Analysis

Retrofitting legacy equipment

Updating legacy machinery to add smart capabilities After her mother took away her devices, a teen girl went viral after allegedly tweeting from her fridge. The reason this was so entertaining is because it’s unexpected — you don’t typically associate fridges with communication, just as you don’t with legacy equipment. Here John Young, APAC director at automation equipment supplier EU Automation, discusses the issues and solutions surrounding retrofitting legacy equipment with smart technology. Legacy equipment was not designed to communicate, but it can be given a new lease of life by retrofitting smart technology — even if it is 20 years old. Retrofitting avoids replacing an entire system by instead adding the required capabilities to equipment that is already installed. Issues with legacy equipment Functional legacy equipment, such as drives, sensors and PLCs, are often the backbone of a factory. As technology progresses, these machines may need to be integrated with newer machines, which come equipped with data collection and communication capabilities. This can cause issues for manufacturers in connectivity and interoperability. New machinery is being produced and saturating the market at an accelerated rate, despite the lifespan of older models not being complete. As technology advances, we don’t want legacy machinery to be left behind — replacing the backbone of the facility would be costly and time-consuming. However, manufacturers don’t want to be held back from collecting data on their processes and equipment that could hold valuable insights. So, asides from ripping entire systems out and replacing it all with new versions, what can we do? Finding a solution Design engineers should aim to implement a roadmap of the factory’s existing digital capabilities and focus on aims, targets and prioritising actions that will effectively increase business value. Some machinery may need replacing with new technology, however, retrofitting viable legacy […]

How viable is additive manufacturing?

The manufacturing and legal issues surrounding additive manufacturing. In 1984, Charles Hull invented the first 3D printer, which used stereolithography to build up a plastic product layer by layer. Over 35 years later, additive manufacturing (AM) is drastically altering a range of industries, from manufacturing to the medical sector. But what are the limitations of the technology? H In some applications, component manufacturing is shifting away from traditional subtractive machining methods and towards additive manufacturing techniques. The broadening of the applications of AM is causing manufacturers to assess the viability of using it in their own facilities. To do this, there are a few considerations to make before turning to 3D technology. Quality not quantity When moving from one manufacturing method to another, quality is a huge factor, particularly in highly regulated industries like aerospace and medical devices. In fact, quality has been one of the major hurdles to the widespread adoption of AM. One critical consideration is that quality and consistency must be the same machine to machine, regardless of location. Powder bed fusion is one of the most frequently used additive manufacturing methods and there is a possibility that it may introduce defects. However, if the process has a constant thermal gradient, it can prevent warping of the product, avoiding the introduction of defects due to incorrect temperatures. Another concern is that unsintered powder will degrade as a result of heat exposure and that this could impact quality, although regular changing of the powder can prevent this from becoming an issue. When investing in an AM system, manufacturers can overcome quality concerns by working with an experienced partner, who provides training and support on best practice. Those looking to invest in AM parts produced elsewhere should be mindful of their supplier’s approach to quality, to ensure that what […]

Connection Technologies Limited – looking forward to the next 20 years

The founder of Connection Technologies, Lewis Woodward, started the business in December 1999. The aim then and still now is to work with the customer and assist them in achieving their goal. “I knew that without a successful customer, I was going nowhere”. 20 years ago, business conditions were different to what they are today. Business then relied on personal contact and who you knew. Then there was no internet and business was largely done with New Zealand based companies. Technical input and having people who knew your business was important. Today “faceless” internet websites located outside NZ shores compete with each other for business. In the “old” days the customer did not need to know the part number of the item they needed, just a description. Today, you must have the part number to order on the web and so often you are drowned with the range of products available “Our aim was to be the best pro-active supplier with a finite range of product focusing on connectors and supporting tooling as might be required for the industrial, military and aviation market”. This was further narrowed down on the basis that Lewis recognised the OEM PCB market in any volume was dying in NZ. The data reticulation industry he had previously been part of was being. fought after at minimal margins, much of the coax market had moved to the data industrial markets. Getting the right staff in any business is always a challenge. Lewis said he was fortunate that an ex-employee from the same industry wanted to move back to Wellington and “this was exactly what we needed. “Hiring knowledgeable staff with industry background has always been a challenge. We needed people who saw sales different from the normal perspective of selling “nuts and bolts” and making their […]

