacturing Action Plan 2024 and
the Tasmanian Defence Industry Strategy 2023 which will underpin thousands of jobs throughout Tasmania,” Ogilvie said. “Tasmanian companies have already exceeded the goals set out in the Defence Industry Strategy, with more than $129 million in defence related contracts over the last three years – a testament to the quality products and technology our state has to offer,” she said. More than 50 defence supply contracts were awarded to Tasmanian companies in 2021-22 alone, attracting around $75m into its economy. “The recent success of Tasmanian
businesses as part of the Hanwha Defense Australia LAND 400 Phase 3 project is expected to deliver more than $100m to the Tasmanian economy, and will secure more than 50 new jobs. “Our strategic, economic and technological environment has changed since we developed our previous strategies, and it is important for our continued success that these changes are considered as we develop the next. “These developments include the recent and ongoing technological developments in robotics, software and communications technology, artificial
intelligence, cyber security, and other advanced fields which are changing the competitive landscape, risks and opportunities for manufacturers. “Work has commenced to develop new strategies that will harness the momentum our Tasmanian companies have generated in this space. “The Rockliff Liberal Government is once again proving that we have the vision for creating more Tasmanian jobs and boosting the economy by working alongside industry and small businesses to support them in achieving success,” Minister Ogilvie said.
Tasmania continues to grow its defence manufacturing capabilities.
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News @MM Anthony Albanese addresses the National Reconstruction Fund
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Prime Minister Albanese believes in the future of Australian manufacturing.
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Prime Minister, Anthony Albanese and Member for Newcastle, Sharon Claydon, addressed the National Reconstruction Fund (NRF) at a press conference at Varley in Newcastle. “This is a site, as is our city in our region, that plays a really critical role in terms of manufacturing for this nation and shaping the future,” Claydon said. “Initiatives like the $15 billion National Reconstruction Fund are vitally important to workers in our region, to companies like Varley, who are showcasing excellence in manufacturing wherever we go,” she said. The Prime Minister spoke about the importance of a future made in Australia. “There is nothing we can do that is more important than making more things here and this decade will determine whether Australia moves forward or whether we stand still, and the world 18 NOVEMBER 2023 Manufacturers’ Monthly
moves past us,” he said. “We imported trains and they don’t fit through the tunnels; they don’t match the stations. “We also have to fix up some of the trains that are used to cart our resources because they’re the wrong size,” Albanese said. The Prime Minister celebrated Varley and its potential to manufacture trains for New South Wales locally and its capabilities for defence, marine and a vast array of vehicles. “I want to pay tribute to the workers here at Varley and to the management who combined, produce things that help Australia, they’re creating jobs, but they’re creating activity here as well,” he said. “We know from the pandemic that we were left vulnerable, and we know that there could be other pandemics, there could be other international
shocks, there’s a range of reasons why national economies have to be more resilient. “One of the fantastic things that we saw here as well this morning is the craft that are being exported to Indonesia to help with their police operations, they’re being exported to the Philippines. “It shows we can make things here, not just make things here for the domestic market but globally,” Albanese said. The Prime Minister explained that Australia has a fantastic opportunity to seize on the growth of renewables. “If you look at areas like hydrogen and green hydrogen, no country is better positioned than Australia to benefit from that,” he said. “We have the best solar resources in the world, we have a great opportunity to take advantage as well of the mineral resources that we have. Albanese mentioned that the of
students enrolled in Fee-Free TAFE courses has increased. “We promised 180,000 Fee-Free TAFE places this year. We not only have met that target, we’ve exceeded it,” he said “There’s now above 220,000 people, including people here being trained as fitter and turners, there’s people being trained in the care sector, there’s people being trained in construction, and making sure that they can have great futures.” Member for Newcastle, Sharon Claydon, said that renewable energy and skills centre developments are government focuses. “The $100 million into the renewable energy precinct at the Port of Newcastle, $16m into the new skills centre for the University of Newcastle, getting hydrogen ready over at Orica and Origin,” “These are the focus of Government looking forward.” manmonthly.com.au
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News@MM Renewables open new doors for Aussie-made steel
Ed Husic views Australian made steel as having a lot of potential to support renewable growth. Renewable energy is offering a host of new opportunities for Australian-made steel, Federal Minister for Industry and
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Science Ed Husic has told the Australian steel convention. In an opening address to the
annual Australian Steel Institute (ASI) convention at Melbourne’s Sofitel Hotel, Husic said Australian-made
steel had a key role to play in the shift to advanced manufacturing, renewable energy and low emissions, including production of wind turbines. “We want to be a country that makes things. Australian-made steel will play a vital role in that vision. The net result is higher paid jobs and greater prosperity for Australians everywhere,” he said. Husic said Australian-made steel was crucial to the economy, employing 140,000 people and generating $30b in annual revenue. “I am the son of a metal worker and I know how important steel is to the nation,” Husic said. “Important as the industry is today, it can be bigger and better,” Husic said. He said the government was looking to boost local jobs including steel jobs through its $15b National Reconstruction Fund.
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News @MM Sevaan Group trials four-day week Leading parts contract manufacturer, Sevaan Group, announced it is trialling a four-day week to evaluate improvement in staff well-being, attracting new talent, and increasing productivity. The trial period will run for three months, from 11th September until the 31st December. The Group is spreading the normal 38-hour, five-day work week over four days. Each day encompasses two shifts, morning and afternoon, consisting of 9.5 hours each. According to Sevaan Group’s CEO, David Green, the management-led initiative gained traction as a result of the positive outcomes attained by overseas companies that have already trialled the four-day week. “The evidence suggests that these firms are benefitting from improved productivity, reduced sick leave and unapproved absenteeism, and a general increase in their employees’ well-being,” he said. “The improved well-being of staff is particularly of interest because it aligns
so strongly with Sevaan’s culture. We are a very employee focused organisation and our staff’s well-being is paramount. We have already introduced an EAP – LifeWorks – which provides staff with confidential, expert counselling across a broad range of issues, should they request it. We are hoping that a four-day working week will further support our staff’s wellness. The evidence suggest that it helps to reduce anxiety, stress, fatigue and burnout,” explained Green. A four-day week is also appealing when it comes to attracting and retaining talent. “The manufacturing market in Australia is already very tight when it comes to hiring new staff. The fourday week provides employees with a shorter working week, and more free time to spend as they please. This greater work-life balance is no doubt attractive to prospective staff, and helps to further differentiate Sevaan and reinforce the Group as an employer of choice,” said Green.
Evidence from US and UK companies which have already trialled the shorter week indicates that there is no fall in productivity, and that in some cases it has increased. When the working week is condensed into four days, the longer weekend allows staff to reenergise themselves. This can translate into better Sevaan Group will track the trial concentration and morale throughout to ensure its success. on the shop floor and in the office, and an increase well-being. And given their commitment in productivity. to making it work, I believe that at the With staff backing the initiative 100 very least, productivity and service per cent, Green is quietly confident that deliverables will not falter. In fact, they the three-month trial will yield positive will probably improve.” outcomes all-round. “As management, Sevaan will monitor the impact of we can only provide the framework to the trial and collate data weekly across help make it happen. It’s our staff who a range of factors including well-being, are critical to the trial’s success. They absenteeism and productivity. The results understand the positive impact it will will be displayed on the shop floor. have on their work-life balance and
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News@MM Investing in Victoria’s manufacturing growth and jobs
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The Victorian Government has announced more funding to support local manufacturing.
