Doug Green

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The hidden cost of absenteeism in manufacturing and why it is rising

By Damien Durston, head of people management solutions at OneAdvanced Australia’s manufacturing sector has always operated under pressure. Tight margins, complex supply chains and rising input costs are part of the landscape. But a quieter issue is now undermining productivity across the industry: absenteeism. Unplanned leave has traditionally been treated as a routine operational challenge. Today, it is seen as something more serious. Employee absenteeism is a major issue for Australian manufacturers, impacting workplace productivity and employee well-being. To maintain business continuity and support their workforce, employers need to analyse absenteeism patterns and implement effective strategies. Absenteeism reflects deeper structural pressures linked to workforce fatigue, an ageing employee base and growing compliance complexity. Together, these forces are amplifying the impact of absenteeism and making it harder for manufacturers to maintain consistent output. The average absenteeism rate in Australian manufacturing is approximately 9-10 days per employee per year, according to The Australian Industry Group. The productivity drain hiding in plain sight Absenteeism has an immediate effect on manufacturing performance. When a skilled operator is absent, production lines can slow, schedules shift and quality may be affected. In specialised environments, replacements are not always readily available, particularly where certifications or machine-specific expertise are required. Supervisors are forced into reactive decisions, adjusting rosters and reallocating tasks at short notice. Overtime costs rise as remaining workers fill the gaps. In some cases, production targets are missed altogether, leading to delays and strained customer relationships. There is also a compounding effect. As absenteeism increases, the workload on present employees grows. This can drive further fatigue and additional absences, creating a cycle that is difficult to break. Workforce fatigue is reaching a tipping point Workforce fatigue is one of the most significant contributors to rising absenteeism. Shift work, long hours and physically demanding roles have always been […]

Dr Gabrielle M Caswell of SpacePort Australia Pty Ltd, a finalist in seven out of 30 Australian Space Awards, 2026

Dr Gabrielle M Caswell of SpacePort Australia Pty Ltd, has been named a finalist in seven out of 30 Australian Space Awards, 2026. Dr Caswell has confirmed her acceptance of the award nominations, she was a finalist in the 2025 (5) and 2024 (3)awards. Dr Caswell says, “It’s an exciting time to be working in space, we are watching the renaissance of human space flight, beyond Low Earth Orbit (LEO), and a return to the Moon.” She continued, “It’s particularly exciting as Artemis II had a smooth launch, and all hands returned to Earth.” Dr Caswell added, “We should remember the pictures of the first landing on the Moon, Apollo 11, Artemis’ brother ship, were directly beamed from Antenna One, Moree OTC, to the world. The Moree OTC station is now decommissioned, the site is 20 minutes from SpacePort Australia. The Honeysuckle Creek Achieves has a wonderful repository of Australia’s long history, of supporting space exploration. It has a great store of images, which are really worth reviewing”. Dr Caswell has spent a large part of her working life in rural and remote environments; she has unique operational insight into the challenges of providing medical care for remote locations, a distinct advantage when understanding the operational space environment. Dr Caswell continues to work in the practices she established over 20 years ago, in rural NSW. SpacePort Austrlaia has a unique niche in the modern space industry, blending engineering with biological and ecological systems management. She continued, “Important concepts for exploration class deep space missions, and remote space colonies, are, by virtue of location, have finite resources. Technology needs to be robust, fixable and serve very precise purposes. The extraterrestrial environment is unique in its overriding hostility towards the human life form.” Dr Caswell’s enthusiasm for science, in all its forms, […]

