Manufacturing Technology

Digital Factory Accelerator: Driving Northern Ireland’s Manufacturing into the Future

From: August issue NZ Manufacturer www.nzmanufacturer.co.nz -Adam Sharman, Senior Partner, Dsifer As New Zealand’s manufacturing industry continues to evolve in the face of global challenges, it’s crucial to look beyond our shores for inspiration and insights. In this article, we review the approach taken in Northern Ireland, where a pioneering initiative is reshaping the manufacturing landscape. This case study offers valuable lessons for New Zealand manufacturers seeking to navigate the complexities of digital transformation and Industry 4.0. In an ambitious move to boost the competitiveness of Northern Ireland’s manufacturing sector, a groundbreaking initiative called the Digital Factory Accelerator (DFA) has recently concluded its pilot phase. This innovative program, spearheaded by the Advanced Manufacturing Innovation Centre (AMIC) and Invest Northern Ireland in partnership with the High Value Manufacturing Catapult (HVMC) and LMAC Group, aims to accelerate the adoption of Industry 4.0 technologies across the region’s diverse manufacturing landscape. The DFA pilot, which wrapped up in June 2024, involved 32 companies ranging from small enterprises to large multinationals. Using the internationally recognised Smart Industry Readiness Index (SIRI) assessment tool, the program provided participating companies with a comprehensive evaluation of their digital maturity and a roadmap for future transformation. One of the differentiators of SIRI is the ability to benchmark globally based on company size, and by sector. The DFA pilot used the XIRI analytics platform provided by INCIT to develop meaningful insights that are crucial in shaping strategies for manufacturing within regions. Key findings from the pilot revealed that Northern Ireland’s manufacturing sector, while producing world-class products and services, lags behind international benchmarks in terms of digital adoption. The average SIRI score for UK manufacturing companies was 1.12, significantly lower than the peer group average of 1.84 (on a scale of 0-5). This gap highlights both the challenges and opportunities facing the […]

Ten tips to make your business case for sustainability stack up

This information is based on a guide we wrote with the Sustainable Business Council and Kaitiaki Collective. It’s a situation we know many manufacturers face. You want to make your business more sustainable. (Bravo!) You can see the many benefits of manufacturing products that reuse resources, avoid modern slavery and create fewer environmental impacts. But – here’s the kicker – you’re struggling to get the business case for making these changes ‘over the line’ with your accountant or finance team. These ten tips will help you. Tip 1. See becoming more sustainable as an investment Sustainable businesses are excellent businesses. They create value in the short and long terms – economically, environmentally and socially. Treat your sustainability programme as an investment and manage it as one. Tip 2. Identify your stakeholders Consider the many people who have a ‘stake’ in your business succeeding sustainably. You will naturally think of your investors, customers, suppliers, team, local community and regulators. Think longer term and wider too. Include the environment and people who will live many years in the future. Tip 3. Confirm where to focus with a materiality assessment Your business case needs to reflect the views of all these stakeholders and your business too. Start with a ‘materiality assessment’. It’s a practical way, using interviews and surveys, to home in on the sustainability activities that your stakeholders and business care about and to prioritise the ones that matter most. A materiality assessment takes a broad view of sustainability and covers environmental, social and economic topics. Include your top priority topics in your business case. Tip 4. Understand who you need to convince Who do you need to influence to get your business case over the line? What are they interested in? What are they concerned about? Who else has their ear? […]

Productivity is the only game in town!