The Victorian Government is backing manufacturers across the state to expand their operations and boost their innovation and manufacturing capability – creating 138 new local jobs. Minister for Manufacturing Sovereignty Ben Carroll announced 14 small and medium sized Victorian manufacturers will share in $3.2 million of funding through the Made in Victoria – Manufacturing Growth Program. The program is providing grants of up to $250,000 to support businesses to introduce advanced technology, boost productivity and competitiveness, and create local jobs. The co-funded projects involve total investments of more than $16 manmonthly.com.au
million, with the businesses operating in a variety of manufacturing sectors including food and beverage, pharmaceuticals, mining, construction, and machinery and equipment. Among the recipients is chassis manufacturer ARV Chassis and Trailers based in Somerton, who will purchase new equipment to grow their core production processes – creating 30 new jobs. ARV Chassis and Trailers Managing Director Harmel Singh spoke about what the grant will mean. “This grant will support us to generate more employment opportunities in the Australian-made caravan industry and contribute to the
local economy,” he said. Mordialloc based business Not a Trace Foods, a health food manufacturer, will grow its allergenfree food production line, with the expansion set to create 21 new jobs. Underpinned by the Made in Victoria 2030: Manufacturing Statement, the program is a key part of the Labor Government’s suite of targeted investments to drive innovation and strengthen local supply chains in our advanced manufacturing sector as Carroll explained. “Manufacturing is critical to growing our economy – that’s why we’re backing local businesses to innovate and adopt new technologies,
to drive investment, compete globally and create good local jobs at home,” he said. These initiatives include the $21 million Manufacturing and Industry Sovereignty Fund, the $15 million Industry R&D Infrastructure Fund, the $20 million Australian Medtech Manufacturing Centre, and the $4.5 million Digital Jobs for Manufacturing Program. Manufacturing is a driving force of the Victorian economy, employing more than 250,000 people, contributing $33 billion to the state’s economy each year, and providing 30 per cent of the nation’s manufacturing output. Manufacturers’ Monthly NOVEMBER 2023 21
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Funding for new advanced manufacturing facility in Townsville Townsville’s defence and aerospace industries will reach new heights with a new manufacturing plant set to get off the ground with Queensland Government support. With funding from the Industry Partnership Program (IPP), Garbutt’s Bridgeman Agencies will build an advanced metal manufacturing and fabrication facility in Townsville, with plans to service local construction and defence contracts. The project cost is estimated to be $1.7 million. The project will create 14 jobs and position the Indigenous-owned company to grow its supply chain into defence and aerospace industries in North Queensland. Deputy Premier Steven Miles spoke about the announcement. “This is another example of an important new project being brought to life with IPP support, creating good, secure jobs and more secure supply 22 NOVEMBER 2023 Manufacturers’ Monthly
chains,” he said. “Since the launch of IPP in 2021, more than $1.1 billion worth of projects have been approved with the potential to create more than 1,850 ongoing jobs. “Importantly, the program paves the way for companies to leverage further funding from sources such as Commonwealth Government programs – ensuring our Queensland industries get their fair share of these national funding programs. “Bridgeman’s project will build on the pipeline of fantastic projects taking shape with IPP support, including Vecco Group’s Townsville vanadium battery electrolyte manufacturing facility. “With our $53.5 million boost to make this program even bigger and better, we’ll be seizing more opportunities and supporting more projects in emerging industries that will supercharge Queensland’s economic future.” The IPP, part of the Queensland Jobs
Fund, is focused on growing priority industries, strengthening local supply chains, encouraging collaboration between all levels of government and industry and leveraging private sector investment. This year’s State Budget included a $53.5 million boost to continue the successful program. The next allocation of IPP funding opened in August, with a focus on unlocking opportunities presented by new global demand driven by the shift to decarbonisation. Bridgeman Owner and managing director, Adam Sarota spoke of his excitement. “We are very honoured to be awarded the Industry Partnership Program grant by the State of Queensland,” he said. “Bridgeman’s manufacturing expansion project will develop our manufacturing capability, deliver positive economic outcomes and create new jobs for Townsville and Northern Australia.
“We are committed to capitalising on regional strengths to build capability, sustainability, and resilience. Our Townsville site will enable Bridgeman to create further full-time employment opportunities for Townsville and local communities for the long term. “As a Supply Nation certified Indigenous company, Bridgeman is dedicated to encouraging partnerships between industries and other Indigenous companies along the supply chain and working alongside Queensland Government agencies to deliver training and career opportunities for Aboriginal and Torres Strait Islander peoples,” Sarota said. “Without the support of the Queensland Government’s Industry Partnership Program grant funding, we would have been unable to expand into Townville, develop our manufacturing capability and create new jobs for North Queensland that deliver long-term tangible and positive outcomes for the region.” manmonthly.com.au
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News@MM Queensland Government puts local bus manufacturing in motion Premier Annastacia Palaszczuk has announced a plan to build 200 buses in Queensland, backing local jobs, skills and training. An initial $134 million investment will drive the plan, with the Department of Transport and Main Roads currently undertaking an independent procurement process. It is expected the plan will restore Queensland’s bus manufacturing sector, which has been subject to significant pressures due to low order volumes. Through the $134 million investment, the Queensland Government is expected to support hundreds of local jobs. Premier Annastacia Palaszczuk spoke about the announcement. “This is an investment in Queenslanders and the future of our skilled manufacturing sector,” she said.
“We know that when we build here in Queensland, we are supporting local workers, local suppliers and the next generation of skilled bus builders. “We make no apologies for backing Queensland workers – whether it’s trains or buses, they are built better when they’re built by Queenslanders. “I look forward to the procurement process coming to an end and the appointment of a bus builder soon after,” Palaszczuk said. The buses will be fully accessible to ensure all Queenslanders have access to public transport, including people in a wheelchair, and people travelling with luggage or prams. Minister for Regional Development and Manufacturing Glenn Butcher added to the premier’s comments. “This is another example of how the Palaszczuk Government is bolstering our
Ahead of the Olympics, the Queensland Government wants to rapidly improve the state’s bus manufacturing. manufacturing sector– delivering good jobs and the services we need to support a growing Queensland,” he said. “200 buses will be built in Queensland by Queenslanders, which is absolutely fantastic. “By putting jobs and opportunities in Queenslanders’ hands, the Palaszczuk Government is investing in the local workforce for generations to come.
“This Government supports Queensland manufacturers every day of the week,” Butcher concluded. Once built, the buses will be owned by the state and operated by Transport and Main Roads. The buses will also support transporting rail passengers during periods of disruption or planned track maintenance.
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Manufacturers Focus
New facility - big future Hysata is developing into a powerhouse in the electrolyser manufacturing game. Opening a new facility in Port Kembla, the company is poised to explode on the international market. Manufacturers’ Monthly sat down with CEO Paul Barrett to uncover the secrets to the company’s success and what the future may hold as it enters the renewable market.
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AUL BARRETT has a PhD in Chemical Engineering from University College, Dublin and after living in the US for close to a decade he developed a passion for renewable energy and made the shift to Australia. “I have a decent technical and commercial background in electrochemistry and coupled with my passion for decarbonisation the role with Hysata was a logical one for me to take on,” Barrett explained. Hysata is an Australian electrolyser company headquartered in Port Kembla that is developing a completely new type of electrolyser, featuring the world’s most efficient electrolysis cell coupled with a simplified balance of plant. Electricity makes up most of the cost of green hydrogen and, therefore, the most efficient electrolyser will deliver the lowest cost hydrogen. This technology breakthrough originated with Professor Gerry Swiegers
24 NOVEMBER 2023 Manufacturers’ Monthly
at the University of Wollongong, who has been working in the electrochemistry field for more than 30 years. His strong research background coupled with his experience solving industrial challenges led to the core invention behind Hysata. “The challenge for existing electrolysers is they are electrically inefficient, they generate too much waste heat and require too much cooling,” Barrett explained. “That core idea of improving efficiency is what started Hysata, ensuring the electrolyser has very little heat rejection and therefore less cooling – so in turn less energy is required to split water as very little of the energy is wasted as heat. “Swiegers and I had a chat in a beachside café where he showed me a graph that demonstrated the success of the system. I was in awe of the cell performance as it was unprecedented – a real game-changer in electrolysis. “So, we brought in some people to
independently test it and the results were the same and we could not believe the performance,” he said. After that success, Barrett joined the Hysata team full time as its CEO and the company began the process of growing its manufacturing capabilities.
What is an electrolyser? The electrolyser is an apparatus that produces hydrogen through a chemical process (electrolysis) capable of separating the hydrogen and oxygen molecules of which water is composed using electricity. Without giving away the secret to Hysata’s success, Barrett elaborated on what makes the Hysata electrolyser so special. “We have a really differentiated technology when it comes to cost and performance, but we have been very thoughtful about the design to give us scope for mass manufacturing,” he explained.
“By having less energy used we are able to lower the levelized cost of the hydrogen,” Barrett said. Green hydrogen is vital for decarbonisation of hard-to-abate sectors such as steelmaking, chemical manufacture, heavy transport and high grade industrial heat. However, it is still economically uncompetitive. Efficient electrolysis is a leading hydrogen production pathway to achieve the goal of reducing the cost of clean hydrogen by 80 per cent to one dollar per one kilogram in one decade. Hydrogen produced via electrolysis can result in zero greenhouse gas emissions, depending on the source of the electricity used. The source of the required electricity—including its cost and efficiency, as well as emissions resulting from electricity generation— must be considered when evaluating the benefits and economic viability of hydrogen production via electrolysis. manmonthly.com.au
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The Hysata team is continually growing and will be growing over the coming years.
