Manufacturing Technology

Have you ignited your Power Rangers?

-Insa Errey, Advisor, NZ Manufacturer www.nzmanufacturer.co.nz How the power of staff engagement leads to energy reduction. While technological advancements and infrastructure improvements play a crucial role in decarbonisation, one often overlooked factor is staff engagement. Employees who are actively engaged in energy-saving initiatives can make a significant impact on energy reduction and as such emissions reduction. This article explores the relationship between staff engagement and energy reduction, highlighting the benefits of fostering an engaged workforce. Raising Awareness: Raising awareness among employees is one of the primary ways staff engagement can contribute to energy reduction. By conducting awareness campaigns, providing training sessions, or implementing internal communication channels to disseminate information, employees become educated about the importance of energy conservation. Ensure the process is fun and relatable, to get your staff onboard. Understanding the impact of their actions, ignites them to become more conscious of their energy usage. Engaged employees are more likely to adopt energy-efficient behaviours and encourage others to do the same. Behaviour Change: Engaging employees in energy savings initiatives encourages them to change their behaviour. Simple actions such as turning off lights when not in use and powering down computers can collectively contribute to significant energy reductions. This can then be extended at their workstation. If their workstation had an Energy Star rating what would it be, and how could this be improved? Engaged employees serve as role models for their peers and promote a culture of energy consciousness throughout the organisation. Employee Empowerment: Engaging employees in energy reduction efforts empowers them to take ownership of their workplace environment. When employees feel empowered, they are more likely to actively participate. Organisations can involve staff members in energy audits, encourage them to identify areas of improvement, and implement their suggestions. This involvement creates a sense of ownership and strengthens the […]

Waikato company key carbon and stainless steel tube player

Precision component production ignited with 3D Tube Laser Cutter Industrial Tube Manufacturing, located in the Waikato, has established itself as a key player in the domestic market of carbon and stainless steel tube. Their dedication to constantly improving and expanding has enabled them to attain remarkable success in the industry. Bolstering its national reputation as a reliable supplier of high-quality steel tube, Industrial Tube commissioned its game-changing 3D Tube Laser Cutter last year – a one-of-a-kind in New Zealand that has sparked a surge in demand for its services and solidified the company’s position as a leader in the industry. Industrial Tube general manager Ian Foster says the company is proud to have been a cornerstone of the Waikato manufacturing community for almost four decades now, catering to a wide range of industries with its broad product offering and excellent service. “With the market demanding efficiency, versatility and extreme attention to detail, investment in automation and innovation has been a key focus for our business,” says Foster. Known as ‘Pro-Tube services’, Industrial Tube offers 3D laser cutting, CNC Drilling, deburring, tapering, swaging and telescoping of tube, including carbon steel, pre galvanised steel and stainless steel, in addition to its extensive milled tube offering. “Pro-Tube raises the bar in terms of what’s possible in tube processing and manufacturing. New technology like the 3D Tube Laser Cutter, coupled with the experience and knowledge of our engineers, means we can deliver more options and alternatives to New Zealand businesses that are seeking high-quality, customised components,” he says. Since its integration into Industrial Tube’s manufacturing processes, the 3D Tube Laser Cutter has unleashed a wave of opportunities for local manufacturers. The precision, speed, and versatility offered by this cutting-edge machinery have elevated the capabilities of businesses, enabling them to create intricate components with precision […]

Who is exporting?

