Smart Manufacturing

The path to a successful career in manufacturing and making a positive impact

Australian Research Council (ARC) Laureate Professor Veena Sahajwalla is an internationally recognised materials scientist, engineer and inventor revolutionising recycling science. As a leading expert in the field of recycling science, and founding Director of the Centre for Sustainable Materials Research & Technology at UNSW. Veena is producing a new generation of green materials, products and resources made entirely, or primarily, from waste. Veena also heads the ARC Industrial Transformation Research Hub for ‘green manufacturing’ – a leading national research centre that works in collaboration with industry to ensure new science is translated into real world environmental and economic benefits. Veena has been extensively recognised for the innovation and significance of her work, including via election to be a Fellow of the esteemed Australian Academy of Science. At the Women in Manufacturing Summit 2023, Veena examined how to use sustainability and circular economy strategies to improve environmental, social, and financial bottom lines in manufacturing. CAN YOU BRIEFLY INTRODUCE YOURSELF? I grew up Mumbai, which is such a fabulous city with so much going on. As a child, it was about understanding, first and foremost, how people actually made a living. It always impressed me that people would do this by fixing shoes, clothes and all kinds of electronic stuff that we had at home. To me, the creation of all these products out of things that were supposedly broken was really fascinating. I see my work not just as science and engineering, but as wider social reform. I have lived with my family in Australia for almost 30 years. WHAT ARE YOU DOING NOW? I’m the Director of the UNSW Sustainable Materials Research and Technology (SMaRT) Centre where we are known for pioneering the high temperature transformation of waste in the production of a new generation of ‘green materials’. Our best […]

Hunter class frigate program passes Preliminary Design Review milestone

BAE Systems’ Hunter Class Frigate Program has successfully completed its Preliminary Design Review (PDR). The review, which started in July, is a technical assessment that ensures the design is operationally effective and underpins the more detailed work that will now be undertaken. More than 1,800 people are now working on the Hunter program, which is transforming Australia’s shipbuilding industry by helping build a world-class, continuous naval shipbuilding capability. A celebratory event to mark the completion of the PDR was held at the Company’s Osborne shipyard to mark the milestone. BAE Systems Australia’s Managing Director Maritime, Craig Lockhart, said: “The Hunter Class Frigate Program has come a long way from initial head contract signing, to the acceptance of the shipyard, start of prototyping work, and commencement of the first Schedule Protection Block. The completion of the preliminary design review is another significant step forward for the program which is developing Australia’s sovereign industrial capability and is growing the nation’s engineering workforce.” Companies from across Australia are working with BAE Systems to support the manufacture of the first batch of three Hunter class frigates. It is anticipated the program will create and sustain more than 5,000 jobs at BAE Systems and the wider Australian defence supply chain, including up to 1,000 apprentice and graduate roles. “Through this national endeavour, we are committed to maximising opportunities for Australian industry. More than 80 contracts have been placed with Australian businesses to support the program,” said Craig Lockhart.

Scott McPherson, Managing Director, SGESCO-MAX

Q & A: Scott McPherson, SGESCO-MAX Managing Director

Tell readers what you do? SGESCO-MAX is a specialist in heavy vehicle safety. We design and manufacture a range of innovative, high-quality solutions to help solve our customer’s complex safety challenges. Some of our key safety systems include: – Anti-rollaway brake system – Blindspot monitoring (radar and vision) – Pedestrian protection (Artificial Intelligence) – Occupant safety on buses SGESCO-MAX enables customers to achieve their Chain of Responsibility (CoR) primary duties by providing greater community safety. We manufacture our solutions at our Brisbane-based factory at Archerfield. As SGESCO-MAX’s Managing Director, my role is to ensure that the company continues to add value to our customers and stay relevant. I’m committed to creating a great workplace for our staff, paying our suppliers on time, building strong partnerships, and providing excellent customer service. Another significant part of my role is ensuring we have the right systems in place. My experience in IT taught me the value of technology in driving business success. What recent developments in the company have made it more refined with processes? Since our inception in 1962, efficiency has been embedded in our culture with the motto ‘Economy through Efficiency’. However, our transition in 2020 from a service to a manufacturing-oriented business opened the door for a review of our procedures and processes, given the shift and new focus. The review highlighted that the legacy ERP system was hampering the business – with many processes dedicated to what the system could do instead of what the company needed. Hence, the goal is to find a new system that would enable our business to move forward. The technology used? We implemented the Wiise Enterprise Resource Planning system, based on Microsoft’s Business Central, around 18 months ago. Your company is now more manufacturing focussed…explain the transition? For the first 58 years, SGESCO-MAX […]

