Smart Manufacturing

Manufacture like a boss

Every part manufactured has a story – the story of how something is made, how much something costs, how much something can be sold for, and if you make it again. A good manufacturing story will be filled with precise detail, perfect accuracy, and guide your future based on a truthful history. And this means your customers will want more. Why? The answer is simple – if you are manufacturing you: Master the four key transactions: Purchasing Receipts, Issuing Material, WIP to FG, Shipping/Invoicing. Know your costs (freight, labour, outside services, overhead, other, material) with accurate precision. Price your parts competitively and profitably. Quote your jobs correctly with speed and accuracy. Reduce your risk by knowing and not guessing. When you are doing the above you are making parts faster, making parts better, watching it all in real time, and knowing exactly what everything costs – otherwise known as “manufacturing like a boss”. Prepare to win Manufacturing can be won or lost in how prepared your company is, not just a person. Employees must be well trained to accurately capture data. Garbage in, garbage out. Employees must hold each other accountable. If you see something, say something. Employees must understand daily processes and how each action impacts costing. If you do not know, ask first. Accurate bills and routers When a work order is generated to drive how much and how long it will take to make the parts, the accuracy of the bill of materials and routers impacts runtime, setup, lead times, and quantities. If the lead time is incorrect, it will tell purchasing to order material at the wrong times, leading to overstock of product or expedited fees to get product in. Realistic due dates If the due date on a work order (often driven by sales) is […]

How Independent Power Producers Can Improve Sustainability

When considering power infrastructure for a mine site, there are three options available to mine operators: rent temporary power solutions, build their own power supply station or contract an independent power producer (IPP). While short-term power solutions have their benefits, independent power producers offer the best of both worlds by providing mine sites with stable, energy-efficient power which is geared for long-term results. This can improve sustainability for businesses and communities while enabling the use of renewable energy innovations. Independent power producers can improve the sustainability of a mine site in a number of ways: Renewable Energy Innovations Renewable energy is an innovative benefit of engaging an independent power producer. Not only can IPPs utilise renewable energy to boost their normal power production, but these methods can also improve cost-efficiency and reduce emissions and waste. Renewable innovations such as waste heat recapture and solar/diesel hybrid technology are what set IPPs apart and can make a large difference in reducing the cost of maintenance and downtime. IPPs which have made the investment into renewable energy will be able to both reduce costs and help to conserve the local environment. Lower Implementation Costs Constructing, running and maintaining your own power station can require a vast outlay of initial capital and, depending on the specifications of a site, can even be cost-prohibitive in the long term. Contracting an IPP avoids the temporal and financial pressures process of power station construction and ownership, saving valuable capital which can be invested into further energy efficiency measures such as renewable energy. The lower initial capital investment of an IPP means that a mining company can be more flexible with their funding, taking advantage of short-term opportunities and lowering their financial risk profile. Manage Safety Independent power producers take on the costs and risks involved in the […]

Quality compressed air for trades and workshop applications

Anyone looking for a super-quiet, efficient and cost-effective supply of quality compressed air for their workshop requires a user-oriented solution. With the space-saving i.Comp 8 and 9, Kaeser Compressors introduces a completely new compressed air supply concept specifically developed with this field of use in mind. These units are tough, powerful, compact, easy to maintain, efficient and much more. At the heart of the new i.Comp family is a new drive concept, which provides a multitude of advantages. It delivers the necessary power to cover the required compressed air demand with infinitely variable control. i.Comp family reciprocating compressors can operate with 100 percent duty cycles. Intelligent solutions – such as drawing the air for compression in through the piston head – ensure exceptional filling performance and, as a result, outstanding efficiency. With a volumetric flow rate of 412 to 580 l/min, the i.Comp Towers can be used for a wide range of workshop and trades applications and assure a constant pressure of up to 11 bar with absolute operational reliability. Made from roto-moulded polyethylene to enable optimum corrosion- and impact-resistance, the attractive sound enclosure not only hides an advanced all-in-one compressed air station comprising a compressor and a refrigeration dryer, but also keeps sound levels to a minimum and helps retain system value. Kaeser’s field-proven Sigma Control 2 controller allows pressure preselection and infinitely variable speed operation, as well as connection to a master controller such as the Sigma Air Manager 4.0. Since i.Comp Tower systems deliver oil-free compressed air, no oil enters the compressed air supply itself. This in turn eliminates the potential for accumulation of oil-contaminated condensate that would otherwise have to be carefully disposed of. In addition, there is no need for oil changes or oil inspection, which of course further reduces overall service costs.