From July issue NZ Manufacturer www.nzmanufacturer.co.nz Ian Walsh, Partner, Argon & Co It is great to see that finally we are talking as a nation about the need to be more productive. Our poor performance in productivity terms is not a new issue or problem, but given the current economic environment, it has become clear to everyone that we have a significant gap to countries with which we compare ourselves. The consequences of this are significant, with many young New Zealanders leaving for foreign shores for better pay, conditions and quality of life. This problem has been disguised for decades by global financial crises, pandemics, earthquakes and media misdirection (“We are the most liveable country!”, “Auckland is one of the top 10 cities!” etc.). Like climate change it has been possible to ignore for a long time. However, most of us are aware that our infrastructure is creaking. We can’t invest in health education, police, transport and other programs to the extent that we would like to, as we can’t afford it. Productivity is essential for economic growth, competitiveness, profitability, job creation, resource efficiency, and work-life balance. Focusing on productivity improvements at individual, organizational, and national levels can lead to numerous benefits and contribute to overall prosperity. I have been to many business meetings, and the focus for any improvement drive is return on investment – they are asking whether investing in an activity makes the business more profitable, more competitive and ultimately whether it will result in better return for shareholders, so they can invest in future programs to improve the product or service, grow the business and offer better products or services. The same is true at a national level, the government can only spend what the economy generates (balanced budgets and low debt). Profit (or in more […]

Electronic governor enhances marine engine speed control

Due to a failure of a Caterpillar Hydraulic Governor on the Tug Vessel “Te Matua”, operated by South Port NZ, Emee NZ Ltd of Mossburn, was consulted to check out the possibility of an improved, reliable, readily available, cost-wise and serviceable system. Having deliberated and sourcing suitable and reliable hardware involved to substitute the original system, it was found that the movement of the Caterpillar 3606 Engines Fuel Injection Pumps mechanisms demanded a high torque to move such from idle to full throttle. The requirement was also to have a system that originally was air control to the Bridge, superseded by simple “Rotational Dial” and have simple 4–20mA wiring connection. Other air control levers and parts subject to age failure were removed. Recommendation and Solution It was decided to use a combination of a GAC ACB 2001 12Ft Lb Actuator and an AXIOMATIC AX100310 Unidirectional Digital Control for each engine to supersede the original equipment. The combination of both these products together with suitable developed programed firmware and a mechanically driven encoder has now made reliable use of this vessel. This equipment was fitted to both Engines and to date has more than proved their worth in speed control which incidentally this vessel is used extensively for moving large ships within the Island Harbour complex and narrow channel entrance. Installation Installation of the Emee System is very simple, with a Manufactured Actuator Bracket fitted to each engine with linkage, also an enclosure for the required wiring and having the Axiomatic Controllers externally mounted for access. The Axiomatic units are totally encapsulated protecting the internal hardware from the sea environment. This is a major plus to eliminate corrosion and damage. A further feature is an emergency “override key switch” which in the event of Bridge Control failure will put the engine […]

EMEX 2024 encourages manufacturing success

From May issue, NZ Manufacturer www.nzmanufacturer.co.nz Brent Spillane, Managing Director, XPO Exhibitions Ltd. EMEX 2024, brought to the productive sector by XPO Exhibitions Limited, is with us at the end of the month, providing the ideal platform for manufacturing and engineering decisionmakers and visitors to sample technology and expertise to assist them on their company’s journey to success. In these challenging business times, EMEX 2024 provides us all with an opportunity to collaborate, share stories on the journey and even find cohorts to work closely with for a better business future. New Zealand, small country, end of the world, needs to be smart. We have plenty of talented people working with advanced technologies who know what they are doing and where the opportunities are – on local or export markets. However, not enough of our manufacturing businesses are using the tools of the day to assist them on this journey, their journey, to work smarter. The issue can be price, return on investment, not being competitive enough in the marketplace or no guarantee of ongoing contracts. Let’s change that thinking! Overall, Kiwis make great products. The expertise, the skill set is there. Determination to get ahead, to be more aspirational, is not the issue. EMEX 2024 is the one place – the only place in NZ – to see this technology under one roof. Learn from the show, ask questions, move ahead. -Doug Green, Publisher, NZ Manufacturer

What is machine learning?