Battery-free sensors close to reality with breakthrough in solar manufacturing

Sensors underpin modern life, but many still rely on disposable batteries which are contributing to a growing waste problem. With lithium-ion battery waste in Australia projected to exceed 100,000 tonnes by 2036, and hundreds of millions of household batteries discarded each year – many used in low-power indoor sensors and data loggers – there is an urgent need for cleaner power solutions. Now an NSSN Grand Challenge Fund project has demonstrated a viable pathway to producing a battery-free, sustainable alternative. Led by Macquarie University researchers, the project achieved a breakthrough in a key manufacturing step for perovskite photovoltaic (PV) cells which can be designed to generate power from ambient light. The team found a way to manufacture these PV cells faster and more energy-efficient using microwaves: instead of taking 30 minutes, it now takes about 30 seconds and uses half the energy. They also worked out how to scale the process for real manufacturing, where material is produced continuously on a moving roll. “If this technology can be scaled, it unlocks sensing applications that simply aren’t viable today, such as sensors embedded in concrete, environmental monitors in remote infrastructure, long-term medical devices, and agricultural sensing under greenhouse lighting, all operating continuously without maintenance,” Project Lead and Senior Lecturer in the School of Engineering at Macquarie University, Dr Binesh Veettil says. The breakthrough uses a microwave-based process to reduce perovskite PV cell annealing from around 30 minutes to about 30 seconds while significantly cutting energy use, enabling fast, scalable manufacturing and supporting future low-cost, self-powered indoor sensor applications. The project also opens the door to more flexible production where perovskite PV cells could one day be printed and integrated into materials like packaging, buildings and clothing rather than just manufactured for traditional panels. “The real barrier has always been the cost and complexity […]

Leading agri-manufacturer deploys automated solution to build best practices

DLG confidently expects Fiix® CMMS technology to pay for itself within its first year by achieving a 10 per cent improvement in uptime and maintenance efficiency Australasian primary producers and processors with diverse and far-flung operations may take a leaf from the book of technology benefits earned by their counterpart DLG Group in Europe. DLG is Denmark’s largest producer of agricultural feedstock and a significant producer of natural vegetable oil, both of which are produced in Australia and New Zealand. The company – which originated as a farmer-owned cooperative – addressed production, processing and maintenance issues with software also available in Australasia, Rockwell Automation’s Fiix® CMMS technology. The results were evident from the outset. Although the production processes in each site are nearly identical, the machines that run these processes are different in make, model, and age from one production line to the next. This has caused considerable complications for maintenance engineers in the past. Because the production environment was so heterogenous, there was often no single standard and documented resolution for any given problem. Problems often presented differently on different production lines and machines. Each time maintenance technicians were faced with this situation, they had to find the resolution for the problem from first principles. Not only did this increase the time taken to find a resolution, but it also complicated the job of finding the root causes of common or recurring faults. Technicians found themselves treating symptoms, which varied from one production line to the next, rather than tackling the common causes of the issue. The lack of a common inventory and tracking scheme for spare parts also caused problems. Often it would be possible to use the same spare part on a range of different makes and models of machinery. But technicians might not know this was […]

Existing tax system would deliver $80 billion more tax from higher oil price, report finds

Australia’s oil and gas industry would deliver almost $160 billion in taxes and royalties to governments over the next five years if high international prices persist under existing tax settings, new independent analysis by Wood Mackenzie shows. This represents around $80 billion more than under typical long-term price assumptions equating to nearly $17 billion per year in additional revenue flowing to federal and state budgets. Australian Energy Producers Chief Executive Samantha McCulloch said the findings reinforce that Australia’s existing fiscal framework including the Petroleum Resource Rent Tax (PRRT) is already working as intended. “Australia’s oil and gas fiscal regime is designed to deliver strong returns to the community, and this analysis shows it does exactly that, especially when prices are high,” Ms McCulloch said. “As global energy markets tighten and commodity prices increase, the benefit flows directly to Australian governments through higher company tax, royalties and PRRT receipts. “The analysis shows the PRRT would deliver the largest uplift in tax revenue, with a 70 per cent increase in oil prices almost trebling receipts from $13.5 billion to $38.9 billion over five years.” The analysis compares a sustained oil price of around US$120 per barrel with a typical long-term assumption of US$70 per barrel, showing government revenues already increase as commodity prices rise. Ms McCulloch said the findings come at a time when global energy market disruptions have underscored the importance of Australia’s oil and gas industry to domestic supply and regional energy security. “Australia’s oil and gas industry is making a substantial contribution to government revenues, while continuing to deliver reliable energy at home and supporting energy security across our region,” she said. “Domestic gas prices remain stable and well below international levels, and our LNG exports are helping secure supply chains for critical fuels into Australia from key regional partners. […]