Sludge dewatering solves environmental and disposal issues

A compact and cost-efficient alternative to conventional dewatering technologies is being introduced to Australia and New Zealand to eliminate costs and OH&S hazards associated with damper and heavier output from poultry processing and major food preparation operations. The KDS Multidisc Separator system from CST Wastewater Solutions – requires no washwater, while capturing 90-99 per cent of solids – is engineered to overcome the limitations of technologies such as screw presses, belt presses and centrifuges currently used. Applications include small-to-medium poultry, fish, meat and dairy plants as well as large-scale food and beverage kitchens and catering facilities which face the challenge not only of handling heavy, sticky wet waste, but also the volume and cost and OH&S hazards of transporting such unhygienic material to disposal facilities. Benefits of particular importance to installations for the poultry industry include: Removal of solids from waste streams Dewatering of sludges and solids Screening and dewatering of chicken processing wastes Removal and dewatering of solids from waste waters Dewatering of chemical sludges from DAF floats The largest energy saving KDS unit can handle about 100kg DS (dry solids) an hour at 98 per cent solids capture, to produce this more hygienic and more compact output that is easier and cheaper to handle and transport. Used for dewatering of dissolved air flotation sludge – a very common application throughout waste water operations – The KDS achieves solids capture of 97 per cent thickened sludge at a dryness of 17 per cent. Waste activated sludge dryness levels are typically 15-18 per cent dryness. The high quality, Japanese-manufactured technology: Uses minimal energy, consuming as little as 06kW hr of electricity Operates at low (63dBa) non-intrusive noise and vibration levels Requires minimal daily maintenance, saving cost and enhancing OH&S performance Occupies typically half the space or less of conventional dewatering […]

Eight myths about AI’s effect on the workplace

The interplay between technology and work has always been a hot topic. While technology has typically created more jobs than it has destroyed on a historical basis, this context rarely stops people from believing that things are “different” this time around. In this case, it’s the potential impact of artificial intelligence (AI) that is being hotly debated by the media and expert commentators. Although there is no doubt that AI will be a transformative force in business, the recent attention on the subject has also led to many common misconceptions about the technology and its anticipated effects. AI is going to be a seismic shift in business – and it’s expected to create a $15.7 trillion economic impact globally by 2030. But understandably, monumental shifts like this tend to make people nervous, resulting in many unanswered questions and misconceptions about the technology and what it will do in the workplace. Demystifying myths Here are the eight debunked myths about AI: Automation will completely displace employees Truth: 70% of employers see AI in supporting humans in completing business processes. Meanwhile, only 11% of employers believe that automation will take over the work found in jobs and business processes to a “great extent”. Companies are primarily interested in cutting costs with AI Truth: 84% of employers see AI as obtaining or sustaining a competitive advantage, and 75% see AI as a way to enter into new business areas. 63% see pressure to reduce costs as a reason to use AI. AI, machine learning, and deep learning are the same thing Truth: AI is a broader term, while machine learning is a subset of AI that enables “intelligence” by using training algorithms and data. Deep learning is an even narrower subset of machine learning inspired by the interconnected neurons of the brain. Automation will eradicate more jobs […]

Food container has long life

Sæplast has extended its range of rugged and hygienic reusable plastic containers for the food processing industry with the introduction of a further size. The new Sæplast 300PE is a square 800x800mm container with a height of 770mm giving it a net volume of 268 litres. This can be increased to 298 litres with the removal of the handle openings. For ease of access and transportation, the container features fork lift entry on all four sides. Like all Sæplast containers, the 300PE offers important hygiene, safety and convenience benefits to ensure the highest food processing standards. The one piece, seamless triple-wall design and closed cell core provides excellent durability, meaning Sæplast PE containers last on average between five to seven times longer than single wall bins. The solid inner core prevents absorption of liquid and the tubs do not have easily broken joints or hard-to-clean crevasses, preventing the harbouring of harmful bacterial growth and making them easy to clean, maintain and repair. The avoidance of splintering, metal tearing or corrugated boxes collapsing delivers safe and easy handling for users. The Sæplast 300PE is available in a variety of colours. Company logos can be incorporated for individual branding, and tracking options include barcode, QR code and RFID technology.