This is what we can really do about climate change

Despite efforts to achieve net-zero by 2050, global emissions are still rising. A new study suggests ways to fast-track efforts to decarbonise the planet. Building a business case for sustainable energy could drive the transition. It’s not too late to stop climate change. According to new research, decarbonising fast enough to stabilise the climate and fast-track the planet to net-zero rests on all of us changing how we think and act – and doing it fast. The report, published in Proceedings of the National Academy of Sciences of the United States (PNAS), identifies six “tipping dynamics”, or interventions, that could act as catalysts to bring about rapid societal and technological change towards a sustainable future. The study highlights the importance of intervening to make fossil fuels less economically – and morally – attractive. A step-change of this kind could bring about tipping points that divert investment and consumer demand away from fossil fuels towards more sustainable energy sources. It says this can be done by: Removing fossil-fuel subsidies and boosting incentives to move to decentralised energy systems and make clean energy production and storage systems more economically competitive. Encouraging financial markets to divest of assets linked to fossil fuels, to divert investment towards less-polluting technologies, leaving investors keen to avoid the prospect of holding ‘stranded assets’ tied to fossil fuels. Building sustainable cities powered by renewable energy. Revealing the “moral implications” of fossil fuels. Disclosing greenhouse gas emissions information. Strengthening climate education and engagement. While awareness of the climate emergency is growing, global efforts to reduce carbon emissions are not moving fast enough to avoid irreversible damage to the planet. Moving from the fossil fuels that drive global warming to cleaner energy sources, such as wind or solar power, is at the heart of global efforts to decarbonize. Yet emissions […]

Factories no longer the sure route to prosperity.

Countries once grew rich through manufacturing – but today there is more than one way to effect structural transformation. Think about countries growing out of poverty and you probably picture something like this: underemployed workers leaving inefficient farms for factories that make textiles and clothing for domestic and export markets. Over time, this shift raises productivity and wages across the economy, while countries’ production and export baskets diversify into more sophisticated goods and services. For the past several decades, this image would have been broadly on the mark. South Korea is a prime example: through the 1950s, a large share of its population still worked in the agricultural sector. Its manufactured exports a decade later were mostly textiles, clothing, footwear and wigs. Two generations on, in 2017, Korea was the world’s fifth-largest merchandise exporter and its ninth-largest importer. Even if your mobile phone and household electronics weren’t made by a Korean company, they almost certainly contain integrated circuits that were. In varied ways, and to differing extents, countries from Bangladesh to Colombia to China have trodden this path. Since the dawn of the Industrial Revolution in late 18th century England, ‘structural transformation’– a term economists use for the process of shifting people and resources out of subsistence work into more productive activities – has begun with labour-intensive manufacturing. And starting in the 1950s, trade has been a key accelerator of structural transformation in developing countries, enabling much faster growth and poverty reduction than would otherwise be possible. Good enough to compete Trade matters in this story because in most developing countries, internationally tradable sectors are typically much more productive than the rest of the economy. Pulling more people and capital out of non-tradable activities and into firms dealing in tradable goods and services therefore makes for better jobs and a […]

Finding the right direction in times of great change

-Dieter Adam, The Manufacturers Network Returning from Europe recently, I found myself on an airplane watching Butch Cassidy and the Sundance Kid. If you don’t know the story it is loosely based on two Wild West outlaws Butch Cassidy played by Paul Newman, and his partner the “Sundance Kid” played by Robert Redford. The pair are on the run from a crack US posse after a string of train robberies and forced to flee to Bolivia in search of a more successful criminal career. I had seen the film before, but this time I watched it from a manufacturing perspective. These two ‘experts’ run a small, highly specialised and profitable business. They could be considered leading operators in their field and they have impressive brand recognition. As the regulatory environment changes, they ultimately realise that their business model is unsustainable, but instead of changing the model, they opt to take their current operations to a different market. That is initially unsuccessful, mainly because of a lack of understanding of local conditions, including language, and a lack of ability and willingness to acquire the necessary knowledge, in spite of the best efforts of their ‘consultant’, the Sundance Kid’s girlfriend, played by Katherine Ross. When they eventually realise they need to adjust their business model, they do so half-heartedly and use their first failure as an excuse to revert to the ‘tried and true’ method, only to ultimately fail spectacularly in the face of overwhelming regulatory action. This movie could act as a great ‘how not to’ guide for manufacturers in times of uncertainty and change. A living example of this in the real world is in the German car industry, which has largely been accused of napping at the wheel’ when it comes to switching from internal combustion engines (ICE) to […]

5G is about to change the world in ways we can’t even imagine yet

Blue sky thinking: We don’t yet know what wave of change 5G will create. 5G networks were rolled out in 2019 and will expand rapidly in 2020. 5G will connect everything and everyone. 5G will underpin remote surgery, self-driving cars – and movies you can download in seconds. We live in a time when words meant to represent significant or unique ideas are so overused, they have been trivialised. “Revolutionary” is such a word, a victim of hyperbolic marketing that has rendered meaningless a term meant to evoke profound change to our world. When everything is “revolutionary,” nothing is. Yet here I am, unable to find an alternative as comprehensively descriptive of 5G and the infinite number of ways the newest generation of wireless technology will change our world. In fact, the revolution has already begun. The global deployment of 5G networks got a running start in 2019 and is set to rapidly expand beyond anything we expected a year ago. But the public understanding of 5G hasn’t caught up. While 3G put the mobile Internet in your hand and 4G gave us mobile broadband – redefining how we interact with our world – 5G will connect everything and everyone. The technologies within 5G were and continue to be designed to vastly expand network capacity so cars, utility grids, appliances, medical devices, industrial machinery, homes, cities, farms and more can all be connected. And 5G will reduce delays and improve reliability, thereby enabling mission-critical tasks such as remote surgery, self-driving cars and enhanced public safety, to make possible secure connections so lightning-fast that an entire movie can be downloaded in seconds. The faster smartphones and always-connected personal computers that consumers are already using on the initial 5G networks are just a hint of the transformations to come. While 3G and 4G technology were designed to […]

