Editorial

Technologies enable smart factories to self-adapt

By Jarrod Kinchington, Infor ANZ vice president and managing director Judging by the headlines, continuous logistics issues, continued pandemic restrictions, and rising prices for raw materials will mean that manufacturers have their work cut out for 2022. In addition, the drive towards sustainability is adding pressure to readjust the manufacturing footprint. Most manufacturers are still stuck with a geographic footprint, which was driven by labour arbitrage around the globe, rather than by factors such as closeness to customers or ecological concerns. To increase efficiency, many producers have started to implement Industry 4.0 technologies. Industry 4.0 came with the promise of a smart factory being profitable at the production lot size of one unit. The concept was introduced at the brink of the millennium change with the introduction of cyber-physical systems to share, analyse and guide intelligent actions for various processes in the industry to make the machines smarter and to lower downtime. Analytics can also be used for other aspects like logistics, demand forecasts, production scheduling and quality control, capacity utilisation and efficiency boosting. But we still stand at the beginning for leveraging the true potential of Industry 4.0. Smart technologies offer no less than the possibility to redesign the global manufacturing footprint, to position factories closer to markets, reduce logistics nightmares and increase visibility of the ecosystem partners, including suppliers and customers. There are six important ingredients for a strategy to create the future-proof smart factory: Customers increasingly demand highly personalised products as well as an enhanced customer experience. Manufacturing companies adopt highly agile cloud-based solutions to gain the ability to increase individualisation, service additions, and serve higher flexibility requirements. The need to reduce delays and transport costs, as well as the drive toward a more sustainable production and the imperative to reduce the distance to the physical end-consumer […]

New Euchner MBM bus module for EtherCAT P

If there is one area where applications are becoming ever-more complex, it’s safety engineering. Euchner has not only kept up with this trend with its Multifunctional Gate Box (MGB) safety door system, but has gone a step further by employing modular design to make the MGB2 Modular fully customisable for maximum optimisation. Available from Treotham, the modular system features a separate locking module, bus module and submodules, making it suitable for implementing a wide range of additional functions. In addition, the brand new bus module MBM is available in a version that connects to EtherCAT P, which means that every single function of the Multifunctional Gate Box 2 (MGB2 Modular) safety door system can also be used with EtherCAT P. Following on from its market firsts in PROFINET and EtherNet/IP connection, this is another success, reasserting the company’s claim as a pioneer of innovative bus systems. In this latest system, comprehensive diagnostic functions in the form of EtherCAT messages and the integrated web server provide a fast and detailed overview of the device status. Due to the ease with which parameters can be set, even replacing the system during servicing is a simple matter and takes no more than a few minutes.

igus 7th axis extends working space by up to 400 percent

Articulated arm robots can travel over six metres, quadrupling their working space: the 7th axis is now compatible with all lightweight articulated arm robots worldwide thanks to a simple Plug & Play kit. So far, models from Universal Robots, Epson and the igus robolink series from Treotham have benefited from this increased mobility. Now Omron, Franka Emika, Doosan, Yuanda Robotics and many other lightweight robotics suppliers are joining the list. The first users of the so-called 7th axis, a linear axis with an electric toothed belt drive that igus launched in 2020, were thrilled according to Alexander Mühlens: “Suddenly, thanks to the additional axis, their articulated arm robots are as mobile as humans. This enables them to take on multiple tasks in automation environments making them significantly more productive,” says the Head of Automation Technology at igus. “We therefore decided to extend the compatibility of the system to all manufacturers worldwide – such as Omron, Franka Emika, Doosan and Yuanda Robotics. With a matching Plug & Play kit of hardware and software we make customisation possible.” Ready-to-connect complete solution for all lightweight articulated arm robots In the future, all lightweight articulated arm robots with a weight range of 10 to 50 kilograms or, depending on the dynamics, a payload of 2 to 20 kilograms can use the 7th axis. Treotham supplies the system as a ready-to-connect complete solution from a single source. It consists of a drylin ZLW toothed belt axis with a length of up to six metres and two parallel rails made of aluminium. These can be mounted on the floor, walls or ceilings and a toothed belt drive with stepper motor for a positioning accuracy of 0.3 millimetres. Also included is: an energy chain for guiding energy and data cables; a switch cabinet integration kit with cables; […]

