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Steel industry leading the charge into the next industrial revolution

Q & A Wayne Carson, Managing Director, D & H Steel…December issue NZ Manufacturer. D&H Steel is one of the oldest and most respected steel fabricators in New Zealand. It is behind some of the largest projects in the country including Auckland Airport, Deloitte Tower, Viaduct Event Centre, and the Kopu River Bridge. In a sector that is constantly changing to meet the latest technological advances, D&H Steel is an industry leader. From an early adopter of welded beams to the latest ISO standards, the company has placed innovation at the heart of its business. HERA spoke to Managing Director, Wayne Carson, about the future of the steel and construction sectors and the opportunity and challenges they face. How are you finding current business conditions? We are enormously thankful to have full order books and our facilities are working 24/6 to keep up with demand. The Auckland market is still very buoyant, and I do not foresee this changing as demand for apartments, office space, and large infrastructure projects continue. The regions are also benefitting both from an increase in government spending and ironically the growth of Auckland as a world city. Auckland is simply becoming too expensive for some industries that are moving to the regions to grow and develop. We are working on several large regional projects including the building of hospitals and large industrial warehousing. Has the pandemic affected your business? Our market share is still strong, but the pandemic has certainly affected our business. Lockdowns, managing close contact staff isolation, skyrocketing labour costs, increases in the cost of materials, and supply chain disruption have been the cause of some very challenging conditions. We are fortunate to be of a size to be more resilient to change but I suspect many smaller manufacturers, are less able to […]

What gets measured gets managed

Ian Walsh, Managing Director, Intent Group I have recently visited a couple of companies and was surprised to see little, if any, data collection in real time. What’s more surprising is that many SMEs don’t even have good in-process data collection. “Oh, that old chestnut”, I hear you say. It is fundamental to any improvement program to have a good understanding of what is going on in your process. Yet here we are nearly in 2022 with a significant number of companies having little-to-no structured data collection to manage their processes. What’s even more criminal is that in this new technology-enabled Internet-of-Things (IoT), industry 4.0 stage, that there really is no excuse. There are many off-the-shelf systems that can be installed, connected up and set going in just an afternoon! These aren’t expensive either – compared to the cost of manual collection, they pay for themselves many times over in a year, not only in the time saved, but also in the quality of information provided. The critical thing with many processes is that many of the “losses” (time, quality defects, lost product and other wastes) are not easily visible as you move further and further from the process. The quality of the data available therefore becomes more and more critical to driving improvement efforts and maximising the best use of your critical resources. The best manual systems can achieve up to 95% accuracy, but most are operating in the 70-90% range and this require overhead to maintain. The issue with these systems is that the data that is usually not captured is the high-frequency short-duration stops. Of course, the low-frequency long-duration stops (like mechanical breakdowns) everyone knows about because everything has stopped. The short duration, high frequency stops however, is more like death by a thousand cuts. It seems […]

Sustainable ways of working = business innovation

-thinkstep – nz In a tough year for many manufacturers, it’s heartening to see innovation continuing to show up through more sustainable ways of working. In this article, we bring you three local people and businesses who’ve used Life Cycle Assessment (LCA) and responsible procurement to build ‘new’ into their packaging, their manufacturing processes, and their products. The business benefits? Opportunities to gain market share, build reputation, strengthen relationships with suppliers, manage supply chain risk, and reduce the costs of materials and disposing of waste. Lorde: making a zero-carbon album Quote Early in making this album, I wanted to look closely at the environmental impact of its manufacture and distribution. Working to achieve zero-carbon status for Solar Power was an eye-opening experience. Lorde Grammy Award-winner Lorde is determined to reduce her carbon footprint. That’s why one of the formats of her long-awaited third album, Solar Power, released in August, is zero-carbon. (Even the name is environmentally apt!) How has Lorde achieved this? By releasing a discless album in a ‘Greenbox’. A Greenbox is an innovative, discless album package made of cardboard. Now, we have a few Lorde fans in our thinkstep-anz team and there were plenty of technical experts eager to help our Kiwi songstress meet her zero-carbon goals. So, we set to calculating the packaging’s carbon footprint using a sustainability tool known as Life Cycle Assessment (LCA). LCA measures a product’s carbon footprint over its life. In this case, this involved calculating the carbon in the raw materials used to make the Greenbox (including paper, inks, and glue), to transport the Greenbox to music retailers, and to landfill the Greenbox at the end of its life. (We hope Lorde’s many fans are ardent recyclers, but we assumed a worst-case scenario, landfilling. In any case, we suspect they’re unlikely to […]