Clean, high-tech: this is the factory of the future

Factories have long held a place in the popular imagination, not just as sources of employment and community prosperity, but also as hectic, noisy, grimy and polluting facilities, where thousands of people are employed in largely low-skilled line positions. Today’s factories are changing. Breathtaking advances in technology, automation and globalisation are transforming how and where manufacturers plan, construct, operate and integrate their factory networks. They are also ushering in significant operational, political and societal changes. From America’s Rust Belt to rural India and China, a chorus of voices is struggling to understand: how are technologies changing how we produce and distribute products? Are automation and free trade taking away valuable factory jobs? What type of skills will be required? How can communities prosper in the face of new production technologies? How and when should manufacturers upgrade their legacy equipment to embrace new technologies to boost yields and efficiency for advantage or simply to remain competitive? Businesses, governments and society alike must understand the technological dynamics at play and collaborate together to ensure tomorrow’s factory towns prosper. What will the factory of the future look like? The key answers will come from the factory floor where new technologies like 3D printing, advanced robotics, the Internet of Things, artificial intelligence, wearable devices, and virtual and augmented reality are converging to create new value, enabling the hyper-efficient and flexible factory of the future. The value created is real: large global producers have increased efficiency and reduced costs by up to 30% across all operations, driven by improvements in overall operating efficiency, lower inventory, energy and water costs, and reduction in incidents involving safety. While the pace of change and how these changes will propagate across networks will differ by industry and country, the factory of the future is a more digital, virtual and […]

Infrastructure spending good news for SMEs

Today’s major infrastructure spending announcement is good news for members in the EMA’s upper North Island region. EMA Head of Advocacy and Strategy, Alan McDonald, says an additional infrastructure spend of $12 billion over four years is a welcome boost, especially with $6.8 billion of it going into the transport sector. “We’ve already seen an additional $400 million allocated to school infrastructure, and the $300m announced for new spend on hospitals is also going into an area that needs the additional funding attention,” he says. For EMA members the most welcome news is the new transport spend, as its region from Taupo North continues grow rapidly without having the necessary connectivity and ease of movement to support that growth. The new funding will be in addition to what has already been allocated in the National Land Transport Plan (NLTP). “Our understanding is that in some cases the funding may speed up projects in the NLTP or supplant already allocated funds. Where that happens the funding that is freed up from the NLTP will then be reallocated for other NLTP projects to further accelerate that pipeline,” says Mr McDonald. “While details about which projects will receive the new funding are being held back – they are likely to be announced in the New Year – there are a number of public transport, rail and road projects across the upper North Island that are virtually ready to go and if brought forward will bring considerable benefits to businesses in the region,” he says. The new National Infrastructure Commission will rightly prioritise the projects, but the EMA’s wish-list of shovel-ready projects would include: The third rail main, rail electrification between Papatoetoe and Pukekohe, the airport to Puhinui link, the north western busway and Mill Road in Auckland; the route south from Whangarei to […]

A year in focus for HERA

In 2019, HERA imbedded its new focus on automation and Industry 4.0 within its new strategy. In support of this, it was announced that we’ll build a new Innovation Centre. This will address the strategic need for the physical facility to facilitate technology transfer, prototyping, research and training to prepare our member companies for the Industry 4.0 transformation. This will also propel our NZ Welding Centre into the only Welding 4.0 facility in New Zealand – and support its rebrand to the Centre for Innovative Fabrication. Supporting the creation of the Innovation Centre was the appointment of our new Innovation Centre Manager, Greg Buckley. He will work closely with Holger Heinzel, our Industry 4.0 Engineer and will see him oversee construction of our Innovation Centre which will commence in early 2020, as well as enhance industry engagement in Industry 4.0, and create a community of practise around this thinking. Recognising the other underlying issues within the sector, we also created Kotahitanga, a HR Innovation Cluster (to address the skills crisis); Matauranga, the Digital Innovation Cluster; (to address industry communications) and Whakamarumaru, the Defence Innovation Cluster (to explore future pipeline opportunities within the Australian Defence program). We also launched “Stirring the Pot”, our new industry-focused podcast. Episodes include: “Ensuring you’re a ‘factory of the future’ in New Zealand”; “The future of manufacturing in New Zealand”; “Addressing the skills gap through diversity”; “The new breed of smart industry- advanced manufacturing”; and “Avoid death by a thousand cuts and automate!”. Improving productivity and capability Last year, we also initiated welding productivity and automation capability assessments for our members. This identifies improvement opportunities and benchmarks performance relative to the rest of the industry. Supporting this focus on improving productivity, we hosted world renowned international expert on the Theory of Constraints (bottlenecks), Arrie van Niekerk. […]

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