Manufacturing Technology

Smart factories have the potential to spark labour productivity

Each industrial revolution has transformed production, delivered better economic output, and, consequently, immense economic gains globally. But something has shifted in the past two decades—manufacturing productivity growth appears stuck. Labour productivity is a major metric of economic output, and gains in productivity are important because, on a macro scale, labour productivity determines the standard of living of people, nations, and the world. Currently economic output is moving in lockstep with the number of hours people work. Enter the Fourth Industrial Revolution—the newest chapter in industrial development that promises to ignite stalled labour productivity in manufacturing via connected machines, people, data, and value chains. In that sense, the smart factory could potentially ignite stalled labour productivity and unlock the key to productivity for manufacturers. But how? Every manufacturer—whether already “running smart” or yet to invest in smart factory technologies—can harvest business value from smart factory initiatives. Smart factory initiatives accelerate business value creation. Companies report as much as 10–12 percent gains in areas like manufacturing output, factory utilisation, and labour productivity after they invested in smart factory initiatives. There is a direct and established connection—primarily through investment and use cases—between smart factory initiatives and the business value realised. What’s more, any manufacturer can use this connection. While there are risks, primarily operational and financial, they are outnumbered by the smart factory’s value contribution. Also, most risks can be mitigated through rational stakeholder selection, an efficient change management strategy, measurable proof-of-concepts, and incremental investments. Early smart factory adopters report average three-year gains of 10 percent for factory output, factory capacity utilisation, and labour productivity. A closer look at labour productivity trends indicates that smart factory initiatives will likely enable the US manufacturers to “observe” triple the labour productivity growth rate during the next decade (2019–2030) compared to last decade (2007–2018). What does this mean […]

Are you leaving productivity on the factory floor?

Gemma Stanbridge, ViAGO International Limited We all have heard how important it is to have workers who are engaged with their roles and motivated to put their best into what they do. Despite this, recent research reports only 12% of construction, manufacturing, and production workers worldwide are engaged in their roles.[1] Sixty-four percent of workers in this sector are not engaged, with 24% of workers actively disengaged. Manufacturing workers particularly struggle with engagement, and this is often due to a process-focus rather than an employee-centred focus that promotes engagement. Workers in production roles are less likely to have any say in determining how their day will be structured or what could be done to improve their job or workplace. In fact, manufacturing and production workers have the lowest rates of engagement among employees worldwide¹. And yet, the primary approaches to improving productivity in this sector focus on process optimisation. Why are we leaving productivity on the factory floor? The Problem with Process-Centred Approaches to Productivity Conventional management in manufacturing continues to put processes ahead of people, despite evidence that employee engagement is a significant factor in productivity. Discussions about increasing productivity focus on getting more out of resources using cost-cutting, efficiency and utilisation targets. Factories with this mentality often offer low wages for long hours, and although workers are expected to increase output and reduce lead times, their efforts are seldom recognised. Unsurprisingly, there’s little motivation for workers to do more than ‘the bare minimum,’ and workers may even act out due to feelings of frustration and the perception they are not valued by management. Management must consider that employees are an important element of any Productivity Journey, and a mindset shift from cost and efficiency measures can increase employee engagement and productivity. A Closer Look at the Impact of […]

Robotics Plus UGV (Unmanned Ground Vehicle) Dr Alistair Scarfe (L) and Steve Saunders (R)

Robotics Plus wins ANZLF Trans-Tasman Innovation and Growth Award

Robotics Plus, a world-leading robotics and automation company developing innovation to unlock new levels of productivity in some of the world’s most labour-intensive food and fibre value chains, has won an ANZLF Trans-Tasman Innovation and Growth Award. The awards celebrate innovation, growth and impact of emerging businesses in Australia and New Zealand. Robotics Plus was founded in 2013 by Steve Saunders and Dr Alistair Scarfe with a simple goal in mind: to improving the quality, productivity and sustainability of the horticultural and other primary industry supply chains. The company’s R&D efforts focus on automation, vision, robotics and AI, to solve the growing challenges in the primary industry globally such as: labour shortages, sustainability for growers and producers, pollination gaps and yield security. Steve Saunders, Chairman and Founder of Robotics Plus, says: “It’s an absolute honour for the team to receive an ANZLF Trans-Tasman Innovation and Growth Award. It is validation of the hard work of a lot of people over a number of years and celebrates our innovation, culture and diversity. “Receiving such a prestigious award provides a valuable opportunity to showcase Robotics Plus to the world. We would like to recognise our fantastic partners and collaborators in the commercial, research and Government sectors, without them this would not be possible.” Robotics Plus CEO Dr Matt Glenn says the company is experiencing strong growth on the back of increasing demand for its world-first platform technologies. “Over the last 18 months Robotics Plus has launched two commercial products, entered the US and European markets, completed a US$10M Series A investment with Yamaha Motor Company and grown from a team of 12 to over 50. We also have a number of new products in the pipeline and expect our growth to continue at the same rate for the foreseeable future. “We’ve been able to […]