The Interview: Tellfrankie.com – Georgie Fenwicke, CEO and Founder

What do you do? Frankie is a Property and Operations Control Centre to get ahead of downtime and breakdowns. We build worldclass software that gets Ops teams and technicians/contractors on the same page. Is yours a growing business? Absolutely – we launched in 2020 through the first covid winter. That sounds a bit dark, but for us – it was extremely valuable as we were able to build a really useful product with our customers. Why did your business start? Operational chaos and complexity of managing property and equipment at scale on budget. We experienced the tools first hand and knew there was a better way. What opportunities do you see? Improve maintenance dollars spent and reduce downtime Increase productivity and revenue for contractors Create simple data driven decision making in a complex world of manufacturing and property maintenance Areas of activity? Potential growth areas? We’re going Global! How difficult is it to get the required required? We’re building a worldclass team at Frankie and have a mixture of Kiwis and American-Kiwis. Sam Minnee, former CEO/CTO of Silverstripe just joined on and in 2022 – we’re looking for great minds in Operations and Software Engineering We have a strong belief in ownership and getting s*** done at Frankie. Our remuneration is a combination of salary + ESOP Do you export? We’re just getting started here! What do you do? I’m the CEO and founder. My background was working in Supply Chain and then transport tech at Uber and Lime. I’m fascinated by workflow at a micro and macro scale and how it has the ability to level up how cities and businesses operate How do you see the current business climate? Positive and full of opportunity in the right places. You only have to start a discussion with a manufacturer […]

BusinessNZ says no

BusinessNZ has confirmed it is refusing to be the Government’s nominated partner in implementing unlawful compulsory national pay agreements known as Fair Pay Agreements (FPAs). BusinessNZ CEO Kirk Hope says New Zealand’s peak business organisation is not prepared to be part of a compulsory scheme that is unfair and out of touch with modern ways of working and has formally rejected the Government’s offer to be the default bargaining party for employers in the FPA scheme. “Compulsory FPAs are unlawful under both current domestic and international employment laws and are totally out of step with how we need to work in 2021. “They aren’t needed, they remove the flexibility and autonomy of modern workplaces and won’t improve pay and conditions for hardworking Kiwis. “We’ve told the Government from day one that FPAs are fundamentally flawed but they haven’t listened. MBIE officials sent us a letter during lockdown formally requesting we become the default bargaining party for businesses. That followed a Cabinet paper in May that wrote us into the proposed system without our agreement. “After thoroughly reviewing the latest proposal, we’ve formally refused the Government’s offer. It’s wrong for us to be part of a scheme that will do more harm than good to businesses and employees. “That also means we have turned down $250,000 in Government funding. The Government will fund the CTU the same amount to act for employees, but that also shuts out all non-affiliated unions, currently bargaining for their members, from the process, giving the CTU a monopoly on bargaining for all employees in New Zealand.” Mr Hope says the BusinessNZ Network, directly and indirectly, represents over 70,000 businesses across the country employing nearly 80% of New Zealand’s workforce, but that still didn’t give the organisation a mandate to represent all businesses. “Our role is to […]

Hutt Valley manufacturer stepping up to fill skill shortages

Like many other industries across New Zealand at present, the manufacturing industry is struggling with a shortage of trained talent due to Covid-19 restrictions on immigration and current work levels. One Hutt Valley manufacturer is taking on this challenge proposing an innovative way to help young people into engineering. MJH Engineering Ltd is one of New Zealand’s leading structural steel fabricators, specialising in the fabrication and installation of large-scale structural steel projects including industrial warehouses, commercial buildings, multi-storey tower-blocks, and seismic strengthening projects. Over the past couple of years, the Seaview-based company has grown in size due to its excellent track record of delivering top quality results and its reputation as one of the preferred steel subcontractors around town. Jeremy Mikoz, HR & Development Manager for MJH Engineering Ltd, says with the demand of projects comes the challenge of finding the right workers. “While there are private training enterprises out there, we’re finding in our industry that many students coming out of these institutions just aren’t receiving the training they need to be ‘job ready’. “On top of that New Zealand is now in one of the worst labour shortages we have seen in the last 10 years which in turn puts more pressure on obtaining talent and solving our work-flow issues.” As a result, Mikoz says they have come up with a solution – the “MJH Welding School.” The school, based at MJH Engineering, would provide a 6-week full-time training course with qualifications to help young people learn on the job skills and theory in welding. At the end of this course, the young people would come out with Unit Standards, a welding qualification, and 240 hours of practical, industry-related training. To top it off MJH Engineering would guarantee the 6 young people with jobs at the end of […]

