Smart Manufacturing

Six tips for going circular (from manufacturers who are doing it)

-Jim Goddin, thinkstep-anz Every expert was once a beginner – and that includes the three New Zealand and Australian manufacturers who share their circular economy (CE) expertise here. Ged Finch, Jason Graham-Nye and David Bell run or work in manufacturing businesses based on CE principles. Ged is R&D Manager at XFrame, a business which designs and manufactures reusable prefabricated structural framing. Jason co-founded gDiapers which designs and makes compostable nappies. David is Manager Sustainability and Insight at steel recycler, manufacturer and distributor InfraBuild. Our three experts have learned a lot about CE since they started out. In a recent thinkstep-anz webinar, they shared their tips for taking a manufacturing business circular. Their advice is relevant for businesses that design and manufacture their own products and for contract manufacturers too. Before we hear from our experts, here’s a look at CE and how it can add value to your manufacturing business. Circular economy in a nutshell CE is often confused with recycling. It’s much (much!) more. CE is based on three principles. Here’s how they play out in the real world of product design and manufacturing at XFrame, gDiapers and InfraBuild. Principle 1: designing out waste and pollution XFrame estimates that their reusable framing can reduce construction waste from a single home by up to 5 tonnes. gDiapers’ products eliminate waste from disposable nappies. InfraBuild recycled 1.4 m tonnes of scrap metal in Australia in 2021. Principle 2: keeping products and materials in use More than 95% of the materials in an X-Frame building can be recovered and reused, many times. The materials in gDiapers’ nappies can be composted and put back into the soil. InfraBuild keep materials in use by feeding their electric arc furnaces with 100% scrap metal wherever possible. Principle 3: regenerating natural systems The timber XFrame use to manufacture […]

Study to research opportunity of carbon capture and storage in WA

A new study investigating opportunities in Western Australia for carbon capture, utilisation and storage (CCUS) and carbon capture and storage (CCS) is a positive step in finding pathways to decarbonise the economy, according to Australia’s oil and gas industry. The Australian Petroleum Production & Exploration Association (APPEA) today backed the study commissioned by the Western Australian LNG Jobs Taskforce, supported by APPEA members bp, Chevron, Eni, Santos, Shell, and Woodside. APPEA WA Director Claire Wilkinson said the research would provide critical intelligence on how best to deploy CCUS and CCS to decarbonise not just the state’s gas industry but many other sectors as well. “The oil and gas industry is committed to achieving net zero greenhouse gas emissions by 2050, with several companies targeting even earlier timeframes,” Ms Wilkinson said. “Decarbonising our existing and future operations means there is a need to invest in renewable energy and lower emission technologies and this study will help inform the investment opportunities in this space. “CCUS and CCS have key roles in lowering the carbon intensity of gas production and in supporting the development of a blue hydrogen industry here in WA, a key enabler to a viable hydrogen industry. “The study will help us chart a way forward with natural gas set to be a key part of a cleaner energy mix.” The study will be conducted by the CSIRO and the Global Carbon Capture & Storage Institute and is expected be completed in the second half of this year. The Western Australian LNG Jobs Taskforce aims to maximise local jobs and establish WA as a global LNG hub. Originally established by the WA Premier in 2018, it comprises of the Minister for State Development, Jobs and Trade; heads of Woodside, Chevron, Shell, Santos, and INPEX, and representatives from APPEA and UnionsWA.

National logistics company to run female-only trucking program

Leading refrigerated logistics company Chill has been given the green light to run a female-only training program for budding truck drivers – one of the first in NSW. The business’ Sydney-based headquarters has been given an exemption to the NSW Anti-Discrimination Act, allowing them to advertise and run a female-only trucking training and education program. Chill lodged the exemption application last year, in a bid to lead the charge for women in the transport industry, particularly in light of growing staffing shortages across both the transport and warehouse sectors. Currently, women make up just 26 per cent of the transport industry in Australia – a figure Chill co-director Lauren Wade is keen to change. “The days of the stereotypical male ‘truckie’ sitting behind the wheel of a big rig are gone,” Ms Wade said. “We’ve seen a significant shift in the transport and warehouse industries, particularly in the last few years, courtesy of the ageing workforce and a severe staff shortage. “It comes at a time when ecommerce and the demand for door-to-door delivery is on the rise, so businesses need to start thinking about a succession plan, with career progression, more family-friendly rosters, and new equipment and procedures.” “Companies across the nation are looking for good-quality, professional truck drivers and warehouse staff and women are critical to filling these positions. “Being able to run a trucking training program that is solely designed for women means we can attract and retain them into employment and gain some momentum for females in the industry.” Chill senior planner Liesel Croukamp, who started her career as a driver and returned to the road during COVID-19, believes truck driving is a fantastic career for women. “I absolutely love being out on the open road and spending time behind the wheel. It gives me time […]

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The value of a digital parts library for manufacturers