Improving manufacturing capabilities and growing the workforce Barrett went on to detail how for the team at Hysata, it has been imperative they manmonthly.com.au
put the right people in the right places, from the original researcher Swiegers, through to those working on growing the manufacturing capabilities. “We have Gerry who, is our expert
on the research side, and we have Scott Abrahamson who is in our engineering department, and he is as equally experienced as Gerry but in mass manufacturing,” he said.
“Scott has close to 30 years’ experience in the high-tech manufacturing space where he had countless product launches including time spent with Apple mass manufacturing millions of high quality Manufacturers’ Monthly NOVEMBER 2023 25
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The Hon Chris Bowen MP officially opened the facility.
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devices and components daily. “We have been thoughtful about how we design the stack, and it will allow us to mass manufacture the electrolyser,” Barrett said. Hysata is in the process of commissioning a 100 megawatt per annum manufacturing line at its site in Port Kembla. The Australian Renewable Energy Agency (ARENA) is contributing to that new production line, but Barrett explained some of the challenges the company faces in Australia. “We need to continue developing our advanced manufacturing talent to ensure we have the pipeline of local skills required to support future industries such as green hydrogen,” he explained. “In the short-term, we will need to bring in some specialised engineers from abroad to ensure we can fulfil 26 NOVEMBER 2023 Manufacturers’ Monthly
our workforce requirement as our manufacturing capabilities grow, and train our local workforce. “Our VP for example has relocated to Australia to immediately meet our needs, including training up the workforce so local talent benefits,” Barrett said. The wider team at Hysata has become heavily invested in the goal of the company to help decarbonising on a global scale. “We have reformed carbon workers, so people from the coal, oil and gas industry that have joined us at Hysata who were excited to shift industries to something that would help the planet,” Barrett said. “We are actually finding it very simple to source local talent and with the twoyear skilled visas, we can supplement our local workforce with those from overseas. “We will see our needs growing
dramatically in the future and we need the workforce to jump in size, so our big focus in the coming years will be meeting our needs. “We need every type of engineer, mechanical, mechatronic, electrical, chemical manufacturing, project managers, so we really need a huge number of skills, and would really love the backbone of that workforce to be domestic,” he said. The company has a range of training programs in development and has started an internship program to get students across from the University of Wollongong.
New facility Hysata opened its new 8000 sqm global headquarters and electrolyser manufacturing facility in Port Kembla back in August. Barrett spoke about the benefits of setting up its global
headquarters in Australia. “Only in Australia could you have a manufacturing facility at a location like ours, it is basically beach front, it is such a nice place to come to work,” he said. “This is a big part of our culture, working somewhere like this means people come to work with a smile on their face. “We were intent on getting a facility that we could grow in – it meets our needs now but has the space for us to grow,” Barrett said. Barrett explained that the thought process in having one main facility as opposed to numerous facilities over the country is ensuring all workers are moving in the same direction and the company has strong clarity on where it is headed. Going to a regional hub like Port Kembla was a simple one for Hysata as real estate was cheaper for both the company manmonthly.com.au
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ManufacturersFocus and its workers. It is next door to a steel works and is close to a number of highquality machine shops, meeting all the needs of the modern manufacturer. Minister for Climate Change and Energy the Hon Chris Bowen MP officially opened the facility and announced $20.9 million funding from the Australian Renewable Energy Agency (ARENA) to support the first 5MW commercial demonstration of Hysata’s electrolyser with Stanwell in Queensland. “We’re delighted to support gamechanging, homegrown innovation that will power our future as a clean energy manufacturer and a renewable energy superpower,” Bowen said. ARENA CEO Darren Miller said the project is a crucial step to enabling purchase orders for the technology. “Hysata is a great example of Australian innovation leading the way in renewable energy. This electrolyser technology could be a game-changer for renewable hydrogen,” he said. “The demonstration at Stanwell’s site will be key to unlocking commercial demand for Hysata’s product by proving the technology works at scale. “ARENA has been involved in this technology since it was just a concept in a laboratory, so we’re pleased to
be supporting this next step toward commerciality. Identifying promising renewable energy solutions and helping them along the innovation chain is what ARENA does best,” Milburn said.
The future Hysata and its customers are buoyed and excited for what the future may hold. The system, the scalability of the manufacturing and the system architecture are all exciting for those involved. “COVID-exposed Australia, it showed us that we need to have more sovereign capabilities in Australia, and we have taken that very seriously,” Barrett said. “There is a serious need to grow our battery manufacturing, turbines, and wider renewable manufacturing abilities. Australia can become a powerhouse of renewable manufacturing. “It is a big supply chain risk that most of what we need in Australia is manufactured overseas but it is also important that what Australia does is different from what is done overseas,” he said. Barrett explained that Hysata has developed technology that differs from anything else available globally. He detailed
that it is challenging for Australian manufacturers to compete on price so creating a difference is what is important. “We are really laser focused on bringing up this 100-megawatt manufacturing line and using that as the platform to get into a multi gigawatt manufacturing capacity shortly thereafter,” Barrett explained. “Another part of our future is giving back to the rest of the industry; we have a lot of work to do ourselves, but we need to bring others along on our ride and help them to grow and improve. “We are really passionate about the Illawarra region, and working with universities in NSW and across Australia to bring talent into our company and inspire the next generation to enter this emerging industry”.,” Barrett said.
Maximising Australia’s renewable potential Barrett went on to explain the importance for Australia to maximise its location and natural resources when considering its renewable manufacturing capabilities. “We have an enormous coastline in Australia, in which the possibilities are endless,” he explained. “We have solar and wind resources
that are simply off the charts, we also have plenty of land space as we are so sparsely populated. “We also have a great continental shelf that does not get too deep too quickly, this allows us to create offshore wind farms far more than other regions globally,” he said. An abundance of natural resources is something that Barrett believes we should be capitalising on more as a nation. “We have so many energy transition materials such as lithium, nickel and copper that we could utilise but as it stands, we are largely exporting these materials to other countries for offshore processing,” he said. “As the world transitions from petro states to electro states, we need to try and position ourselves at the forefront of this and while it might seem difficult initially, we have so much working in our favour,” Barrett explained. “It is not only about manufacturing devices like electrolysers and solar panels locally but finding ways to value add to those exports - like exporting green chemicals, green fuels or green iron. This creates both a huge commercial opportunity as well as playing a significant role in decarbonising hard to abate sectors.”
The electrolyser is one of the most energy-efficient versions on the
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Manufacturers’ Monthly NOVEMBER 2023 27
Business combination Combining to become one stop shop The merger of Regal Rexnord and Altra Motion has allowed the companies to provide better solutions to the manufacturing industry in Australia.
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EGAL Rexnord and Altra Motion have joined forces to become a one-stop shop for Australian manufacturers for any need from conveyors through to generators. The two businesses are now under the umbrella of Regal Rexnord IPS Oceania, combining decades of experience under one roof. Separately, the businesses have been providing some of the most respected brands in the industry, including Falk, Rexnord, Stieber, Marland Clutch, Tollok and Autogard to name a few. Now that the merger is complete, Regal Rexnord can take its proven service to the next level; it has complete solutions for any manufacturer. The company was originally established more than half a century ago, focussed on the domestic manufacture of metal cutting tools and gear boxes. In 1955 it was known as Beloit Tool and set up shop in a roller rink in Beloit, Wisconsin. It has moved its corporate headquarters and re-branded its company several times since 1955. It currently resides in downtown Beloit, Wisconsin. In 2021, following the merger
Bringing the company in allows Regal Rexnord to offer highly-engineered solutions.