Adoption of Industry 4.0 paves the way for growth in manufacturing

by Dr Troy Coyle, CEO, HERA Our world is changing. Climate change and pandemics have garnered much attention but there is another revolution underway. One that is likely to change the very fabric of the way we live and work. It is called Industry 4.0 and is the next stage of the industrial revolution. In 1794, the industrial revolution forever changed manufacturing with the introduction of the mechanical loom. Things changed fast. A mere hundred years later the first production line enabled mass production. Jump forward another hundred years and we witnessed the birth of industrial robots, that together with advances in electronics and IT have automated much of the manufacturing process. Today, we are entering a new age – Industry 4.0 – the age of cyber-physical systems; the marriage of physical production, and smart digital technology. It is not sci-fi. It is not the realm of filmmakers and futurists. Change is happening now and promises to transform industry as much, if not more so than, the introduction of water, steam, and electricity did in the past. What is Industry 4.0? In essence, Industry 4.0 enables companies to have better control and understanding of their business. The new technologies save time, boost productivity, and reduce waste. A panacea for considerable and sustainable growth. A quick search of the internet will provide you with a mountain of anachronisms – IoT, IIoT, CPS, AI, Big Data – to explain Industry 4.0. It is a catch-all term that encompasses all the technologies that enable businesses to collect and analyse data to help automate and streamline their systems and processes. It promises faster response times, increased efficiency and profits, and better quality products at a lower cost. Impact of new technology HERA’s latest report in collaboration with BERL, ‘Modelling the potential economic impacts of […]

Why manufacturing needs a new approach to cybersecurity

– by Robert Nobilo, Regional Director ANZ at Virsec Cyber-attacks continue to be an increasing concern for every industry. But recently they’re becoming a bigger issue for the manufacturing industry than most others. Cyber criminals frequently target manufacturing operations for their ransomware attacks. According to PwC’s Cyber Threats 2020: A Year in Retrospect report, the manufacturing sector and retail sectors shared the dubious honour of being the industries most targeted by ransomware: each accounted for 17 per cent of the total, well ahead of the second sector, technology, media and telecommunications with 10 per cent. The PwC report detailed one ransomware attack on a multinational manufacturer based in New Zealand; “The attack saw the vast majority of its systems encrypted and rendered inoperable, breaking its supply chain, halting global manufacturing and distribution, and putting its banking covenants at risk.” Another manufacturer hit by a cyber attack was local brewer Lion Australia, which also produces dairy products. In June 2020, it was hit by two ransomware attacks within 10 days, forcing it to halt beer production. The attackers were reported to be demanding a payment in excess of $AUD 1 million. Earlier this year, JBS USA Holdings, the world’s largest meat company, was hit by a ransomware attack and, as a result, paid a $11 million ransom. JBS Australia, Australia’s largest meat and food processing company, was disrupted by this attack and forced to close 47 meat processing plants in Australia. With these and other successful attacks, manufacturing will continue to be a high value target of ransomware gangs. The costly impact of ransomware on manufacturing The manufacturing sector is particularly sensitive to the impacts of ransomware and other cyber-attacks on two counts. Firstly, any disruption of day-to-day operations would likely leave a manufacturer unable to meet production demands, resulting […]

think step webinars

WEBINAR The EU, TCFD, and trade Thursday 28 October 2021, 3:00pm NZDT Hear from EU expert Caroline Lambert on what the European Union’s sustainable reporting requirements will mean and how they will impact non-financial reporting requirements in New Zealand in thinkstep-anz’s upcoming webinar. WEBINAR Planetary Accounting: Going beyond carbon Thursday 25 November 2021, 3:00pm NZDT How can we safely operate within the environmental limits without causing permanent harm to earth? In thinkstep-anz’s upcoming webinar, the Planetary Accounting Network Founding Director Kate Meyer and thinkstep-anz’s Technical Director Jeff Vickers will discuss how LCA and planetary accounting work together to minimise the causes of irreversible damage from our activities. www.thinkstep-anz.com

The Interview: Scott Matthews, Chief Executive, Easy Build Ltd

-by Rebecca Reed Why buy a modular house? Most of us dream of home ownership, in fact most people would argue that it’s a human right. We have all been raised in an environment in NZ where you commonly design your own home, and every home is different. The building industry advertise this all the time, but then customers wonder why the house is often poorly insulated, expensive and requires lots of heating. This is very different to many parts of the world where people by a house off plan and it is one of perhaps 30 in the same location that looks similar. I often make the analogy that if you want a good, reliable and fairly priced car, you would buy a Toyota Corolla, however if you want something different you would drive a custom build or a Ferrari. Looking at a modular home vs. a custom designed home, the pricing difference is similar, but you’ll get better bang for your buck with a modular home in terms of build time, thermal efficiency, environmental friendliness, and other benefits, when compared to a standard construction house of the same price. Modular homes are normally quick to build, well insulated and built, minimise waste and are normally priced the same as a similar sized home, but superior quality. Where did the concept come from for your company? The concept is relatively old, with the original inventor using this method some 30 years ago. However, the designs were brought up to date and the business was launched in its own right 5 years ago. We have a simple but enduring purpose. We want to provide Kiwis with warm, robust, and affordable housing because we believe everyone should enjoy living in their own EasyBuild home. What is your point of difference? We’re […]

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