Family business suppliers to the pneumatics industry

JWR Pneumatics is a family run business dedicated to providing technical sales and great customer service to the pneumatics industry. Jonathan Wood, general manager (pictured), started JWR Pneumatics in May 2021. He gained his qualification and experience in the Hydraulic and Pneumatic industries, both in New Zealand and in Melbourne, Australia over ten years. JWR Pneumatics understands how freight and manufacturing time delays are frustrating, adding huge costs to the end user. Their team is focussed on keeping good stock levels to give customers a fast order turnaround. JWR Pneumatics prides itself in being willing to go the extra mile. They understand that manufacturing can be difficult to forecast future sales and have overcome this problem by having an agreement with existing customers, by keeping high volume custom products on their shelves, enabling them to give an immediate supply to customers, without unnecessary delay. JWR Pneumatics imports pneumatic equipment from Italian supplier Airwork. Airwork is an Italian manufacturing company with 25 years experience who specialise in the design, manufacturing, and supply of standard and customised solutions in the pneumatic automation industrial field. Airwork manufactures all their pneumatic equipment in Italy to the highest standard while maintaining competitive pricing. JWR Pneumatics keep a wide range of plastic push-fit pneumatic fittings from sizes 4mm up to 16mm and a wide range of pneumatic valves in stock ranging from solenoid, pilot and manual operations, in sizes from 1/8 BSP threads to 1/2BSP thread sizes. They also stock air filtration units and standard ISO size cylinders. Although JWR Pneumatics is committed to selling Airwork pneumatic equipment, they are not limited solely to Airwork products. They are also resellers for Master Pneumatics and Festo. JWR Pneumatics are more than happy to brand match where possible to make the refitting of replacement pneumatic components as easy […]

Industry 4.0 technology proposed to ACC to augment and improve employees lives through use of wearable tech

-Greg Buckley, Innovation and Transformation Architect, HERA Late last year HERA, with industry partners, submitted an expression of interest to ACC’s Injury Prevention Fund, which invited EOIs specifically relating to innovation to reduce harm and injury in the workplace associated with psychosocial and mental health risks. We have since engaged further with ACC and submitted a full proposal explaining how these risk factors could be reduced in sectors relating to our organisation through the use of Industry 4.0 technology. The potential employee wellbeing and financial benefits from better management of psychosocial risk factors in higher-risk workplaces (such as construction and heavy engineering) are massive. In 2020, approximately 170,000 workers were employed in the New Zealand construction sector, with the ACC-related cost of the construction sector totalling nearly $450m over the past three years. HERA currently has 250 member organisations with around 25,000 workers in total, which equates to an approximate ACC cost per annum of nearly $22m. What is HERA, with its partners in innovation, proposing to introduce with the support of ACC? A three-year programme of work, including ongoing research, which involves the deployment of wearable technology to track biological and physiological markers among employees who work in fields where heavy machinery is operated. The programme is aligned with emerging research on the link between the stress response and bio-markers that indicates an individual’s propensity to psychosocial risk and negative mental health impacts. By measuring health vitals such as heart rates and sleep cycles – as well as other bio-markers associated with stress – the wearable technology can track individual responses and overlay this data with survey data on mental health submitted by each employee. It is an example of using wearable tech to gather and marry up data to optimise health and safety in the workplace. If someone […]

Hutt Valley businesses step up to help build talent pipeline in the region

-Rebecca Reed It’s the same old story for every business, particularly those in the manufacturing sector…how do you fill the shortage of tradespeople and find the right workers for the job? The lack of skilled workers in Aotearoa has only intensified since Covid, with employers battling to attract and retain talent to keep up with their workflow demands. In the Hutt Valley Chamber of Commerce recent Business Confidence Survey at the end of 2021, 56% of employers in the region said they were struggling for talent. Chief Executive, Patrick McKibbin, has been a long admirer of an innovative model born out of the Hawkes Bay that has become a real success story in attracting and retaining young talent. This model was the brainchild of engineering employer, Patton Engineering. After struggling to find and attract the right workers, particularly apprentices, Patton Engineering decided to do something about it themselves. In 2018, Patton Engineering partnered with Hastings Boys’ High School to create a model to support students towards a pathway into engineering that could be rolled out nationwide. To realise this vision, they focused on secondary students who were undertaking trades training as part of their technology class. Machinery, materials, and gear were provided to the school through sponsorships, grants, and donations. Patton Engineering also engaged their suppliers, like Steel and Tube, to provide the school with materials at the same cost it sells to Patton. This Steel and Tube deal is now available to all schools across New Zealand. How exactly does the model work? Essentially Patton Engineering, and now another 31 employers working with the school, provide work experiences through the year and then get to see and select the future employees for their business. For the business this has a fantastic ROI with lower cost to recruit, lower churn […]