AI-driven workflow targets next-generation semiconductor materials

Researchers at UNSW have developed an artificial intelligence–assisted workflow that replaces slow, iterative materials discovery with a targeted, data-driven approach. Designing advanced materials remains largely trial and error. Small molecular changes can radically alter performance, but with millions of possible combinations, identifying viable candidates is a major bottleneck. Hybrid perovskites are semiconductors used in applications such as solar cells and LEDs and are built by combining inorganic layers with organic molecules. These organic components play a critical role in determining how the material behaves, particularly how it transports electrical charge. Unlike previous trial-and-error approaches, the team’s system works backwards from a desired outcome — such as how a material should handle electrical charge — to identify molecules that could deliver it. It then screens large numbers of candidates and filters out those unlikely to be practical to make. Applied across millions of possibilities, the approach narrowed the field to a small set of promising candidates. These were then checked using detailed simulations to confirm their performance. The work tackles a long-standing expensive and time-consuming problem in the field, where researchers have typically made incremental changes to known materials rather than exploring new ones systematically. While the candidates have not yet been tested in the lab, the researchers say the approach could help speed up the development of new materials for electronics and energy technologies by making the search process far more efficient.

Mapei invests $60 million on new Melbourne plant to support Australia’s growing construction industry

Mapei, a global leader in chemical solutions for the building industry, has officially commenced construction on its new state-of-the-art manufacturing facility in Truganina, Melbourne. “Mapei has been actively present in the Australian construction industry for more than 30 years and expanding our footprint into Melbourne marks an important milestone for the business. With the state’s construction sector focused on delivering high-quality infrastructure for the next generations, we’re proud that our local plant will provide our partners with industry-leading materials at a pivotal time for the sector,” said Mapei CEOs Veronica Squinzi and Marco Squinzi. Set to open in 2026, the plant will play a critical role in supplying its high-performance building materials to infrastructure projects across metro and regional Victoria – such as the Suburban Rail Loop and North East Link. The launch of the plant is also particularly timely, especially with Victoria’s Big Build looking to deliver over 180+ major road and rail projects by 2051. The Melbourne facility represents a significant moment in Mapei’s commitment to expanding its Australian footprint and supporting the nation’s growing infrastructure and construction industry. Mapei Australia General Manager Marco De Santis said: “This new facility is more than just a factory; it reflects Mapei’s commitment to growth and innovation in this market, as well as our long-term focus on supporting Australia’s construction industry. By increasing our local manufacturing capabilities, we aim to enable faster delivery, lower transport emissions, and improved support for the evolving needs of our customers and partners in delivering critical infrastructure projects across the state”. Strengthening the construction supply chain amid national challenges Mapei’s investment comes at a pivotal time for Australia’s construction industry, which is grappling with supply chain disruptions, material shortages, and labour constraints. With the national infrastructure pipeline valued at over $213 billion, and Victoria contributing a significant share [1], the pressure to deliver projects on time and within budget has never […]

