Future of Manufacturing

Australia could benefit from a global shift to emissions-free steel

John Pye, Associate Professor, School of Engineering, ANU, Australian National University;Alireza Rahbari, Research fellow, School of Engineering, ANU, Australian National University; Emma Aisbett, Fellow, Australian National University;Frank Jotzo, Professor, Crawford School of Public Policy and Head of Energy, Institute for Climate Energy and Disaster Solutions, Australian National University; and Zsuzsanna Csereklyei, Senior Lecturer in Economics, RMIT University. Australia is the world’s number one exporter of both iron ore and metallurgical coal, the key ingredients of traditional steel making. Together, these materials make up a very large part of Australia’s export income. But as the world moves towards net-zero emissions by 2050, the conventional way of making steel, using coal to power a blast furnace, will come under question. Iron and steel production, in total, account for close to 7% of the world’s greenhouse gas emissions. This is incompatible with a net-zero world economy, where residual emissions would need to be compensated through carbon dioxide uptake from the atmosphere. The mature technology of coal-fired blast furnaces currently dominates the steel industry, generating 90% of its emissions. For years, decarbonising steel production has been seen as particularly challenging. But now, alternatives to the centuries-old practice of using coal to produce iron and steel are emerging. Researchers have been working on a number of new pathways to make steel with little or no emissions. The most promising process relying on the use of hydrogen. Our new research shows the steel industry can develop and implement green steel production processes to contribute to the great decarbonisation effort needed. For Australia, this presents an enormous new opportunity to future-proof and expand our steel industry as the world acts on climate change. How can we produce green steel? To eliminate emissions from this sector, several things are needed. First, we must use steel efficiently in well-designed structures. Second, we must […]

Growth fuels relocation for Kemppi Australia

Kemppi Australia, part of Kemppi Oy, a leading international welding equipment manufacturer, has moved its head office into new purpose-designed premises located at Unit 2, 463 Victoria Street, Wetherill Park, NSW. The recent relocation is in response to the company’s continued growth. According to Kemppi Australia’s Managing Director, Paul McVicar, the old premises could no longer meet the company’s existing needs for additional space let alone accommodate any future growth. The new, large two-story building houses Kemppi Australia’s Sydney-based staff, warehousing facilities and service centre. The service centre features work bays with the capability to handle multiple equipment repairs and maintenance contracts simultaneously. The much larger warehouse can accommodate additional stock of equipment and consumables. The extra space will also help make shipping and tracking of Kemppi equipment and goods more efficient. The new office space has been fitted out with a bright, modern design to support staff collaboration and productivity. While the consolidation of office space across two floors allows the company to further streamline internal processes and enhance communications. According to Paul, the Kemppi Australia team are excited about the new facility. “It’s not only a more pleasant and efficient environment in which to work and grow, it will also allow us to better serve our dealers and customers.”

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.

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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. […]

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.

AMW 2022 – Where technology meets innovation

Preparations are well underway for 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. “We’re getting very excited about the way the work on AMW has been going,” says Kim Banks, Head of Events at AMTIL. “The response from industry has been incredibly positive, with the exhibition space already fully booked apart from a handful of stands. This is a really big, important new venture for AMTIL, so we’re really thrilled with the enthusiasm for it that we’ve seen out there.” AMW will occupy more than 9,000 square metres of exhibition space at the ICC Sydney, with more than 140 organisations taking stands to showcase the latest manufacturing technologies, processes and support services. Six dedicated zones will cover a range of specialised aspects of the modern manufacturing landscape: Additive Manufacturing. Australian Manufacturers Pavillion. Machine Tools & Ancillary Equipment. Manufacturing Solutions. Robotics & Automation. Weld Solutions. While AMW is a brand new event, AMTIL can bring plenty of experience in staging industry exhibitions to ensure the 2022 show will be a success. Since 2000, AMTIL has operated Austech, Australia’s premier advanced manufacturing and machine tool exhibition. The last Austech exhibition – held in Melbourne in May 2019 – was attended by industry professionals from across Australia and around the world, with more than 170 organisations showcasing state-of-the-art manufacturing hardware, software and support services. Going forward, Austech has now been incorporated into AMW, an exhibition encompassing all aspects of the manufacturing industry in Australia. AMTIL took the decision to launch AMW after Reed Exhibitions announced in mid-2020 that it […]