Phebra unveils $10m upgrade of Sydney manufacturing plant

Leading Australian pharmaceutical firm Phebra has boosted the size and production capacity at its Sydney manufacturing plant with the installation of new European-designed machinery, which can aseptically fill up to 7,500 vials with critical medicines every hour. The Bosch aseptic-filling machine, designed and purpose-built for Phebra, is the centrepiece of a $10 million upgrade of the company’s multi-purpose sterile manufacturing facility at Lane Cove West. Phebra CEO, Dr Mal Eutick, said the new machinery would significantly expand the company’s range of critical medicines produced for local and overseas markets. “Our investment in this state-of-art machinery and ancillary infrastructure, delivers additional production capacity and allows Phebra to meet the demands of future growth, especially export opportunities,” Dr Eutick, said today. “The machinery is supported by a newly approved microbiological testing laboratory and other critical support systems and infrastructure and will ensure we maintain high-levels of compliance along the production line in accordance with Phebra’s best practices and focus on the highest quality.” Dr Eutick said technicians from Bosch spent three months installing and testing the machine with Pheba’s local staff. “The machinery has expanded technical capabilities and skills development for our existing staff and will create new employment opportunities as we ramp-up our production across the range of our critical medicines,” he said. “The new machinery has been successfully installed and secured and testing and validation is currently underway.” *Phebra is an Australian based specialty pharmaceutical company which develops, manufactures and markets critical medicines in Australia and across the world.

Seequent opens up 3D modelling world to improve geological risk management

Central ‘single source’ management of complex geological data unlocks higher value for mining and minerals, civil engineering, environmental and geothermal energy industries. Seequent, a developer of revolutionary visual data science software, has released Central 2.0 an advanced central management platform for an organisation’s entire geological modelling activity that connects geology teams and company executives to insights and data not previously available to improve geological risk management. Central was developed for use with Seequent’s Leapfrog 3D geological modelling software.as part of the company’s collaborative industry development process to better meet future needs in the mining and minerals, civil engineering, environmental and geothermal energy industries. Shaun Maloney, CEO of Seequent, says: “The critical importance of managing geological risk has been demonstrated by many recent high profile project failures. We’re laser focussed on helping companies to get on the front foot to manage their geological risks – by effectively communicating this to project stakeholders, and enabling robust risk management plans to be developed.” Seequent has worked with dozens of organisations in each of its core sectors over the past six years to better understand how to help shift each industry to where it needs to be. It has backed this with multi-million-dollar investments in product R&D to extend the company’s overall capability. Maloney says in today’s increasingly complex business environment, organisations are often running multiple projects at the same time and often from different locations, creating a huge amount of geological data that they need to rely on for important investment and environmental decisions. “Ultimately it’s about providing the insight and confidence organisations need to make time critical business decisions about their earth, environment and energy challenges. By enabling people to see stories within the most up to date data – it builds up a whole picture for projects – for example, allowing […]

Eight myths about AI’s effect on the workplace

Schaeffler and the future of predictive maintenance at 2018 IMVAC conference

What sounded like science fiction just a short time ago is now digital reality in Australasia in the new predictive maintenance solutions presented at this year’s IMVAC conference on the Gold Coast from August 6-9. The International Machine Vibration Analysis and Condition Monitoring (IMVAC) professional development conference heard presentations from technology leaders such as the global Schaeffler Group, highlighting advances in its industry 4.0 “Smart Factory” automation and data exchange technologies. Schaeffler’s latest predictive maintenance solutions enable machinery operators to look ever more clearly into the future – they provide machine operators with vital information about the future condition of their machines. Predictive maintenance allows not only the capacity utilisation of factories, mines, utilities and processing plants to be optimised, but also makes it possible to plan maintenance intervals at precisely the right time for optimised “Total Cost of Ownership” calculations. An important prerequisite for predictive maintenance is automated rolling bearing diagnostics, a function that is used in motor gearbox units, for example. These units are used not only in machine tools but also in belt conveyors, presses, and steel mill rollers, for example. Schaeffler BEARINX software is one of the leading programs for performing rolling bearing calculations. It enables rolling bearing supports to be analysed in detail – from single bearings to complex gear systems and linear guide systems. All calculations are performed in a consistent calculation model. Even for complex gears, the contact pressure on each rolling element is considered in the calculation. Because machine drives are operated virtually without interruption, they require intensive maintenance to prevent production downtimes. Therefore, it is important for operators to know the condition of the drive components at all times, and why the bearings are becoming particularly important as a central machine element. The latest generation of the FAG SmartCheck diagnostic system […]

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