28 NOVEMBER 2023 Manufacturers’ Monthly
Combining the two organisations will create a one stop for manufacturers. with Rexnord, Regal Beloit Corporation became Regal Rexnord Corporation. By uniting Altra’s automation capabilities with its electromechanical expertise, it is better together. And together, it is creating a better tomorrow
for its customers, its associates, and its communities. Harnessing its extensive engineering expertise from some of the best in the business, Regal Rexnord can work as one unit to provide solutions that go beyond the initial sale of the product. The company plans to work with customers to provide maintenance and bespoke solutions to suit any project with the flexibility of an engineering powerhouse. “Regal Rexnord IPS is now even better placed to offer highly engineered solutions,” Regal Rexnord IPS general manager Shane Rock told Manufacturers’ Monthly. “We’re seeing a lot of opportunities in being able to offer solutions that aren’t just standard off the shelf. “Our ability to do bespoke modifications locally has certainly expanded with the merger given the much broader product range,” he said. The aim of Regal Rexnord is to establish synergies in application expertise that ensure end-to-end client support. “Being able to engineer those products together is something very few suppliers are able to do,” Rock said. One way the company is putting
this into action is through its IoT digital platform, Perceptiv intelligence. An interconnected matrix of smart digital solutions that have the potential to empower and elevate everything in the Regal Rexnord universe, Perceptiv uses cloud technology to track, report, communicate and share performance data. “In the near future, I expect Perceptiv will be able to communicate between our products and offer the customer even more valuable information on their system,” Rock said. The merger also means Regal Rexnord is expanding the way it does business. The company is incorporating Altra Motion’s strong field service work capabilities into its offering, bringing maintenance and engineering solutions direct to the customer like never before. “Now that we have this field service capability, it’s something we can expand into,” Rock said. “I think the customers will be happy that someone can go to a facility and have knowledge of the complete system a manufacturer is using.” “The plan is to provide everything from commissioning through to repairs and general servicing. Regal Rexnord wants to ensure its
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The company is far better placed to support industry now. team are equipped with knowledge it needs to provide the best customer experience possible. “In the past, we’ve looked around to other suppliers,” Rock said. “Now, everything is internal – our own products.” “That means we can optimise our engineering design and become more agile as we’re involved the whole way through.” Agility in an industry as diverse as manufacturing in Australian cannot be underestimated, and it’s Regal Rexnord’s customers who are the first to benefit. “Early feedback from the customers is they think the merger is a good thing,” Rock said. “They can see the benefit of speaking to one company about the entire system provided by Regal Rexnord. “All of the brands that we have now are all well respected, market leaders in the manufacturing industry so customers know they can trust in our offering.” Regal Rexnord sales director Junior Eltagonde told Manufacturers’ Monthly the company’s increased scope of knowledge paired with its name-brand recognition is what sets it apart. “We’re a one-stop project management package for manufacturers,” he said. “We’ve heard from customers in the manmonthly.com.au
past that they’re looking for avenues for complete solutions where they can utilise brands that are well known in the marketplace. “We offer a complete package – the depth of knowledge we have for engineering and the quality of our range means the whole team can work together collaboratively to provide a solution for the customer. “We go from selling the product to helping the customer commission it onsite to providing extra technical support and troubleshooting for areas they need assistance with,” he said. As eyes turn to net-zero targets, the renewable space is growing rapidly for manuafcturers and a number of products from Regal Rexnord can be found in wind turbines. “Svendborg Brakes is involved in wind energy,” Rock said. “Renewable energy was not an area Regal Rexnord was heavily involved in, so the Altra Motion merger has really opened that up.” The Regal Rexnord–Altra Motion merger is opening some interesting doors for crossover in the workshop. Rock said Altra Motion’s mobile service is something the company plans to on
foster under the Regal Rexnord banner. “We’re looking to expand what Altra can do to cover the entire product range so the customer gets someone on site who can service the complete drive train,” Rock said. The company plans to roll out its expert services to on-site operations early next year, with teams across the
world working on interconnecting Regal Rexnord range. The merger allows Regal Rexnord to grow its footprint in Australian manufacturing like never before, with a culture of knowledge and focus on customer service that has been a cornerstone of the companies separately for decades.
Feedback on the merger has been positive from customers thus far.
Manufacturers’ Monthly NOVEMBER 2023 29
Welding Automation Decades of experience While most people think of automation and robotics in manufacturing as a recent arrival, Robotic Automation has been delivering these solutions for 35 years to manufacturers across Australia and New Zealand.
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OBOTIC Automation (RA) has been operating in Australia and New Zealand since 1988 and has installed and supported more than 3600 installations across manufacturing, welding, warehousing, health, testing labs, and even banking. One of RA’s specialities is its welding division, which has long seen its MOTOMAN robotic welders utilised in numerous manufacturing applications. The enduring partnership between MOTOMAN Yaskawa and RA, dating back to RA’s inception in 1988, has fostered a deep mutual understanding of each other’s requirements and a keen awareness of what Australian customers seek in their automated welding solutions. MOTOMAN stands as one of the industrial robotics industry’s largest manufacturers, boasting a remarkable track record of over 540,000 robots installed worldwide since 1977. Renowned for its unwavering reliability, MOTOMAN remains committed to constant improvement and ongoing product development. This dedication translates into extended operational longevity, minimized downtime, reduced maintenance expenses, increased profitability, and unparalleled peace of mind for its customers.
shops with small batch sizes and high variant diversity. This cobot welding cell maintains a consistent and high welding quality while being easy to install. The cobot combines the strength and accuracy of the industrial robot with the safety features necessary for humanrobot collaboration. The IP67 protection class provides superior capabilities for applications in rough welding environments. Due to direct teaching and the customised welding wizard software, operating and programming the Weld4Me robot is easy to learn for welding personnel, even without prior robotics knowledge.
ArcWorld welding cells RA also offer self-contained welding cells
MOTOMAN ArcWorld Welding Cell and Weld4Me Cobot. for a flexible, space saving and costeffective solution. Easy to install, operate and relocate, each ArcWorld cell is
prepared for TIG, MIG or MAG welding, depending on requirements. The positioner variants of different types and
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Entry level solutions Today, robots are tasked with a variety of roles beyond simple repetitive tasks. However, small, and midsized companies face hurdles in robot implementation due to safety requirements necessitating separate working areas. Yaskawa’s human collaborative robot (HC Series) offers an affordable, versatile, and user-friendly solution. These robots cater to customers seeking seamless automation, enabling them to work alongside humans. The Weld4Me Cobot package is an easy-to-use, collaborative robot-based MIG or MAG welding station. It offers top performance for small welding 30 NOVEMBER 2023 Manufacturers’ Monthly
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RA has a vast range of systems for any challenge. manmonthly.com.au
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WeldingAutomation enabling it to be trusted advisors in designing the right system to suit your needs without compromise.
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setting RA apart as trusted advisors in system design without compromise.
This comprehensive range of proven systems sets RA apart from others,
RA’s offline robot programming solution uses smart software to automatically generate robotic welding programs directly from CAD information. This easy-to-use desktop application makes offline robot programming simple and has powerful tools to ensure you get high-quality welding results with minimal programming effort. MotoSim® is a comprehensive software package that provides accurate 3D simulation of robot cells. This powerful simulation software can be used to optimise the whole system, reach modelling, and cycle time calculations. This enables highly accurate off-line programming of complex systems. Laser Vision enables MOTOMAN robots to precisely find and track weld joints at high speeds and in real time, even while the parts are turning on a coordinated positioner resulting in precise optimised, highly accurate welds. With so many possibilities available, you can be sure RA can provide the most suitable automated solution and return on investment to suit your manufacturing process.
World’s largest range of workpiece positioning peripherals Robotic Automation prides itself on developing solutions for any unique challenge thrown its way, and its robotic welding solutions are pivotal to this. The Swedish MOTOMAN Yaskawa facility alone produce over 2.5kms of robotic servo tracks each year, including all associated cable and control options. With access to MOTOMAN Yaskawa’s wide range of knowledge and expertise in robot technology, RA can provide a complete package fully tailored to the requirements of a manufacturer, using system components all from a single source. With so many years of robotic welding experience, Yaskawa provides an unrivalled rich portfolio of standard and customised work piece positioners with multiple simultaneously controlled axes, providing high speed and superb precision. This encompasses compatible Tracks and Gantries for all applications, manmonthly.com.au
Automated welding can help to meet skills shortages head on.
Manufacturers’ Monthly NOVEMBER 2023 31
Vehicle hoists Going Australian made For over 35 years, Endurequip Hoists has been offering a wide range of hoists and workshop lifting equipment to the heavy vehicle industry.
ow Creating A Better Tomorr
l Rexnord and Altra Industria The global merger of Regal ushers in a new era in Motion into Regal Rexnord IPS s. Renowned brands with Industrial Powertrain Solution g end to end deliverin products in world class powertra Manufacturing industry. Powertrain Solutions to the
The hoists are simple to move and can meet the challenges faced by any manufacturer.
The Portalift hoists can be used for maintenance or manufacturing, they have excellent versatility.