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Decarbonising our cities

The built environment accounts for 39 per cent of gross annual carbon emissions worldwide. How to account for embodied carbon emissions Operational emissions – for example from the electricity it takes to heat or cool buildings – account for some built environment emissions. But embodied carbon emissions also contribute a significant proportion. They are carbon emissions caused by construction as well as the extraction, manufacture and transportation of construction materials. Replacing an energy-inefficient old building could reduce operational emissions but add to embodied carbon emissions. And balancing that equation can be challenging, as calculating embodied carbon emissions involves uncertainties. Different databases give different values for embodied carbon coefficients, which represent the amount of carbon emitted per unit of material. But experts can help navigate this uncertainty. “We all have to commit to transparency in our approaches to embodied carbon calculations. We need to share data sources, and methodologies and assumptions used in our calculations. And only then can we foster trust and comparability so that we can ultimately reduce embodied carbon,” said Dr James Helal, Lecturer in Sustainable Structural Design and Assistant Dean (Sustainability) at the University of Melbourne. Designing new buildings to minimise carbon emissions “To reach our net zero emission goals, we must reshape the way we think about buildings. They’re not just shelters. They’re living, breathing entities that should be designed and operated with a clear understanding of their impact on our ecosystem,” said Dr Behzad Rismanchi, Senior Lecturer in the Department of Infrastructure Engineering at the University of Melbourne. Specifying carbon targets, including embodied carbon, and engaging with engineers or sustainability consultants early is crucial. “Optimisation [of building designs] can only take us so far,” said Environmental Designer Lucy Marsland from Atelier Ten. Applying circular economy principles to building design will inherently achieve decarbonisation. “Circular economy at its heart aims to keep […]

Q & A: Cathy Clennett, Head of Commercial and Corporate Development, Hiringa Energy

Can you provide some scale on the size of the green hydrogen facility? The GEGHA project will see the installation of the 27 MW Wathagar Solar Farm, which will produce roughly 45,000 MWh of energy per annum — the equivalent to powering over 4,000 homes — used to make 3,800 MT of anhydrous ammonia to displace the equivalent of 6,800 MT of imported urea, as well as enough low-carbon hydrogen to displace more than 1.4 million litres of imported diesel. How long is it estimated the facility will take to construct? Construction for the facility is underway thanks to partial funding from the NSW Government’s Hydrogen Hubs Initiative. The $35.8 million awarded by the NSW Government will help us enhance the capacity of the world’s first Good Earth Cotton farm. We anticipate construction will take up to 15 months, and our objective is to have the facility fully operational by mid-2025. How many jobs will the facility create? During the construction period of the facility, we estimate the GEGHA project will bring approximately 100 jobs to the region with further opportunities in the operations space once the project is completed. We’ve estimated approximately twenty full-time, high-quality operations jobs will result from the GEGHA project. However, we are in discussions with Moree Council and the NSW Government about extending the project to a special activation precinct which would be able to provide the same benefits to farmers in Moree looking to mirror what we’ve done with Sundown Pastoral. In this case, the scale up project would look to employ approximately 40 additional employees — with a diversification of roles beyond pure agricultural work. What are the benefits to the local economy? Australia’s hydrogen industry is at an inflection point, which is forecast to generate $50 billion in additional GDP, and create […]

Remondis Hygrogen Waste Collection truck

REMONDIS Australia’s global breakthrough with zero-emission hydrogen powered waste collection truck

REMONDIS Australia has achieved a global breakthrough by introducing one of the world’s first hydrogen powered waste collection trucks to its operations. After extensive trials, the carbon emission-free truck has participated in its first scheduled residential waste collection in the Illawarra region of New South Wales. The Fuel Cell Electric Vehicle (FCEV) relies on hydrogen which combines with air to generate electricity for motor function. Only water vapour is emitted, and nothing harmful to the environment. L-R, John Edgley (Hyzon), Wollongong City Lord Mayor Gordon Bradbery, Chris Wade (Remondis), and Shellharbour City Mayor, Chris Homer. REMONDIS Australia CEO Björn Becker said the truck going into formal operation was historic. “We’re demonstrating that carbon-free transport can and does work in industrial settings,” Mr Becker said. “We’re hopeful that this is the start of a bigger journey whereby companies around the world follow REMONDIS’ lead and turn to fleet decarbonisation. “This should be likely as economies of scale take effect, making the take-up of such technology the norm and not the exception. “REMONDIS has gone all-out to deliver this ground-breaking environmental initiative at the earliest possible time and it’s something we’re very proud of.” REMONDIS NSW South Coast Region Manager Chris Wade said the truck would be fine-tuned through collaboration with its maker, Hyzon Motors, in coming months. “The ultimate aim is to have the hydrogen truck matching our current diesel trucks in all facets,” Mr Wade said. “That includes completing about 1,000 bin lifts over about eight hours. “Trial runs in recent months have been promising, giving us confidence to put the truck into formal operation, serving many of the 300,000 residents in the region. “Putting the truck through full commercial paces will give us additional information and enable adjustments to be made if necessary. “With distinctive markings indicating that it […]

Sevaan Group trials 4-day week

Leading parts contract manufacturer, Sevaan Group, announced today it is trialling a 4-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, 5-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 4-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.” “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 4-day working week will further support our staff’s wellness. The evidence suggest that it helps to reduce anxiety, stress, fatigue and burnout,” explained David. A 4-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 4-day 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 David. Evidence from US and UK companies which have already trialled the shorter week indicates that there […]