ROKLive 2026 returns to Adelaide to explore the future of industrial automation

The South Pacific’s largest event dedicated to industrial automation ROKLive 2026 will build on the success of ROKLive 2025 (pictured) on the Gold Coast, which saw more than 900 problem solvers come together for keynotes, training, networking and a showcase of the latest industrial automation technologies Rockwell Automation, a global leader in industrial automation and digital transformation, has released the program for its premier Australia and New Zealand event, ROKLive 2026, which will this year return to the Adelaide Convention Centre from June 23rd to 25th. Bringing together professionals from manufacturing, mining, utilities, and heavy industry, ROKLive 2026 will serve as a key platform for learning, collaboration, and innovation. The multi-day event will feature an extensive program of expert-led sessions, interactive demonstrations, and networking opportunities designed to help organisations navigate an increasingly complex industrial landscape. With industries under pressure to improve efficiency, sustainability, and resilience, the 2026 program places a strong emphasis on practical strategies and real-world outcomes. Attendees can expect deep dives into topics such as industrial AI, connected operations, cybersecurity, and data-driven decision-making. Event highlights include: Expanded conference program featuring a broad range of sessions across key industry themes, including smart manufacturing, digital engineering, asset performance, and sustainable operations Interactive hands-on labs enabling attendees to explore the latest automation technologies and software in real-world scenarios Industry-led keynotes and panels delivering insights into emerging trends, leadership, and the future of industrial operations Technology showcase presenting cutting-edge solutions from Rockwell Automation and its partner ecosystem Beyond the formal sessions, ROKLive 2026 will provide valuable opportunities to connect with peers, exchange ideas, and build relationships across the industrial sector. The event continues to attract a diverse community of engineers, plant managers, system integrators, and business leaders. As industrial environments become more connected and data-driven, the need for skilled professionals and robust […]

Ancient tectonic processes the key to locating rare minerals essential for modern technologies

New research from Adelaide University has revealed that geological processes dating back billions of years are critical to locating the rare earth elements needed for modern technologies and the global clean energy transition. Published today in Science Advances, the study shows a strong global link between ancient subduction zones – where tectonic plates collide – and the formation of rare earth element (REE) deposits and carbonatites, a type of hot molten rock called magma, known to host these valuable resources. Rare earth elements are essential components in technologies such as electric vehicles, wind turbines, smartphones, and defence systems. However, locating economically viable deposits remains a major global challenge. Led by Professor Carl Spandler from the School of Physics, Chemistry and Earth Sciences, the research team reconstructed Earth’s geological history over the past two billion years using advanced plate tectonic modelling. They identified regions of the Earth’s mantle that had been fertilised by subduction processes, where material from one tectonic plate is forced beneath another, releasing fluids and elements into the overlying mantle. The Adelaide University researchers found that these fertilised mantle regions now underlie approximately 67% of carbonatites and 72% of REE deposits formed over the past 1.8 billion years. For older deposits, that figure rises to 92%. Prof Spandler said the findings provide compelling evidence that ancient subduction zones play a fundamental role in creating the conditions needed for rare earth deposits to form. “This research shows that the ingredients for these critical mineral deposits were put in place many million to even billions of years ago,” Prof Spandler said. “By identifying where these ancient processes occurred, we can significantly narrow down the search areas for future discoveries.” The study also challenges previous theories that linked these deposits primarily to mantle plumes –columns of hot material rising from deep within the […]

Faster approvals critical to realising Queensland’s Taroom Trough opportunity

The Queensland Government’s welcome plan to unlock the Taroom Trough represents a significant opportunity to strengthen Australia’s fuel security and economic resilience. Australian Energy Producers Chief Executive Samantha McCulloch said the Taroom Trough has long been recognised by industry as a highly prospective basin with the potential to play a major role in Australia’s energy future. “The Taroom Trough is an exciting opportunity for Queensland and Australia — a significant oil resource that could bolster our fuel security and help to reduce reliance on imports,” Ms McCulloch said. “The industry has long recognised the potential of the Taroom region, and the Queensland Government’s Taroom Trough Development Plan is an important step in encouraging exploration and investment.” Ms McCulloch said the focus must now shift to ensuring projects can proceed without unnecessary delay. “Faster, more efficient approvals and stronger policy settings will be critical to unlocking Taroom and similar basins,” she said. “We need all levels of government working together to fix the approvals system. Carving oil and gas projects out of streamlined reforms under the EPBC was a missed opportunity, and it makes even less sense now given the impacts of the global energy crisis. “There is a significant opportunity not just in Taroom, but across Australia — but it will only be realised with the right policy settings and investment certainty to bring new supply online. “That means encouraging exploration, delivering much faster approvals, and addressing activism and lawfare that is delaying critical energy projects. “Australia has substantial undeveloped oil resources, and developing them is key to strengthening fuel security, supporting regional jobs and helping shield Australians from future global energy shocks.”

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Doug Green

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