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ANUFACTURED in Brisbane at a state-of-the-art 6000 square metre factory, Portalift from Endurequip Hoists is the only Australianmade portable heavy vehicle hoist and the only chain-driven model. Each Endurequip Portalift Hoist has a high load capacity that can lift up to 7.5 tonnes. When used in a combination of four, six, eight or 10 posts, the set of hoists can lift heavy vehicles that range in weight from 30 to 75 tonnes. Thus, offering a versatile solution to customers that can shoulder the burden of vehicles from the light rigid to prime movers and the heaviest of buses and coaches. Endurequip Portalift Hoist is the only supplier of portable heavy vehicle hoists to the Australian Defence Force, which speaks volumes about the brand’s reputation and credibility. One of the biggest features of using the Portalift hoists in the workshop is longevity. Rated IP65, the Endurequip Portalift hoist is tough, durable, and longlasting and offers complete protection in the workshop. You can use the additional hoist and gearbox covers to further protect the hoist. Endurequip offers customers a structural manufacturer’s lifetime 32 NOVEMBER 2023 Manufacturers’ Monthly
warranty on the Portalift, which includes on-site service or servicing through authorised service centres Australia-wide. This can reduce downtime and maximise the safety of mechanics when they are operating around lifted trucks or buses. Endurequip offers a complete solution for all your workshop lifting and handling requirements which include vehicle ramps, A-Frame trailer adaptors, small-wheel adaptors and engineered solutions. In short, Endurequip can provide a unique workshop solution that makes servicing and maintaining heavy vehicles easier than ever before. Being Australian-made means Endurequip supports the Australian economy. Whether it is by employing locals at the Brisbane factory or buying steel from local companies, the funds are used to contribute to the local economy and grow local manufacturing. As per the Australian-Made website, every $1,000,000 generated by an Australian manufacturing company results in 10 full-time jobs, which means you are supporting local job creation. Also, buying local gives you peace of mind because you know where your products come from, the materials and the
standards required to manufacture these products, and who to contact should you require help, support, or advice. Hence, when it comes to servicing
Rexnord IPS can help the heavy industry’s fleet of vehicles, one t to find out Regal Get in contac ial Powertrain Solutions. you with end to end Industr www.regalrexnord.com of the safest ways to do1300so258is by using an nord.com regalrex stralia@ sales.au 726 Endurequip Portalift hoist to lift a truck or bus off the ground. Sydney
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Fluid Power Fluid power solutions in Motion
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Motion Australia is expanding its offerings to the manufacturing space with the recent acquisition of Powell Industrials.
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OTION, a global leader in industrial solutions, is thrilled to announce its acquisition of Powell Industrial, a prominent Australian-owned supplier of industrial and hydraulic hose and fittings offerings. This strategic move further solidifies Motion’s commitment to providing comprehensive fluid power solutions to customers in the Asia-Pacific region. Powell Industrial is a leading Australian-owned supplier of industrial and hydraulic hose and fittings solutions. With a reputation for providing dedicated offerings, Powell Industrial is a market leader in Australia, offering a comprehensive range of products and services to meet the needs of various industries. Heath Fitzpatrick, chief operating officer for Motion, expresses his enthusiasm about the acquisition explaining how bringing the company on board will help support current and
future customers. “The acquisition of Powell Industrial aligns seamlessly with our five-year strategy to expand our fluid power solutions offerings to current and future customers,” he said. With a goal to bring existing fluid power businesses under one focused line of business, Fitzpatrick highlights that the recent acquisition of Powell Industrial is all a part of Motion’s long-term vision. “Over the next five years, we have a clear plan to significantly grow this line of business, both organically and through strategic acquisitions,” Fitzpatrick said. Darrin Sargeant, Managing Director from Powell Industrial, highlights the strategic synergy between the two companies. “Today, between Powell Industrial and Motion, there are many existing suppliers we both utilise. Being part of Motion will provide an opportunity for Powell Industrial to grow our business and
The acquisition allows Motion to be a more complete company.
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Motion Australia is better positioned now to support Australian manufacturers.
34 NOVEMBER 2023 Manufacturers’ Monthly
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FluidPower become a leading player in the market,” he said. This acquisition promises to be a progressive new chapter for both Motion and Powell Industrial customers. By combining their expertise and resources, Fitzpatrick says the newly united companies is set to become one of the largest providers of industrial and hydraulic hose and fittings products are service offerings in the Australian and New Zealand market. “Customers can expect an expanded product range, premium offerings, and a true one-solution provider,” he said. “We are genuinely thrilled about the growth opportunities that this partnership will bring. It aligns perfectly with our mission to offer the best value to our customers.” The acquisition of Powell Industrial by Motion marks a significant milestone in the fluid power solutions sector, promising to deliver enhanced offerings and value to customers across the AsiaPacific region.
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Customers can expect a more diverse product range.
Manufacturers’ Monthly NOVEMBER 2023 35
Electronics Components Rising like the Phoenix A fire at its facility might be expected to spell disaster for the future of a company – but not for Elexon Electronics. A mere six weeks after a fire destroyed its main factory it is back in business with new components rolling off the production line. recovery plan IntelliDesign had used during its recovery. “Andrew Ward, one of the owners of IntelliDesign also called me soon after to implore us to get our test equipment out of the facility as soon as possible,” Faller said. “The mix of smoke and water is incredibly corrosive and destroys anything that otherwise had survived the fire. “So, with our insurance provider and Fire Investigation Unit on board, following strict PPE and safety rules, we commenced with removing and cleaning anything salvageable on day three after the fire.,” Faller said.
Wide range of support
The new site has been a hive of activity recently to help get the company back online..
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ANUFACTURERS’ Monthly got the opportunity to speak with CEO Frank Faller to learn how Elexon Electronics is recovering far quicker than the company ever expected, thanks to support from an incredible array of suppliers and competitors. During the early hours of the morning on August 12 a devastating fire destroyed its long-standing manufacturing facility based in Brendale and, with it, its worldclass equipment. “It became clear very quickly that all of our manufacturing equipment was destroyed, equipment that we had spent years acquiring either through government grants or shrewd investing,” Faller said. “The silver lining was that much of our raw materials were not destroyed, which to restock would have taken anywhere from 26 to 58 weeks. It would have crippled us. “Initially the call came from our security company because a motion sensor had triggered an alarm. When viewing on a CCTV, a spot fire could be
36 NOVEMBER 2023 Manufacturers’ Monthly
seen. By the time one of the owners of Elexon arrived, the building was almost completely engulfed in flames,” he said. IntelliDesign, an electronics manufacturer from the South side of
Brisbane that suffered through fire ten years ago, was the first to help. Wendy Weeks, IntelliDesign’s quality manager, was the first visitor on the site and she delivered supplies and a copy of the
Almost every electronics manufacturer in Australia has reached out to the Elexon Electronics team, from Grabba (Crystalaid Manufacture) in Queensland, through to GPC in Sydney, Entech in South Australia and Extel Technologies in Victoria. “We are incredibly grateful for this support, and we have identified an opportunity to partner with Extel Technologies in Melbourne,” Faller said. “The company has much of the same Mycronic PCB assembly equipment so it
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The team has come to work every day with a smile on their faces, willing to help the company recover.
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Elexon Electronics recently took home the Defence Teaming resilience award, something that has proven to be well deserved. was a great opportunity to contract work to them. “Due to the compatibility of our equipment and theirs, it was simple to transfer our data and information to them and supply our parts and components. “We expect them to be an important part of us continuing to send our quality products to market until we are back at full capacity in January 2024,” he said. While some of Elexon Electronics’ competitors have been incredibly supportive, its suppliers have gone above and beyond to deliver a solution for the company. “Two of our suppliers – Suba Engineering and HW Technologies, based in Sydney – were instrumental in providing a number of solutions for us throughout this process,” Faller explained. While these two companies are competitors in their field, they worked together to help support Elexon Electronics during these challenging times. HW Technologies had a complete Mycronic SMD production line for Elexon manmonthly.com.au
Electronics to rent but were missing a critical component, Faller picks up the story. “HW Technologies had everything we needed in its showroom, but they did not have a reflow oven which is a critical
component for our process,” he explained. “Its competitor Suba Engineering offered to deliver a reflow oven to its site to allow us to have everything we needed in the one showroom. “That is something we would never ask of them, but the two companies were willing and encouraged collaboration between themselves to support us, we could not believe it,” Faller said. Utilising the showroom in Sydney was a short-term solution for Elexon Electronics, the next step was to ensure it could get itself back online and delivering for customers as soon as possible. Elexon Electronics discovered a new facility only one and a half kilometers down the road. Covering 1500 square meters in warehousing and 1,500 square meters in office space, it was the perfect site for the company to set itself up. The immediate steps were to plan to build a dedicated manufacturing cell within the warehouse with a suspended ceiling, air conditioning, ESD measures and other important safety and security components for the site. While the company waited for these aspects to be completed it set up a marquee in the warehouse to have a space for new machinery and raw materials to be delivered. “Suba Engineering was fantastic, they had a piece of machinery slated to go to a customer in South Australia, they contacted them to understand if it was possible to send it to us in Queensland instead,” Faller detailed.