Machine learning is a form of artificial intelligence that is able to learn without explicit programming by a human. For most of our history, we’ve thought that learning—the ability to adjust our behaviour based on collected information—was something only humans did. The past few decades have changed all that. We now know that animals of all kinds learn from experience, teaching, and even play. But it is not only animals that learn: there’s increasing evidence that plants do,too . And if you’ve ever unlocked a phone with facial recognition, or interacted with a virtual assistant, you’ve experienced firsthand that machines, too, are capable of learning. Machine learning is a form of artificial intelligence (AI) that can adapt to a wide range of inputs, including large data sets and human instruction. Some machine learning algorithms are specialised in training themselves to detect patterns; this is called deep learning. The term “machine learning” was first coined in 1959 by computer scientist Arthur Samuel, who defined it as “a computer’s ability to learn without being explicitly programmed.” It follows, then, that machine learning algorithms are able to detect patterns and learn how to make predictions and recommendations by processing data and experiences, rather than by receiving explicit programming instruction. The algorithms also adapt in response to new data and experiences to improve over time. How did machine learning evolve into generative AI? Machine learning as a discipline was first introduced in 1959, building on formulas and hypotheses dating back to the 1930s. But it wasn’t until the late 1990s that machine learning truly flowered, as steady advances in digitisation, computing languages capable of greater nuance, and cheaper computing power and memory enabled data scientists to train machine learning models to independently learn from data sets rather than rely on rules written for them. The broad availability of inexpensive […]

Kiwi aeronautical firm Inks multi-million dollar export deal with Royal Thai Air Force

New Zealand’s aeronautical sector is set for a multi-million dollar export boost following the signing of an agreement to supply Thai Aviation Industries Co., Ltd (TAI) who provide aircraft maintenance for the Royal Thai Air Force. A new Memorandum of Understanding (MOU) signed between Thai Aviation Industries Co., Ltd (TAI), a leading maintenance, repair, and operations organisation (MRO) in Thailand and, NZAero, New Zealand’s only commercial aircraft manufacturer, will provide for the exclusive supply of parts as well as collaborating to expand TAI’s MRO capability for the service and repair of Government aircraft in Thailand. The agreement was signed during a seven-day mission led by Rt Hon Prime Minister Christopher Luxon with an accompanying business delegation to Singapore, Thailand and the Philippines. The diplomatic visit is designed to strengthen bilateral ties in the region, diversify trade and promote New Zealand’s strong expertise and innovation across key sectors including manufacturing and technology. Prime Minister, Christopher Luxon, said: “New Zealand has a serious ambition to lift our relationships with this region in ways that deliver real benefits and that advance our shared security and economic interests. The MOU signed by NZAero in Thailand is a great outcome on all fronts and I would like to congratulate NZAero on its success in South East Asia.” Stephen Burrows, CEO of NZAero, says Thailand’s government has launched plans to create a world-class aviation hub for the Asia-Pacific region. He says Thailand has the second-largest economy in ASEAN and an annual defence budget of over $10bn. “The new multi-year agreement signed between Thai Aviation Industries Co., Ltd and NZAero is set to triple the value of parts and maintenance exports to that market and help strengthen our relationship so that as their existing fleets are phased out, our new utility aircraft are seen as a viable […]

Small is our Superpower

From February issue of NZ Manufacturer “AMA is committed to working collaboratively towards a system that works smoothly and supports a sustainable, prosperous future.” -Catherine Lye, CEO, Advanced Manufacturing Aotearoa (AMA) New Zealand has a strong manufacturing sector, but it could be better, stronger, more productive. Technology is a key enabler. When it comes to boosting productivity in the manufacturing sector, small is indeed New Zealand’s superpower. Despite New Zealand’s size, our manufacturing & tech sector has capitalised on this characteristic to drive efficiency, innovation, and competitiveness. “New Zealand’s small market allows us to develop and market-test in a small scale before scaling up to export to larger markets. Manufacturing onshore means we have more control over quality and our IP, and we support local suppliers, which all helps grow the economy.” Nick Coubray, CEO (New Zealand Advanced Manufacturing Report 2023). Our manufacturing and tech sectors have many great individual players, but we lack the coordination necessary to realise their full potential. New Zealand needs growth. New Zealand needs companies that are going global and internationalising, growing prosperity and potential for all NZ. But we could do better. Through modernising our manufacturing, we can continue to foot it with the best in the world. “Buckleys is embracing Industry 4.0 with its ongoing investment in CNC machines which are bigger, faster, more accurate, and can process more than one job. Continued development with senior operators on their use of digital tools is an ongoing programme, ensuring the investment is fully realised. Additionally, the business has purchased an enterprise resource planning system, enabling better data-driven manufacturing and processing improvements. This digital investment enables Buckley Systems to maintain its growth trajectory.” Arron Sands, CEO. There is opportunity for enhanced production through improving coordination and awareness across manufacturing, tech, agritech, aerospace, and energy. Silos […]