Capricornia’s smart road to A$4.74 million Chinese joint venture

Australian scleral lens manufacturer Capricornia Contact Lens has signed a A$4.74 million joint venture with Chinese ophthalmic products distributor, Guangzhou Ruitai Biotech Co., Ltd. The two companies will establish EPICON (Chengdu) Medical Technology Co., Ltd in Chengdu, China. ‘Through the hard work over the past three and a half years, the accelerated registration of the first Rigid Gas Permeable scleral lens in China via the Real World data program was achieved. This is a remarkable milestone for both Capricornia and Ruitai,’ says Tony Capitano, Managing Director, Capricornia Contact Lens. ‘EPICON will focus on the R&D and manufacturing of scleral lens and other ophthalmic products,’ says Yongliang Lin, founder of Guangzhou Ruitai. ‘It will provide a whole set of innovative solutions in areas related to adolescent myopia, ocular surface diseases, refractive correction, and contact lens care products.’ A fast-tracked journey to China Founded in 1985, Brisbane-based Capricornia Contact Lens manufactured its first scleral lens in 1994. It is one of the earliest manufacturers of scleral lens in the world. The firm’s designs include lenses for Orthokeratology, irregular corneas and specifically the treatment of Keratoconus. Capricornia also manufactures a comprehensive range of custom soft and rigid gas-permeable lenses using state-of-the-art computer-controlled lathes. Guangzhou Ruitai Biotech is a high-tech enterprise focused on research and development, manufacturing, and sales of ophthalmic medical devices. Committed to the ophthalmic industry, Guangzhou Ruitai has invested in ocular surface repair, the prevention and control of adolescent myopia, and the treatment of glaucoma. Many of the company’s ophthalmic products enjoy the largest market share in their respective segments. In June 2019, Austrade Shenzhen introduced Guangzhou Ruitai to Capricornia. This came after China’s State Council released a policy allowing the Hainan provincial government to directly approve the import of certain medical devices that were not previously registered and approved by […]

Royal Wolf innovation to the fore

National shipping container company Royal Wolf has engineered a new twist on the backyard pool house with a luxury design that cost almost $50,000 less than comparable structures using traditional building methods. Royal Wolf Geelong Branch Manager Justin Van Loon had received quotes of up to $80,000 to build a 10mx5m pool house from landscaper builders before a lightbulb moment had him approaching Royal Wolf engineers for a solution. “The quote to do it using two shipping containers was significantly cheaper and we actually ended up with a larger pool house than we initially planned,” says Justin, who lives in Leopold, Victoria. “All up it cost about $30,000-$32,000, which included buying two containers, all modifications done by Royal Wolf and then completing other works ourselves like electrical and flooring.” Within weeks of Justin consulting the Royal Wolf team, engineering and workshop plans compliant with building regulations were drawn up, including a design for concrete footings. “The Royal Wolf engineers took into account our home address, wind ratings and all the different aspects that impact building structures and designed the pool house accordingly,” Justin says. “They also advised us on what materials we needed in order to strengthen the 12mx4.8m building and the window openings. The team modified the containers based on the drawings that were supplied by the engineers. “They removed two side walls of one container and one side wall of the other container, which was then strengthened and stiffened up with wide window openings, doors welded closed and the exterior painted.” Once complete, the pool house was delivered and placed by Royal Wolf at the Van Loon home. From sketch to completion, the project took just 10 weeks. “The best part was we had very little disruption or inconvenience at our home – we had the concreters dig […]

BlueRoom wins national innovation award

BlueRoom, a world first, multiplayer, mixed-reality simulator created by Australian company Real Response and being used by the Royal Australian Air Force, took out the most Innovative Project Award for 2023 at the Simulation Australia Awards in Adelaide. The groundbreaking BlueRoom Simulator emerged from a company of medical professionals and software developers in St Kilda, Australia, and is now enabling Navy, Army, and Air Force medics to master the use of real medical equipment and navigate intricate medical scenarios within a virtual environment. The BlueRoom Simulator leverages state-of-the-art mixed reality (MR) technology, utilising the Varjo XR3 headset, to provide an immersive and interactive platform for medical practitioners. Unlike traditional virtual reality (VR) experiences that rely on controllers, MR empowers users to engage with the virtual realm using their own hands and physical movements, mirroring real-world interactions. This pioneering technology holds immense potential within the medical field, offering professionals the opportunity to hone their skills in diverse and challenging settings. From field operations and remote hospitals to helicopters, aircraft, and naval vessels, the BlueRoom Simulator enables medical practitioners to develop muscle memory and refine their techniques. The award judges stated that “the innovative combination of mixed reality was judged as an outstanding solution for highly engaged learning. The efficiency in relation to cost, as well as the ability to develop fine motor skills is a great use of a novel technology.” Co-founder of Real Response and registered Paramedic, Benjamin Krynski, expressed the game-changing nature of the BlueRoom Simulator, stating, “BlueRoom completely reimagines what is possible using simulation – a student can be placed into any environment, and a trainer can manipulate the scene and adjust the patient’s condition all while the student is performing interventions using their own hands with real equipment.” One of the most remarkable features of the BlueRoom Simulator is […]

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