“That customer was more than happy to wait a little longer so we could take delivery, that is just another example of the incredible community we have in manufacturing. “Five weeks after the fire we built our first boards in our new facility at our new warehouse, along with technicians from both suppliers to help us with the initial setup. “By having that marquee set up, we were able to accept delivery at our new warehouse and was going to save us double handling the equipment as it arrived in Queensland,” he said. A capability Elexon does not have at the moment is flying probe testing, something that can be done at Crystalaid Manufacture, and the company was more than happy to help.. “They have what is almost the exact same machine we did, and they offered us access to it including a desk for our test engineer.” he said. “Bosch Power Tools also reached out recently to offer some tools on loan for us to use until we could source our own,” Faller said.
The future The prospect of an event such as what occurred to Elexon Electronics is enough to send a shiver down the spine of any manager or CEO of a company, with many expecting to be out of commission for 12 to 18 months, not producing goods after six weeks like Elexon Electronics. Getting back online is testament to
Only six weeks after the fire, the first products rolled off the production line.
Manufacturers’ Monthly NOVEMBER 2023 37
Electronics Components
The support from suppliers and manufacturers alike has been overwhelming for Elexon Electronics.
the determination and skill of the Elexon Electronics team, but also the support of the wider manufacturing community in Australia. “This whole process takes time, while a lot has fallen into place for us such as the new facility and the ability to source manufacturing equipment, the support of the wider industry is what made it happen. “We are lucky this new facility will actually suit our needs better, it has a huge warehouse floor, and more space that can better set us up for the future. The wider team at Elexon Electronics has been an incredible asset to the company’s success over the journey, but they became integral to the recovery process. “These are the moments that you need a strong team and that is what we have here at Elexon Electronics,” Faller said. “It has always been a focus of ours to develop a positive, strong, and inclusive culture, and these are the times it pays off, I have been amazed by our team throughout. “The prospect of cleaning equipment or components is a daunting one and to do it day after day can be difficult, but everybody did it with a smile on their face and were 38 NOVEMBER 2023 Manufacturers’ Monthly
encouraging each other, it really shows the commitment of the team,” he explained. Elexon Electronics understood seeing the company where you are employed going up in flames would be scary for any of its employees, so it knew it had to act fast. The company maintained an open line of communication throughout, and they knew that on the other side of the recovery it would have a lot of work to do. Not one team member has departed throughout the process, a testament to the success of the organisation. “I would never have thought we could turn the situation around so quickly,” Faller said. “Six weeks after the devastating fire, we produced the first set of PCB boards for one of our main products. We already started building a few simple assemblies and by the end of October, we will be working on a job for a defence customer. It would have never happened without our amazing team, the support of our community and the patience of our customers. “I always look at everything we do as an opportunity and this situation is no different,” Faller said. “We know we will come out at the
other end of this as a much stronger and resilient team, we are very upbeat and positive about our future. “Last year, we took home the Defence Teaming Centre resilience award and that takes pride of place in my office, we feel we well and truly deserve it after everything that has happened to us,” Faller chuckled.
Safeguarding for the future In order to prevent a catastrophe like this from occurring again at Elexon Electronics, it has worked tirelessly with industry professionals such as Fire Service Queensland to develop safe storage and handling strategies for Li-batteries. This work encompasses a fire safety plan, reviewing process, staff training, lithium fire extinguishers and blankets, and even an advanced early detection system. From now on, Elexon will store all lithium batteries in an insulated and temperature-controlled 40-foot container outside of the building. Its plan also involves careful control of batteries inside the building, with only the required production quantity for any given day to be taken inside. These will
be stored in a separate room outside of the production area and purpose-built fireproof transport carriers will be used at all times. At the day’s end, all remaining batteries, semi-completed and completed goods will be returned to the purpose-built container for safe storage. There are new technologies on the market such as Aqueous Vermiculite Dispersion (AVD) extinguishing agent. It is a new technology that uses fixed and portable delivery techniques to effectively combat lithium-ion battery fires. Elexon will be using a mix of the AVD Lith-Ex extinguishers and fire blankets, ensuring it has the safest and most advanced lithium fire solutions at our facility moving forward. Elexon Electronics is learning from challenges. “Despite our consistent efforts to maintain safety, we experienced significant setback. For this reason, we want to take on the role of industry mover and shaker and share our learning and experience with our community to prevent others from facing similar adversities,” Faller concludes on a positive note. manmonthly.com.au
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Management Consulting
Seizing an opportunity for growth Manufacturers’ Monthly spoke with the RSM management consulting team to explore how manufacturers can navigate the challenging circumstances of an ever-changing industry.
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URRENTLY, the manufacturing sector appears to be heading further toward industry 4.0, digitalisation, automation and decarbonisation. These trends are creating challenges for businesses that are struggling to adjust to changes in the manufacturing industry. RSM partner and business coach, Don Holley, said that combining these trends with regulation and legislation can create a complex environment of operating for manufacturing companies. “We’ve got these macro trends of digitalisation of everything, often referred to as industry 4.0, decarbonisation of our economy – you combine that with substantial regulation and legislation to to drive compliance and you get a very complex environment for operating,” he said. manmonthly.com.au
A changing industry that is becoming more digitised and concerned with carbon emissions can pose many challenges for manufacturers, but it can also present opportunities for growth, innovation, and success. RSM’s management consulting supports manufacturers to make sense of change, to suggest and implement changes necessary to be successful in an ever-evolving industry. ““RSM has a management consulting capability designed to support our mid -market clients,” Holley said. “While advising clients on other areas around risk, compliance, finance etc we often spot further opportunities for improvement – and so the consulting capability increases our capacity to support them. ” “The management consulting
is to actually help them drive that improvement in their organisations.”
Rules for change Holley said that manufacturers will need to shift and maintain that pace pace. Things have changed from “ business as usual “ to innovation as usual” He says leaders must adopt new skills, create new leadership styles, and use approaches that are suited for a more digitalised work environment. Industry leaders must become familiar with technologies such as Internet of Things (IoT), artificial intelligence, automation, and digital twins to get ahead. Manufacturers should become data driven – Holley said that the effective leaders of the manufacturing industry will be those that insist on making decisions based on data.
Throughout his experience working with manufacturers, Holley observed three common changes that industry leaders can make to improve their chances for success. “There are three things that stand out for me that need to change for leaders in the manufacturing space,” he said. “These are being more proactive, creating more adaptable organisations, and improving transparency.”
Becoming proactive Digitalisation and climate change can bring uncertainty to the manufacturing industry and ultimately alter the way that the industry operates. Manufacturers can seize an opportunity for growth by adapting to shifting market needs, new technologies, and changing environmental rules. Manufacturers’ Monthly NOVEMBER 2023 41
Management Consulting
Holley said that industry leaders can be hesitant to respond to these changes –often waiting to see how the industry reacts to change, before adjusting themselves. “If you look at compliance, sustainability, and clean energy – the problem is that when things are changing so quickly, you’re always playing catch up,” he said. “That can be risky. So, you really must anticipate what’s coming in order to do something about it.” “For example, manufacturers by nature, tend to be good at projecting forward with functions such as inventory control and manufacturing schedules,” Holley said. “But when it comes to improving productivity and strategy, they need to think creatively about their desired future goal, and then reason backwards to discern how they’re going to get there.” “To do that requires a different way of thinking, which is a challenge. But it also requires taking the time out of their day-to-day operations to be more strategic when thinking about it,” Holley continued. Holley elaborated that to meet the demands of the converging challenges of climate change and digitalisation, 42 NOVEMBER 2023 Manufacturers’ Monthly
manufacturers must also equip workers with the skills to navigate these challenges. He says that leaders need to train workers to be able to handle both advanced technologies and sustainable business practices. Investing in education to cultivate internal talent can be more costeffective than waiting to recruit when the need arises. Holley said that talent planning will be a core leadership responsibility. “In many cases they are so busy in dealing with the day-to-day operations, that they deprioritise planning, and so that makes it really difficult to be proactive. ”
Becoming adaptable Holley said that as world governments become more focused on the environment and climate change concerns, manufacturers will need to adapt. He suggests that leaders must make taking care of the environment a big part of how they make decisions. “If you’re a supplier, for example, to an organisation that’s very environmentally conscious, and you’re not able to demonstrate that you’re carbon efficient, then its likely you won’t get the contract,” he said.