Low cost process monitoring for CNC transfer machines

Innovative new application software enables users of high throughput, multi-process CNC machine tools to implement process monitoring without incurring any additional hardware costs. The software is likely to be of especial interest to users of high-end production systems such as transfer machines, where even relatively small operating issues can rapidly escalate into much larger, more expensive problems unless proactive remedial action is taken. Through real-time monitoring of the power/current values of the electric motors on a transfer machine throughout its milling, turning or grinding processes, it is possible to minimise system downtime and maintain production quality by guarding against faults. Typically, these would include worn or damaged tools and undersize or oversize workpiece blanks. Known as NUMmonitor, the software initially operates in ‘learn’ mode to acquire the varying loads and drive currents of motors when the CNC machine tool is running at optimal performance levels and with a sharp new tool. Up to eight motors can be monitored simultaneously throughout the machine’s operating cycle, and the software accommodates up to 11 different error detection criteria per motor. In the case of multi-NCK systems, a further 8 motors can be monitored for each additional NCK. On transfer machines, it is generally sufficient to monitor just the load (power) of the spindle motors. Both the level and duration of each load event that occurs during the ‘learn’ cycle are measured and recorded, and the process can be repeated to obtain average values. There is no limit to the number of different load events that can be accommodated during a complete machine cycle. Minimum and maximum curves are automatically generated from the ‘learn’ cycles, with the user able to define the types of error detection and the logic (for combining different error criteria, if desired). These machine cycle-time related operating parameters form ‘known […]

AI can make a positive impact

AI technologies are beginning to have a major impact on New Zealand’s economy and society, NZTech chief executive Graeme Muller says. Reports show that changes brought by AI will be as significant as the ongoing changes that have brought computers and internet into all aspects of business, government and everyday life over the last 30 years, he says. Muller was commenting on the New Zealand AI Forum’s latest research report which highlights the importance of AI for New Zealand’s future growth. “Last year the AI Forum released a report that called for a national AI strategy, that would be nice, however technology is moving so fast we just need to get on with it. “It is excellent that this new report identifies we should immediately begin considering the role of AI to support all of the existing national strategies,” he says. “We need to consider AI in all sectors including health, education, agriculture and banking. AI will be useful in almost every way of life in New Zealand. “For example, how can AI reduce the road toll? According to this study, AI has the potential to save 64 lives a year, prevent 7200 injuries and more than $800 million in social costs. “The research clearly highlights the value of AI for achieving New Zealand’s wellbeing, sustainability and economic goals.” The report provides a showcase of AI case studies, analysis of what’s needed to boost acceptance and adoption and a first examination of Māori attitudes, perceptions of and engagement with AI. The research identifies that New Zealand urgently needs to increase its focus on areas such as investment in AI, skills and talent, research, trusted data, ethics and regulation. The report shows how AI solutions can be used to improve wellbeing, productivity and sustainability.

New equity deal announced for industry automation specialist

CR Automation managing director Peter Jenkins. An award-winning industry automation specialist is set to significantly extend its market reach thanks to a new equity partnership with a horticultural heavyweight. Following recent collaboration on a number of projects, CR Automation (CRA) has decided to sell a 50 per cent equity stake to Jenkins Group – a key industry player throughout Australasia’s horticulture post-harvest industry. With subsidiaries in New Zealand and Australia (Tauranga-based Jenkins Freshpac Systems Ltd and NSW-based J-Tech Systems PTY), Jenkins Group provides an extensive range of labelling, packaging and handling systems to the fruit and vegetable industry across both countries. Hawke’s Bay-based CR Automation provides automation, robotic and post-harvest solutions to a broad range of industries including food and beverage, water and wastewater, materials handling, cool storage, meat and wool processing and general manufacturing. Managing Director Peter Richards says the 18-year-old tech company has experienced exponential growth over the past three years and has been looking for an equity partner who could help sustain that growth and ensure longevity. “We wanted a partner founded on similar ideals who would add value and provide market access beyond our existing client base,” Richards explains. “Jenkins Group are an innovative, family-owned company with 136 years of success behind them. They are very client-focused and trade with a high level of integrity which is an excellent fit for us.” Innovation is at the core of both companies, and CRA won the “Most Innovative Solution” award for ABB robotics at the 2019 ASIA Value Provider Conference. Richards says he is immensely proud of the engineering capacity the CRA team has developed and recent growth was primarily due to a strategic initiative of developing bespoke material handling and machinery for a broad range of industry players. “Jenkins were very impressed by CR Automation’s engineering capacity […]