The Fourth Industrial Revolution is transforming traditional manufacturing processes and supply chains thanks to digitalisation. Information regarding parts can now be digitised and this presents significant opportunities for many sectors within the Australian manufacturing market to leverage reduced parts lead times and product improvements using Additive Manufacturing (AM) technology to attain components virtually on demand. Digitalisation in the form of a secure, cloud-based parts library, plays an important role in implementing an effective AM system. It supports parts re-engineering and production turnaround speeds, client supply chain management and product quality continuity. Overcoming a key manufacturing challenge One of the more persistent challenges faced by manufacturing firms revolves around quick repair and turnaround of faulty equipment. This often requires rapid replacement of components, and advanced manufacturing methods such as AM can make this possible. AM facilitates significantly reduced lead times and unit costs for low volume components and obsolete parts, whilst offering re-engineering possibilities to enhance component durability and increase performance. The benefits of a digital parts library for manufacturers Reverse engineering and digitalising physical components to build comprehensive parts libraries can be used to simulate complex processes and equipment operations. This allows parts that are failing and replaced at a high frequency to be quickly identified, even to the smallest component level. Using this data, engineers can then embark on focused R&D projects including qualifying stronger materials and revising inefficient designs to improve the mean-time-to-failure rate for these parts. The performance of the new and improved parts can then be simulated to validate improvement even before the parts are manufactured. Therefore, a digital parts library allows for more accurate predictive maintenance methods to be put in place. A secured digital parts library also forms an essential link in any AM-ready process as it provides inherent time and cost saving benefits. […]

Probuild collapse – a tragedy that could have been avoided

Following the news that Australian construction industry giant Probuild has fallen into voluntary administration, leading credit reporting agency CreditorWatch assessed the warning signs that existed in advance of the collapse and how they could have been avoided. “This news comes as a devastating hit to the Australian construction industry,” says CreditorWatch CEO Patrick Coghlan “the demise of a business with the scale and reach of Probuild is bound to send shockwaves through the industry, as thousands of small businesses are impacted. Sadly, I fear this is the tip of the iceberg, and we could see many more going under, as an industry that was already under significant pressure is dealt another heavy blow.” Red flags in plain sight for industry partners The writing was on the wall for Probuild which, like the rest of the construction industry, struggled to survive a perfect COVID storm of supply chain disruptions, cost blowouts and increased worker absenteeism. CreditorWatch listed Probuild under a D1 or D2 RiskScore Rating from October 2021, with its risk of default or insolvency significantly higher than the average Australian business. This score was awarded based on a variety of factors, including the rapid increase in credit enquiries from August 2021 onwards. “The data underlines just how crucial it can be for small businesses to monitor the vital signs of their stakeholders and to identify those suppliers and debtors that could be at risk of default, in order to adequately assess their credit risk,” continues Coghlan. In the past five years, Probuild had 1,588 credit enquiries, of which 545 were lodged in the last 12 months alone. This increase is in line with the wider construction industry, which currently sits at the top of the ANZSIC Division for credit enquiries on 255, well above manufacturing on 75 and Professional, Scientific […]

bp signs licensing agreement for Honeywell UOP’s Ecofining technology.

Under the agreement, bp will revamp hydroprocessing equipment at its former refinery site in Kwinana, Australia, to Honeywell UOP’s Ecofining process for a capital-efficient, fast-to-market path to produce approximately biodiesel at the underutilised plant. The refurbishment would enable bp to produce 10kbd diesel and sustainable aviation fuel (SAF) from renewable feeds, integrating with its existing terminal operations. This production aligns with the company’s efforts around pre-feed engineering for its proposed diesel and SAF project in Western Australia. Renewable feeds have substantially similar molecules to petroleum-based diesel and jet fuel and can be used as a drop-in replacement without engine modifications, in the case of SAF in blends of up to 50 percent with the remainder as conventional jet fuel. Depending on feedstock choice, diesel and SAF produced from the Ecofining process is expected to result in a significant reduction in greenhouse gas emissions compared with conventional diesel or aviation fuel from petroleum.

RS Components webinar introduces new ranges to reduce MRO spend

Financial efficiency and saving time were the focus of the recent RS PRO Webinar held in late 2021, which attracted attendees from across the Asia Pacific. During the webinar, attendees were introduced to key RS PRO ranges and service offerings, including some of the recent range additions across Hand Tools, Sensors & Connectors, Automation & Control and Facilities Maintenance products. Decisions have consequences. And because every decision matters, every part matters. That’s why RS PRO offers an ever-expanding choice of over 60,000 quality-tested products engineered for demanding manufacturing and industrial environments. Scott Philbrook, Managing Director of RS Components ANZ said the webinar was a great success, showcasing our huge portfolio of quality-tested products for a range of industries and working environments. “With huge local stock holding of the RS PRO range across Asia Pacific you can get the products you need, when you need them.” He explained. “This webinar showcased our ever-growing range of RS PRO products, outlined the potential applications and gave us the ability to answer questions directly from industry participants.” Scott Philbrook said. The RS PRO range offers customers a choice where the combination of quality, performance and price create exceptional value. Our range of more than 60,000 high-quality, competitively priced industrial products and electronic components can be as much as 30% on branded alternatives. To ensure customers have complete confidence in the RS PRO offering, all products and components are backed by the RS Seal of Approval, representing leading industry standards for audit, inspection, test and certification. “Our local portfolio has recently seen significant increase with thousands of new product lines added to complement our existing RS PRO offering. The expansion in the range is meeting demand in the Australian market for affordable options for engineers looking for choice” says Scott Philbrook, Managing Director of RS […]