“There’s also increased pressure from consumers who want more environmentally sustainable products.” Industry leaders can adopt sustainable practices by fostering a culture of sustainability, setting ambitious eco-friendly goals and ensuring that sustainable practices are at the centre of their company operations. Holley reiterated that manufacturers must learn to adapt to emerging technologies. These technologies can help manufacturers to work better, create less waste, and minimise environmental impact. Holley emphasised the importance of becoming a data driven manufacturer – he said that the effective leaders of the manufacturing industry will be those that insist on making decisions based on data. Data can enable manufacturers to gain competitive advantages by affording them insights into energy consumption, emissions and resource usage.
Becoming transparent Holley concluded that another imperative change that manufacturers must make is to be transparent – they must establish trust with their workforce and suppliers. “Suppliers and customers must be treated as genuine partners. So, you
must be transparent, you have to be collaborative,” he said. To be effective in addressing climate change concerns, manufacturers must be able to muster the support of their workforce. Manufacturers will need to work with stakeholders, customers, regulators and communities. Holley said the best way forward is to adopt a transparent and inclusive leadership style. “Leaders need to role model working cross functionally. to solve some of the problems facing their businesses,” he explained.
RSM’s practical services RSM provides several services to help manufacturers become industry leaders. Their services include guidance in developing business and transformation strategies, business models and digital transformation roadmaps. RSM can optimise manufacturing capabilities through leadership team alignment and development, organisational design and restructuring, operational assessments and executive coaching. To help to deliver plans, RSM can also provide project management resources, program reviews, and audits. manmonthly.com.au
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IN CONJUNCTION WITH
Engineering Focus Cleaning Queensland’s ocean’s Dr Ruirui Qiao from the Australian Institute for Bioengineering and Nanotechnology (AIBN) is working with her team of researchers to refine new polymerisation techniques – the team’s goal is to provide a sustainable alternative to conventional plastics; she spoke with Manufacturers’ Monthly to explain. Dr. Ruirui Qiao, a group leader and NHMRC Emerging Leadership Fellow at AIBN, University of Queensland.
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R Ruirui Qiao will be working with AIBN colleagues, Professors Tom Davis, Xuan Pang and Xuesi Chen from the Changchun Institute of Applied Chemistry (CIAC), also in collaboration with the Chinese Academy of Sciences (CAS). The CAS already has more than 20 years of experience in producing degradable plastics for various manufacturing applications and by partnering with the research team, the institute will bring a wealth of knowledge and assets to the project. Dr Qiao says that building the relationships between Australian and Chinese research groups will strengthen their respective manufacturing capabilities. “We are fostering collaboration
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between research groups in Queensland and China to further our strengths in polymer science and additive manufacturing,” she said. The research project was recently accelerated when the collaboration received $125,000 dollars from the Queensland-Chinese Academy of Sciences Collaborative Science Fund. The fund has enabled the team to purchase new equipment necessary for their research, and to also support the researchers working on the project.
Researching solutions for Queensland’s ‘pollution crisis’ The longevity and low degradability of conventional plastics poses a threat to Australian marine ecosystems – including
the Great Barrier Reef, a pivotal part of Queensland’s tourism revenue and its marine ecosystem. “This is really important, because plastic pollutants are actually killing more than one million seabirds and around 10,000 marine animals every year,” Dr Qiao said. “We are trying to develop new seawater degradable plastics that are compatible with 3D printing technology and biodegradable polymer developed by our CAS partner from China. “This is what inspired me to establish this new platform and to work with these materials,” she explained. Their goal is to commercialise a new line of products in Australia and China within five years to replace traditional
plastics and tap into a biodegradable market – which is expected to exceed $9.5 billion by that time.
The crisis Queensland’s grand jewel, the Great Barrier Reef, currently contributes $6.4 billion dollars to the Australian economy each year and supports around 64,000 full-time jobs. Plastic debris and pollution pose a threat to Queensland’s marine ecosystems, and subsequently, all the industries that depend on it The Queensland Government has already committed more than $1 billion since 2015 on initiatives and actions to protect the Great Barrier Reef. More than 80 per cent of marine manmonthly.com.au
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EngineeringFocus Dr Liwen Zhang, a PhD recipient for advanced macromolecular design, demonstrates 3D printing techniques.
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will remain completely degradable in marine environments. “We need these materials to be degraded under the same water found in ocean environments, which contain much higher levels of saline relative to soil,” Dr Qiao said. “The temperature in the ocean is a little bit lower than the temperature on land. There are so many differences between different environments,” she said.
Establishing what will work
debris found in the Reef is plastic, which can break up into smaller pieces and travel vast distances, increasing the impact far beyond Australia’s shores. 1.5 million tonnes of plastic are consumed each year which equates to approximately 65kg of plastic for every man, woman and child in Australia – only 20 per cent of that plastic waste is then recycled. Two per cent of all plastic leaks into the environment which equates to roughly 300,000 tonnes of waste per year. The Great Barrier Reef Marine Park Authority categorises plastic waste based on the size of the debris; the primary categories of debris are microplastics, macroplastics and secondary microplastics. Microplastics are plastic items less than five millimetres in size – this can include microbeads from personal care products and microfibres from synthetic clothing materials. Whereas macroplastics are plastic items that are greater than five millimetres in size, such as bottles or straws. Secondary microplastics have been broken up from large pieces of macroplastics, including abandoned, lost, or discarded fishing gear – like crab pots and fishing nets.
3D printing technology and creating plastics that completely degrade in highsaline environments. The primary challenge lies in synthesising degradable materials that are easy to produce, durable, customisable, and sustainable. “Some industries require special
shapes for certain applications made with these plastic materials, but how to combine these with 3D printing technology is currently a challenge,” Dr Qiao said. The team has already synthesised prototypes, but until research has been completed, it is still unclear whether they
The research team is working to establish a catalogue of plastics that are degradable in seawater, then test these materials in marine environments. The research process will examine the viability of these materials breaking down sustainably. “We want to develop an original library of seawater-degradable polymer materials at first and we will want to test their degradation in the sea water environment,” Dr Qiao said. The research team plan to eventually produce and distribute their material to the manufacturing market once the research has been completed.
Challenges for the research team The research team has encountered several challenges throughout their research – such as creating degradable plastics that are also compatible with manmonthly.com.au
Dr Zhang examines polymer material, which will be used to create degradable plastic prototypes.
Manufacturers’ Monthly OCTOBER 2023 45
Engineering Focus
The customisable seawater-degradable plastics are developed in the labs at the AIBN. “We will want to also integrate this type of polymer materials into the 3D printing technology. In the end, we want to establish the bulk synthesis of this plastic materials.” Dr Qiao said. Dr Qiao said one technique they will use – called ring-opening polymerisation – will allow them to precisely control the mechanical strength and shape of the plastics while giving the plastics a lowtoxic polyester backbone. “This means the plastics are able break down to a molecular state in marine environments,” she said.
Degradable plastics in manufacturing The degradable plastic materials will have various manufacturing applications once the research process is completed. The CES have already established these materials in agriculture, and they have successfully used the plastic materials as protective membranes for crops. Dr Qiao says that the research team 46 NOVEMBER 2023 Manufacturers’ Monthly
anticipates that these plastic materials will also be used in pharmaceutical and biomedical industries. “We will be more looking at biomedical applications initially,” she said. “There are advantages to using degradable plastics in the medical field. The utilisation of biodegradable plastics holds great potential for reducing environmental impact,” she said. “By incorporating biodegradable materials into healthcare products, such as medical devices, packaging, and more, the industry can reduce its ecological footprint.” “Degradable plastics can be strategically employed for controlled drug release, reducing the risk of infection.” “The medical and pharmaceutical applications can include drug encapsulation, surgical instruments, tissue fabrication, as well as customised prostheses.”