NZ Manufacturer, June 2023 A mere 30 New Zealand companies, according to the Productivity Commission, account for over half of all exports. They say focus really needs to be on innovation and moving away from volume to value-added products. So, what are overseas trade visits for? Do business legations need to be vetted to determine that the ‘fact finding trip’ is not just an overseas holiday? Do they bring back business for the country? How much money has government invested over the years in trade visits that result in absolutely no return? Dairy is New Zealand’s biggest export earner – worth about $19 billion a year. The largest increase for the year ended December 2022 was for milk powder, butter, and cheese. This is New Zealand’s largest export commodity group, making up 28 percent of total exports over the year. This industry group, with a proven track record, doesn’t need to justify the trip; they have established markets and maintain them very well. To get more than 30 companies contributing to our export success, we need to increase productivity which needs: a positive attitude and involvement of management; proactive employees; good working conditions; tools and equipment available to raise productivity and the availability of input supplies. The four determinants of a nation’s productivity are physical capital, technology, human capital, and natural resources. Technology is a decisive factor in productivity, along with physical capital (equipment used to produce products), human capital (the knowledge of labourers), and natural resources. Now all of this sounds logical but obviously is not being put into practice(properly) if only 30 companies generate most of our export revenue. What are the restraints? At present, the shining light for export growth appears to be the gaming industry. What is everyone else doing? We are in a constant state of […]

Empower Software celebrates 21 years in business.

Empower Software have pioneered engineers’ and manufacturers’ use of labour productivity software using touch screens on the workshop floor, since commencing business in 2002. Empower Software is cloud based, an Add On and an App; manufacturing clients interface to their accounting software. Empower is supplied and supported as SaaS (Software as a Service), low cost monthly fee based. They currently have 240 manufacturing and engineering clients, mainly throughout Australia and New Zealand including US, Canada, UK, South Africa and the Philippines. There are an estimated 80,000 SME based manufacturing and engineering businesses throughout Australia and New Zealand, 80,000 businesses an estimated 30% still use manual time sheets “today” for workshop staff to manually record their jobs and times worked on each job. An estimated 60% do not track their workshop staff time on their jobs at all because manual time sheets produce information that is “too little, too late, too inaccurate and too costly to produce”. Manual time sheets cost approximately $80 per workshop staff member per week to produce; in comparison the Empower Software App is approximately $15 per staff member per week – so it is an obvious substitution to adopt technology and use the Empower Software App. Empower Software suits manufacturers and engineers who wish to replace manual time sheets, as well as those manufacturers who wish to commence tracking time on jobs for the first time, using technology. Lean manufacturing, Digital Manufacturing, Industry 4.0 are all being heavily promoted to Australasian and NZ manufacturers by government and industry groups as the means to be labour cost competitive and Empower Software “rides that wave”. Touch screens on the workshop floor and Empower deliver for 90% of manufacturing clients a 20% to 40% reduction in labour times on jobs and 20% to 40% reduction in labour cost […]

New Zealand research to fly on International Space Station

Dr Sarah Kessans. A research facility prototype developed in Christchurch will soon orbit Earth aboard the International Space Station (ISS) under a partnership between the Ministry of Business, Innovation and Employment (MBIE) and US space company Axiom Space. The facility for studying protein crystal growth in space, developed by Senior Lecturer at the University of Canterbury’s School of Product Design, Dr Sarah Kessans, in collaboration with teams from Arizona State University and Christchurch companies Asteria Engineering Consultancy and Intranel, was one of two projects selected for initial feasibility studies in 2022. “We signed a Memorandum of Understanding with Axiom last year and agreed to two feasibility studies, one of which led to Dr Kessans’ project,” MBIE Director of Innovative Partnerships Joe McKay said. “This facility could lead to major advances in medical, biotechnological, food science, and agricultural innovation and we are excited to support the next step.” Sarah’s research facility is scheduled to fly on Axiom Mission 3 (Ax-3) later this year, which will be the third private astronaut mission to the ISS. “Being able to conduct this research on the ISS is such a huge opportunity and really is critical to what we’re trying to achieve in terms of scientific innovation and future commercial outcomes,” Sarah said. “When protein crystals are grown in microgravity, they can develop into larger and higher quality crystals than what we can grow on Earth. These crystals can then be used to create high-resolution pictures of the protein’s structure. If we have a detailed picture of what virus proteins look like, for example, we can develop things like antiviral drugs and vaccines.” Current facilities for protein crystal growth on the Space Station require significant time and resources for astronauts to mix samples, set up experiments, observe growth and adjust settings as needed. By developing […]