Advanced Manufacturing for SMB: The path to smarter, modern and better operations

From NZ Manufacturer, December issue, focussing on ‘The Year in Review’ Catherine Lye – CEO, Advanced Manufacturing Aotearoa If you hate the phrase ‘we’ve always done it this way’ and lead your business/team with ‘we’re going to try different, we’re going to try this, we think this will be a better way to improve quality & efficiency’, then you may identify more readily with advanced manufacturing. After all, manufacturers are all about advancing their business every day and trying to find the next thing that will make them better, faster, more competitive. It is, however, important to recognise that not all small medium sized businesses (“SMB”) in New Zealand’s manufacturing sector may readily identify with the term “Advanced Manufacturing”. The majority of New Zealand’s SMB’s may be operating with traditional methods and technologies that have been effective for their specific needs. Factors such as limited budgets, resistance to change, distractions with a global pandemic or not knowing where to start with integrating Advanced Manufacturing tools and techniques can contribute to this reluctance to adopt – after all there is a lot that you could do but what should you do? In the context of a small to medium sized business (SMB), advanced manufacturing embodies a transformative approach that simply translates to “Smarter, Modern, Better” operations. “Smarter Manufacturing” entails harnessing data analytics and automation to make informed decisions in real-time, optimising resource allocation, and reducing waste. The higher value of thinking is around the integration of tools, knowledge, and data. The challenge is finding easier ways to manage and extract data in an easy-to-understand report for everyone. It can make your eyes bleed figuring out what’s going on with 10,000 rows of daily data – you can chart it one way and it is meaningless, chart it another way that […]

The Interview – Jill Cooper

From December issue of NZ Manufacturer www.nzmanufacturer.co.nz Tell readers what you do? My expertise is in high temperature materials and processes. When I left full time work at BlueScope NZ Steel to care for my premature baby, I found it difficult to fit back into the workforce. I expect it’s improved now but employers were not at all flexible with regards to family responsibilities, so I have been doing consulting work on whatever comes up; reline quality assurance and incident investigation for Ballance at their ammonia plant, process and containment for CarbonScape are two examples. I also formed my own company – Advanced Materials Technologies – NZ Limited – which was a collaboration with an ex colleague based in Queensland, Australia to supply Australian and New Zealand with materials sourced from Harbison Walker International, a US company renowned internationally for the quality of its products. Most recently, I am interested in the technologies which can be utilised to slash the (extremely high) CO2 emissions generated by the steelmaking industry and, have been advising and assisting Helios with their novel sodium-based reduction process. This has been a very fruitful relationship, unfortunately disrupted by the war that has broken out there. When I am not working, I am often out wingfoiling on the Manukau and Waitamata harbours. What has been your involvement in green steel making? I’ve been promoting the possibility of low emissions iron and steelmaking to whoever will listen for many years, including the outgoing Climate Change Minister, Hon James Shaw who has been politely listening to my representations since he became co-leader of Green Party. Although, numerous commentators have been claiming that the steelmaking sector would be hard to abate, there has been a small group of dedicated scientists and engineers working on alternative, non carbon, reductants for decades. […]

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