Drug encapsulation made from degradable plastics can also optimise outcomes for patients. “Compared with conventional capsules, degradable plastic capsules offer a tailored drug release mechanism, optimising therapeutic results while mitigating side effects,” Dr Qiao said. “They also bolster drug stability, safeguarding delicate compounds, and hold the potential to facilitate precision delivery to specific tissues or organs.” Dr Qiao continued to explain that degradable plastics can enhance the efficiency and sustainability of medical instruments, which are designed for short-term contact with tissues or fluids. “This includes items like surgical implants, such as sutures, clips, and pins,” she said. “As well as drug delivery devices, wound dressings, tissue scaffolds, and certain types of endoscopic tools.” “The use of degradable plastics in these instruments can reduce the need
for additional surgical procedures to remove them, as they can gradually break down and be absorbed by the body.” “This ultimately improves patient comfort and reduces the risk of complication,” Dr Qiao added. The research team have plans to manufacture and market the material on a global scale – they already have established avenues through their current research partners. “We are very confident that, in the future, we will translate our product to either the Australian or the Chinese market,” Dr Qiao said. They aim to commercialise a new line of products in Australia and China within five years to eventually replace traditional plastics and tap into a biodegradable market – which is expected to exceed $9.5 bn within that time frame. The team will soon be testing their existing prototypes in marine environments when their project officially starts its early trials in October, later this year. manmonthly.com.au
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Commitment to quality United Fasteners’ triple ISO certification for its Head Office, South Australia, and Western Australia branches is a remarkable accomplishment that cements the company’s status as a leader in the industry.
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NITED Fasteners, a renowned name in fasteners and industrial supplies, recently earned triple ISO certification, encompassing its Head Office along with its South Australia and Western Australia branches. This achievement reinforces the company’s commitment to excellence and sets a new industry standard. United Fasteners is Australia’s largest independent distributor of fastening products and industrial supplies. Over the years it has established itself as a market leader and is recognised for exceptional service, timely delivery, competitiveness, and total solutions. It stocks a comprehensive range of products, including: fasteners and fixings, abrasives, cutting tools, sealants, adhesives, lubricants, hand tools, safety, construction chemicals, materials handling, petrochemical and special manufacture. It has a team of over 250 people that are technical experts and solution focused, with in-depth product knowledge and sourcing experience across fastening products and industrial supplies. The company is still fully Australian owned with 13 branches nationwide and over 75,000 SKU’s delivering a range of solutions.
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ISO certification United Fasteners’ attainment of ISO certifications for Safety, Environmental and Quality across three key entities, ensures a uniform approach across the organisation; one which provides a safe and harmonious workplace, care for the natural environment and upholding the delivery of high-quality products and services to customers.
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leadership, showcasing relentless pursuit of safety, environmental responsibility, and quality. It’s a significant accomplishment with far-reaching positive impacts.
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Ultra-Slim Intel Celeron J6412 fanless box PC Interworld Electronics is excited to feature the ACS-2310A Ultra-Slim Intel Celeron J6412 Fanless Box PC from APLEX technology. With its compact size, rugged/fanless design, wide operating temperature, various mounting options, and wide range of additional features, the ACS-2310A is suitable for a wide variety of industrial applications, including manufacturing, process control, warehousing and mining. The ACS-2310A is powered by the Intel Celeron J6412 processor and supports up to 32GB SoDIMM DDR4 memory. It has 2 x USB 3.2 ports; 1 x RS-232/422/485 serial port, 1 x DP and 1 x HDMI graphics output port; and 1 x 2.5GbE LAN and 1 x GbE LAN ports. It also supports 1 x MO-297 SATA Half Slim SSD and 1 x M.2 M-Key 2280 for SSD, which can be used simultaneously, providing even more storage options. It’s wide range of I/O and storage options enables users to integrate the ACS-2310A with a number of peripheral devices and applications making it suitable for a variety of solutions. The ACS-2310A is also a rugged, durable and reliable fanless system that features a tough casing (aluminium heatsink and steel chassis) and an operational temperature range of up to -20°C to 70°C, enabling it to continuously run even in harsh industrial environments. It supports a wide range DC 9~36V input and is extremely compact (207 x 130 x 41.5mm), making it a good option for applications with limited space. manmonthly.com.au
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It supports both Windows 10 & 11 providing increased flexibility for future applications. It also has a range of mounting options, including bench/wall, VESA, and DIN mounts, making the device adaptable to a range of environments. The combination of performance, ruggedness and flexibility in such a compact device makes the ACS-2310A an ideal solution for your needs. For more information visit the ACS-2310A product page at Interworld Electronics. Manufacturers’ Monthly NOVEMBER 2023 49
The Last Word
INNES WILLOX – Chief Executive of the national employer association Ai Group
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The unemployment rate dropped to 3.5 per cent earlier this year.
Approaching full employment
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O its credit the Federal Government’s Employment White Paper has ignited a heated discussion about full employment. What does it mean; and who has the right to use the term “full employment”? A constructive direction for this debate to take would be to switch focus to the question of how to reduce unemployment. Making inroads into Australia’s unemployment, and underemployment, is a sensible policy direction that should attract widespread support. It is an ambition at the intersection of economic growth, resilience, social inclusion and opportunity. A curious bout of backslapping 50 NOVEMBER 2023 Manufacturers’ Monthly
broke out recently when Australia’s unemployment rate reached a fiftyyear low of 3.5 per cent. The mood was less congratulatory among those who can recall that around 1973, and for a long period before that, Australia’s unemployment rate was more likely to be below 2 per cent than above it. Yet in her June 2023 address at an Ai Group function in Newcastle, then Reserve Bank of Australia Deputy Governor (now Governor), Michele Bullock, suggested that slowing the economy to reduce inflation to the 2-3 per cent target range could give rise to an unemployment rate of 4.5 per cent. This statement was met with vocal criticism from the ACTU and protests were
organised at her next speech. What was missed by the ACTU and in many lead articles covering the speech were some very telling comments by Bullock about “structural unemployment” – when people who are unemployed and looking for work don’t have the skills sought by employers trying to fill vacancies. This is a situation that resonates with employers who, over the past couple of years, have reported an intensifying inability to find suitable people. Bullock went on to suggest that policies that directly addressed the skills and vacancies mismatch were better suited to making inroads into structural unemployment than the conventional monetary policy easing prescribed in
elementary economics textbooks. Critically, given the disruptions expected ahead for the Australian economy, including from further digitalisation of the economy and its decarbonisation, she further suggested that, “this is not only a short-term issue but it’s a longer-term issue because the economy’s structure changes over time and the skills that we all need … are going to change over time.” For the business community these insights are hardly worth protesting about: rather, they should be taken on board and acted on. And that is what the Employment White paper is proposing. The Australian business community has been at the forefront of advocating manmonthly.com.au
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for a concentrated effort at raising the employability of people who can’t find a job. Ideally the initiatives would be more broadly available to others at the margins of the labour market – including people who are currently employed but face the risk of losing their jobs in the wake of disruption. Such training initiatives sit at the intersection of economic growth, resilience, social inclusion and opportunity. Serious inroads could be made in reducing the underutilisation of Australian workers (currently underestimated in official statistics at about 10 per cent of the workforce – despite the country having reached ‘full employment’).
GDP would be higher, as would average household incomes and the taxation revenue required to fund the activities we want our governments to provide. We would improve the outlook of people who otherwise would be at risk of being left behind and we would improve the inclusiveness and cohesion of our country. Addressing a problem of this scale is daunting and complex. It will require changes in teaching and learning from early childhood education and in primary and high schools. It will need increased and more flexible tertiary education and training for those adults, often for whom english is a second language, without the level of language
and literacy skills that allows them to succeed in finding and retaining a job. And it will require a renewed focus on workplace-based foundation skilling programs including digital literacy. As well, more is needed to assist the development of skills among areas of entrenched disadvantage. For instance, the unemployment rate of Australia’s indigenous peoples is 3 to 4 times higher than for the overall population and the labour force participation rate is significantly lower. The situation is particularly acute in remote and outer regional areas. A similar focus on the foundation skills shortages experienced by many people with a disability is also required.
The unemployment rate for people with a disability is roughly double the rate for the overall population and participation rates are much lower. Whatever else it does, the federal Government’s Employment White Paper would have done a great service if it drew attention to the importance of fixing the mismatch between Australia’s current and future labour force requirements and the skill sets of people at the margins of the labour force. Among the benefits would be to make substantial inroads into structural unemployment and by doing this, significantly reduce the level of unemployment at which the economy would be constrained by inflation.
The Ai group discusses the address from Michele Bullock from the reserve bank.
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