Kayasand receives backing from NZGIF to reduce carbon emissions from concrete

Kayasand, a distributor of premium sand manufacturing technology, is opening its first V7 high-technology manufacturing demonstration plant in New Zealand, which uses waste products such as recycled glass, concrete and slag, and turns them into premium sand for concrete. Kayasand has received the backing of New Zealand Green Investment Finance (NZGIF) via a $3.5 million equity investment. The green investment bank was established to accelerate investment that helps reduce greenhouse gas emissions. A further $1.8 million of private investment has been secured alongside the NZGIF investment bringing the total raise to $5.3 million. Natural sand supplies are becoming harder to access and traditional concrete manufacturing processes, including the impacts of sand dredging on coastlines such as Pakiri, 100km north of Auckland, are not sustainable over the longer-term. Dr Bram Smith, Kayasand General Manager, says “Our technology can reduce or in cases eliminates the need for natural sand dredging. It uses by-products and recycled materials such as quarry crusher dust and recycled glass to manufacture a sand of such quality that it makes stronger concrete than natural sand when mixed with cement. Our goal is to reduce carbon emissions from concrete production by up to 20% using this method.” Kayasand technology is used in over 300 plants across Japan, China, India, and Australia. The picture shows a V7 plant in Japan. NZGIF Chief Executive, Craig Weise, says the deal is an important step and is a boost for the construction sector and consumers who are eagerly looking for more sustainable building materials. He says, “Auckland’s infrastructure requirements alone are projected to be $26 billion over the next decade and if New Zealand is going to meet its CO2 emission reduction targets, we need to find alternative manufacturing and building methods. We are delighted to invest in Kayasand to help deliver its […]

NZ start-up FabriBotics poised to revolutionise metal manufacturing

FabriBotics, a new manufacturing start-up based in Tauranga, New Zealand, has developed technology in large-scale metal additive manufacturing. The company’s proprietary technology allows for the production of custom metal parts ranging from 1kg to 1000kg in size, using a variety of weldable materials, including stainless steel, aluminium, steel, and bronze. Founders Mike Fry and Ben Jackson began working on the 3D printing (Wire-Arc Additive Manufacturing, or WAAM) technology during an MBIE-funded research program at TiDA Ltd. The start-up has secured pre-seed investment from KiwiNet to further develop the technology and business. The applications for FabriBotics’ technology are vast with the ability to produce custom, large metal parts applicable across many industries, with 1kg to 1 tonne being the target size. Industries include heavy industry, power generation, marine, mining, agriculture, food processing, transport, and architecture. The technology offers a cost-effective solution for creating complex shapes and reducing the costs of machining. Using additive manufacturing to produce near-net-shape billets, the technology minimises material waste and maximises the efficiency of the manufacturing process. The technology also eliminates the need for expensive tooling required for traditional casting methods, making it an attractive option for replacing one-off cast components. Furthermore, the technology enables extensive repair options for broken metal products, offering a sustainable and economical alternative to replacing entire components. New Zealand is ideally placed to benefit from FabriBotics’ technology due to its long supply and logistics chains, high cost of labour and low value of metal waste. The ability to produce custom and niche metal parts on-shore will provide a much-needed solution for industries that currently have limited options for prototyping, spare parts and repairs. Commenting on the launch of FabriBotics, newly appointed Commercialisation Director Iain Hosie says “The potential for FabriBotics’ technology to revolutionise metal manufacturing in New Zealand is immense. With the ability […]