Beckhoff automation solutions

Founded in 1980, by Hans Beckhoff as a one-man operation, Beckhoff implements open automation systems using proven PC-based control technology. Primary areas their product range covers include industrial PCs, I/O and fieldbus components, drive technology, automation software as well as control cabinet-free automation. Products that can be used as separate components or integrated into a complete and mutually compatible control system are available for all sectors. The company’s new automation technology stands for universal and industry-independent control and automation solutions that are used worldwide in a large variety of different applications, ranging from CNC-controlled machine tools to intelligent building control. Development of innovative products and solutions based on PC-based control technology is key to the company’s continued success. The company has recognised many standards in automation technology that are taken for granted and introduced to the market as innovations. Beckhoff’s philosophy of PC-based control as well as the invention of the Lightbus system and TwinCAT automation software are milestones in automation technology and have proven themselves as powerful alternatives to traditional control technology. EtherCAT, the real-time Ethernet solution, provides a powerful and future-oriented technology for a new generation of control concepts. Beckhoff is headquartered in Verl, Germany and there are 4,500 employees worldwide and 1,900 engineers. The company has 39 representative offices worldwide from an overall total of 75 representatives worldwide. The corporate headquarters of Beckhoff Automation GmbH & Co. KG in Verl, Germany, is the site of the central departments such as development, production, administration, sales, marketing, support and service. Beckhoff has been represented in Australia since 2000, and in 2006 founded its own head office and warehouse in Melbourne. The first sales office in Sydney was established in 2011 and is now the National Engineering Hub responsible for project implementation. Beckhoff’s Managing Director, Nick Psahoulias, has been with the company […]

Book now! Registrations open for Australian Manufacturing Week 2022

Online registrations are open now for visitors to the inaugural Australian Manufacturing Week exhibition, taking place in Sydney in June 2022. Owned and operated by AMTIL, AMW is Australia’s premier manufacturing solutions event. Under the theme ‘Where technology meets innovation’, AMW 2022 will take place at the International Convention Centre Sydney (ICC Sydney) in Darling Harbour from 7-10 June 2022. The opening of registrations marks a major milestone in the build-up to the exhibition. Preparations for AMW 2022 have been marked by high levels of early interest, with the floor space almost entirely booked out well before the end of last year. “It’s great to finally have opened up registrations for visitors to AMW,” says Kim Banks, Head of Events at AMTIL. “We’ve had an incredible response from exhibitors, with stands getting booked faster than any of us had anticipated. There’s clearly a really strong appetite across the industry for an exhibition like AMW. Now we’re just concentrating on welcoming as many visitors to the show as we can.” AMW will occupy more than 9,000 square metres of floor space at the ICC Sydney, with more than 155 organisations taking stands to exhibit some of the very latest manufacturing technologies, processes and support services. AMTIL will be making regular announcements between now and the start of the event about its plans for the show, so it’s worth keeping an eye on the AMW website as well as its social media channels for the latest updates. The AMW exhibition will consist of six dedicated zones offering a comprehensive view of the modern manufacturing landscape. The Austech Machine Tools & Ancillary Equipment Zone will host an extensive range of metalworking and machine tool technology, including the latest state-of-the-art cutting tools from Iscar Australia. Exhibitors such as Automated Solutions Australia and Epicor Software […]

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Brooke revved up for a career in mining

Brooke McNee was born with a passion for performance vehicles in her veins. “My grandma has always been into cars, she passed that passion onto my dad, and as soon as they took me to my first Summernats I was hooked,” Brooke said. “Add to that growing up on a cane farm surrounded by a culture of big agricultural equipment, and there was no chance the McNee love of machinery and motorsport would skip a generation.” Now the 22-year-old is about to jump behind the wheel of an 85 litre, 3,500 horsepower engine as one of 60 new trainee haul truck drivers at Bravus Mining and Resources’ Carmichael Mine. The Burdekin local said getting to learn and qualify on Bravus’ fleet of Caterpillar 796 AC mining trucks was the “opportunity of a lifetime”. “I first began applying for mine operator roles in 2019 and when I wasn’t successful moved into a good job in real estate, which I really enjoyed,” she said. “But when I saw this traineeship advertised I knew I had to apply. “Not only is this my start in an amazing industry and working with massive, sophisticated machinery, it’s an opportunity that will open doors to other goals like building my first home.” Bravus Mining and Resources CEO David Boshoff said Brooke and her peers would undertake a four-week program of desk-based and supervised on-the-job training, including both day and night shifts. The 60 trainees will be employed by Bravus’ mining services contractor MacKellar, and their start dates will be staggered from the end of February through to May 2022. “We’re delighted to continue to invest in regional Queenslanders and give Brooke and the other trainees a paid, structured, environment to kick start their career in mining,” Mr Boshoff said. “We had just shy of 4,000 applications […]

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