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 […]

How to master manufacturing’s data and analytics revolution

Manufacturing is on the verge of a data-driven revolution, but like all revolutions it will require the right actions, individually and collaboratively, to realise its full potential. Within a few years, manufacturers will collaborate in hyperconnected value networks in which data‑and‑analytics applications drive productivity, new customer experiences, and societal and environmental effects. Indeed, data and analytics are a key driver in realising the “Factory of Future” by enabling transparency, predictions and autonomous systems. Already today, we see leading manufacturers applying data and analytics to achieve their objectives for efficiency, sustainability and resilience. The imperative to boost efficiency and productivity is driven by intense cost pressures as well as liquidity issues arising from Covid-19 pandemic-related business disruptions. Sustainable operations are at the top of the agenda for many companies.. At the same time, they are seeking to build more resilient and connected supply chains, so they can anticipate and react faster to disruptions. Most companies recognise that data and analytics are rapidly changing the way they manufacture goods. Despite the high ambitions and strong value proposition, companies have not yet tapped the full potential. A triad of interconnected success factors Successful companies have demonstrated that three elements must be combined to drive full-scale implementation of data and analytics. First, they focus on value in selecting applications. Second, they establish a solid technological backbone comprising both information technology (IT) and operations technology (OT). Third, they promote organisational readiness to ensure that investments deliver the anticipated returns. Examples from various industry sectors demonstrate the importance of these success factors: Petrochemicals: A large petrochemical client of Schneider Electric is leveraging advanced process control to improve asset productivity and energy consumption in a highly complex integrated plant. The advanced process control is informed by an accurate digital twin based on a thermodynamic model. Moreover, effective visualisation […]

7 steps to reboot your business

Edwin Dando co-founder Radically If you’re one of the many businesses struggling in Auckland after months of lockdown Edwin Dando from Radically has 7 steps to get your business cranking. As Seth Godin says, ”Opportunity is another word for a problem to be solved.” Put yourself in your customer’s shoes If you’re in business your job is to create a customer. Too many businesses think about what they need not what do my customer’s experience. So what is life like for them right now? What are the problems? What can your business do for them to make life a bit easier? Understanding your customer and their real pain points is the first step to unlock opportunities. Validate what your customer needs It is easy to think you know what your customer needs, but it’s wise to validate this. Call people you know. Ask them what similar challenges they have had. Ask your customers the same questions. When they visit your business or you speak with them, use this as an opportunity to find out their challenges. Remember every problem is an opportunity for you to add value. Engage your team A common mistake many business owners make is assuming they have to solve all their business problems alone. This can make running a business very lonely! Don’t forget your team are naturally creative and probably have some good ideas. Don’t ignore the receptionist who often sees everything but is never asked for their view. Your retail staff probably see some easy wins and just wish someone would listen to their suggestions. Create a culture of real interest in your customers so that everyone thinks about how to add value to them. Design solutions Talk through possible solutions to your customer’s problems with your team. Get creative! Don’t dismiss any ideas […]

Automation in today’s economy

With labour shortages forecast to continue and predictions that up to 30% of the workforce may have to isolate in the coming months, businesses are increasingly looking to automation as a solution to reduce the impact of a tightening labour market. Over the last 18 months businesses have been grappling with a severe labour shortage, with unemployment dropping to 3.2 percent earlier this month, the lowest level on record. Caleb Nicolson, TMX’s New Zealand General Manager, says “the number of enquiries about automation have increased significantly across both our New Zealand and Australian businesses as organisations look for solutions to staff shortages. “Businesses are facing inflation, high wage costs, closed borders and now, the reality that staff may have to isolate for long periods of time over the next few months. Automation is increasingly being seen as a way to reduce the impact of these external factors.” “More businesses see automation as a way to increase efficiency and reduce their reliance on a shaky labour market – that trend is accelerating in a covid environment. Businesses are recognising that incorporating automation can also help protect their people and customers by freeing up space and reducing staff contact in warehouses,” says Caleb. He states that while traditionally automation was the domain of large corporates, there is now increased interest from small to medium sized businesses who are able to access automation at a lower price point. “Small to medium businesses are also the ones who are hit hardest by labour shortages and increased labour costs, so for them, an investment in automation is one which can pay dividends long term. “Automation doesn’t always have to be on a grand scale. There are a range of solutions available, from simple technology such as leveraging your existing WMS with pick and putwall processes, […]

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