Overcoming the security challenges of Industry 4.0

Lani Refiti, ANZ Regional Director at Claroty The Covid-19 pandemic has impacted every industry in very different ways. The need to maximise remote working has been universal, but certain industries have seen demand for their products and services surge; while for others, demand has diminished to virtually zero in some cases. Manufacturers with heavily digitised and sophisticated operations were well-placed to manage both the transition to remote working and the demand fluctuation for their products and services. They were able to rapidly pivot from in-person to remote working, and to spin up production of high-demand goods such as hand sanitisers, personal protection equipment and ventilators. Meanwhile, manufacturers with less sophisticated operations found themselves scrambling to react. The technological capabilities that enabled manufacturers to successfully adapt their operations during Covid-19 can be summed up in one phrase: Industry 4.0, the next generation of manufacturing technology. The concept was conceived in Germany as Industrie 4.0 and made its debut at the 2011 Hannover Fair. It has come a long way since then and means different things in different countries. The Australian Government says, “Industry 4.0 is transforming how businesses operate by connecting the physical with the digital world.” It gives as examples, “Artificial intelligence, advanced automation and robotics.” Industry 4.0 embraces machine-to-machine communication, human-to-machine communication and the idea of a connected ecosystem that links customers, supply chains and production facilities. It enables real-time communication to ensure smooth operation of supply chains, the tailoring of supply to meet demand and, in more advanced versions, the concept of direct control of production according to demand. Industry 4.0 has increased manufacturers’ flexibility, competitiveness and their ability to exploit new market opportunities. Industry 4.0: where IT meets OT However, there is a major hurdle to realising the vision of Industry 4.0, one that manufacturers have struggled […]

CSIRO combines best of humans and machines

Australia’s national science agency, CSIRO, will be part of reinventing the way humans and Artificial Intelligence work together, contributing to global efforts to design a completely new capability called ‘Collaborative Intelligence’. The newly launched $12 million Collaborative Intelligence (CINTEL) Future Science Platform aims to move beyond machines replacing people or automating their jobs, and instead to create teams that maximise the benefits of both human and machine intelligence. One of CINTEL’s first projects will draw on the expertise of CSIRO’s Robotics and Autonomous Systems Group who recently claimed a silver medal in the international DARPA Subterranean Challenge. The challenge, which has been described as the ‘robot Olympics’, involved using teams of robots to explore and locate objects in unmapped underground environments under the supervision of a human operator. CINTEL Leader Dr Cécile Paris said lessons from the challenge could help inform future human/robot teaming. “The project will focus on developing a richer, dynamic human-robot collaboration, enabling humans and robots to respond in real time to changes in the environment and make better decisions, together,” Dr Paris said. “CINTEL will research dynamic situation awareness and mechanisms to ensure a collaborative dialogue between humans and robots throughout, for example, a rescue mission. “Rescue missions are often ill defined and dynamic, and the humans must use their own knowledge and skills, like reasoning, intuition, adaptation and experience, to identify what the robots should be doing. CINTEL will investigate how humans can fully utilise their unique skillset in collaboration with the robots for successful outcomes.” Other early CINTEL projects include developing a digital team member to help scientists make sense of the massive amount of information in modern biological collections and supporting cybersecurity analysts with collaborative surveillance. The program will be run by CSIRO in collaboration with research and impact partner Saber Astronautics, as […]

RS Components helps industries get ahead with the Industrial Internet of Things

RS Components has announced a broad range of industrial electronics solutions supporting designers and engineers to meet increasing and evolving electronics demands. Featuring brands by market-leading global manufacturers, the RS industrial electronics solutions offering includes the latest parts and components for designers and engineers creating smart devices and embracing the Industrial Internet of Things (IIOT) to deliver connected solutions for businesses, factory floors, and various industrial environments. Some popular and locally stocked products in Australia and New Zealand include sensors, power and circuit breakers, semiconductors and dev kits as well as test and measurement instruments from leading global brands including Schneider, TE Connectivity, Fluke, Phoenix Contact, Raspberry Pi, and more. Products from the range equip engineers with the tools to unlock productivity through IIOT. High-performance and high-precision tools comply with worldwide standards, and aid in detection and measurement, smart automation, and precision monitoring. Engineers are at the forefront of developing solutions that allow organisations to make informed and timely decisions. Harnessing IIOT enables manufacturers and industrial sectors to have better insight and sharing of data, enabling efficient plant maintenance and process improvements. “With locally-stocked products, we offer reliable access to industrial electronics solutions to help organisations innovate and get ahead swiftly. RS teams are also committed to working closely with customers who are just beginning their IIOT journey,” says Sean Fredericks, President, Asia Pacific at RS Components. Engineers looking to strengthen their IIOT capabilities can now access a reliable stock of over 650,000 industrial and electronic products, sourced from over 2,500 leading suppliers, on the RS websites for Australia and New Zealand. For more information on the expanded products visit: https://au.rs-online.com

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Future of Manufacturing