Innovative 3D solutions for AEC Industry

FARO, renowned for 3D imaging solutions for construction BIM, has an innovative set of 3D solutions specifically developed for AEC professionals. FARO Indoor Mobile Scanner As 3D Laser Scanning becomes more ubiquitous across various industries, there is an ever increasing need to make the scanning process and data processing more efficient. Conventionally, this has been addressed with a variety of mobile mapping solutions. However, these solutions typically have limitations in terms of accuracy and data fidelity. The Indoor Mobile Scanning solution enables kinematic 3D scans to be completed up to 7X faster than a series of traditional, fixed point scans over comparable areas. Thus, projects that took days can be executed in just a few hours. Additionally, as the Mobile Scanner includes fixed scan capability as a standard feature, users can simply switch to high-fidelity scan mode in real time for seamless integration with mobile scan data. The Indoor Mobile Scanner solution combines several leading technologies, including FARO’s patented Focus Laser Scanner technology, which have been optimised to operate in concert. Current owners of Focus Laser Scanners or ScanPlan products will have a simple upgrade path to the Indoor Mobile Scanning solution, which protects their original purchase investment. FARO As-Built Modeller FARO As-Built Modeler Software enables AEC professionals to leverage the smoothest Scan to BIM workflow in the industry to date. As-Built Modeler is specifically designed to minimise the effort and time required to create as-built documentation, which is the main task across AEC professionals in the building, facility and infrastructure design phases. This comprehensive and innovative platform automates many cumbersome processing steps that must be performed manually today. Powerful tools allow the easy creation of CAD objects that can be directly imported in any CAD system independent of the specific CAD software, dramatically simplifying the modelling workflow for FARO […]

Xcelerator speeds digital future of industry

Xcelerator is an integrated portfolio of software, services and application development platform that can be personalised and adapted to fit customer and industry-specific needs to help companies of all sizes become digital enterprises. Xcelerator combines the full portfolio of Siemens’ software for design, engineering and manufacturing with an expanded Mendix low-code, multiexperience application development platform. The Mendix platform now includes cloud and app services for digital engineering and Internet of Things (IoT) powered by MindSphere the cloud-based, open IoT operating system from Siemens, in addition to Mendix’s market-leading unified low-code and no-code development environments. Unique to Xcelerator, this platform drives digital transformation by enabling anyone in the ecosystem, including citizen developers and engineers to easily build, integrate and extend their existing data and systems.

5G to enhance manufacturing efficiency

More than one million people have subscribed to a 5G mobile contract in South Korea, meaning demand for the high-speed technology has easily outpaced the country’s adoption of 4G. The need for speed isn’t just essential for rapid telecommunication — we’d all rather communicate using faster and more reliable methods. 5G has created quite the media buzz recently. Although uptake continues to face its challenges, with the Australian government banning Chinese telecommunication giant Huawei’s 5G rollout in the country on national security grounds, the world is racing to implement the infrastructure. Next generation 5G networks can be 100 times faster than 4G, making communication between devices and servers much faster. This opens up a wealth of possibilities for manufacturing, helping the industry to increase its competitiveness and boost efficiency. The instant era Manufacturing runs on a tight schedule. Margins are squeezed more than ever as products are increasingly varied, customised and complex. Factories need to receive and transmit a wealth of data to keep their equipment informed — and fast. Ultra-reliable and low-latency communication (URLLC) is a new service category that will be supported in 5G, created to meet the requirements for 5G in industrial applications. By making the most of this category, machines can receive greater roaming power. In fact, 5G has very low latency, around 10 milliseconds in comparison to the 20-30 milliseconds with 4G, so equipment can be monitored in real time by human workers. With plans to reduce this latency to as little as one millisecond, the factory floor will receive updates on machinery almost instantaneously. Cutting the cord According to Ericsson’s report on 5G’s potential, enhanced communication will also mean greater flexibility for manufacturing robots. 5G will handle more complex data transmissions, such as cloud robotics where the cloud’s processing is relevant for the immediate […]

Central Innovation talks to us

Peter Ranyard, Country Manager New Zealand, Central Innovation How is Central Innovation finding the current business climate? The economic climate in New Zealand has remained stable on the back of a new government, after nine years of the previous body. Despite some recent slowing due to better design and strong innovation practices, the economic climate in New Zealand still shows steady growth. Having said that, a number of our clients are finding success in export markets such as the USA and Europe, even though, there has been some uncertainty with political and international factors like the Financial Services enquiry in Australia, Brexit, and the trade wars between the US and China. Where will future business opportunities for the company come from? Our goal is to continue to see our customers finding success in export markets, particularly with the USA and Europe. This should help drive more growth. We are also investing in new solution offerings for the manufacturing sector with our DataSuite solution for example, which helps manufacturers integrate their design, production and ERP systems to reduce inventory costs and improve their time to market. Is the growth in technology aligned with the market’s needs? Yes, we’re seeing an increasing demand for data generated from the design process and other business processes. One of the challenges we come across is that many New Zealand firms don’t have the ‘know-how’ technology to confidently choose a supplier that is well versed with the market and can surely support the business to see a solution implementation through to completion. This is coupled with an underlying need to have a ‘suite’ of solution-based products that makes business processes in design and execution more palatable and less onerous. How can governments assist businesses to get ahead today? Firstly, by providing stability and certainty which helps […]

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