HERA recognises leading Metalminds at Future Forum Awards

In the picture: Innov8taiao (steel is sustainable) Award. The heavy engineering industries’ top innovators and changemakers were recognised at the HERA Future Forum Nation Dinner on 5 May 2023 at the Christchurch Art Gallery Te Puna o Waiwhetū. Sponsored by New Zealand Steel, the awards celebrated the significant impact that individuals and teams are making across Aotearoa, honouring outstanding projects, innovations, and research that demonstrate leading vision and contribute to success within their respective industries. Dr Troy Coyle, HERA’s CEO, says, “I would like to congratulate the winners, finalists, and scholarship recipients for 2023. All of the work they do across the country invaluably contributes to the success of the industry and nurtures the values that will ensure we are servicing a better tomorrow. It is a privilege to acknowledge longstanding dedication, alongside new leaders and up and coming talent.” The 2023 award winners are: Keith Smith Memorial Award – Geoff Bird, Structural Technical Development Manager at Beca. Geoff’s contribution to the industry is a longstanding one, supporting HERA’s Structural Division in 1983 and moving on to become the Structural Manager of New Zealand Steel in 1992, where his work became instrumental in the widespread use of structural steel in multi-story buildings. Geoff is a significant knowledge benefactor for the industry, participating in HERA’s Steel Research Panel and SCNZ technical working groups. He is also an honorary lifetime member of the Structural Engineering Society (SESOC) and a Fellow of Engineering NZ. Next Gen Leadership, Leading Metalmind Award – Mike Ryan, GM of Operations at Farra Engineering. Mike impressed the judges with the breadth of projects for which he was able to achieve the seemingly impossible, as a result earning the informal title ‘guru of solving crazy engineering problems for the hydro industry’. His problem-solving work at the Burrinjuck Hydropower Station […]

Kemppi adds Pulse model to X5 FastMig welding range

Leading international welding equipment manufacturer, Kemppi, has released its latest addition to its range of X5 FastMig welders – the new X5 FastMig Pulse. The X5 FastMig Pulse multi-process welding system has been specifically designed for steel, aluminium and stainless steel welding in industrial environments. The machine delivers a range of features that help significantly enhance arc welding productivity. Built using energy-efficient inverter technology, the X5 FastMig Pulse offers faster welding and quality welds thanks to Touch Sense Ignition, effortless operation, excellent welding ergonomics, flexible equipment setup and is industry 4.0 ready. Faster welding, better quality weldsA high-performing machine, the X5 FastMig Pulse features the latest in ignition technology – Touch Sense Ignition – as standard. When combined with WiseSteel software, which is also included in the X5 FastMig Pulse, it delivers precise ignition capability and stable arc control. The X5 Pulse tackles the challenges of globular arc by alternating between short arc and spray transfer. In short-circuit transfer, it improves the arc stability adaptively, providing better out-of-position steel welding capabilities. In spray transfer mode, micropulsing of the current and voltage increases travel speed significantly. In doing so, the X5 Pulse helps to minimise the spatter produced by a traditional globular arc, as well as the need for post weld cleaning, saving the welder both valuable time and cost, while helping to deliver better quality welds. For more challenging steel, stainless steel and aluminium applications, the arc control can be further optimised with optional MAX welding programs and Wise special processes. Effortless operationDesigned to be hassle-free, the new model can be quickly set up thanks to Weld Assist.This feature guides the welder to set the right parameters for each application so they can start welding faster. The X5 Pulse is also very easy to operate. It features a large, graphical and […]

Cost effective automation

Low Cost Automation reduces the barriers to getting started with automation and gives special assistance to small and medium-sized companies in increasing their competitiveness. To this end, motion plastics specialist igus has built up a broad network of 55 robotics providers and 40 integrators over the past three years – and new partners are constantly being added. As a result of continuous developments and product innovations, affordable robotics has become especially interesting for small and medium-sized companies. And the number of offers on the market is increasing. For instance, igus Low Cost Automation represents a broad portfolio of articulated arm, linear, delta and SCARA robots. Product modularity means that single components or individual complete solutions can be assembled according to the build-or-buy principle. The focus is always on a low entry-level price and quick payback. This is where igus high-performance plastics play to their strengths. They are tribologically optimised and especially durable, lightweight, lubrication-free and maintenance-free, and cost-effective to produce. The most cost-effective solution that works Over the past three years, igus has built up a broad, constantly growing partner network. As part of the LCA partner programme, the motion plastics specialist works with integrators who provide customers with additional expertise, experience with end customer projects, and joint project experience. Igus started with seven partners around two years ago, and now have almost 100. In order to refer interested parties to competent integration partners in their area, they are constantly expanding their network. Together, they can offer customers a wide range of automation solutions – focussing on applications with a total investment volume of less than €45,000. Typical services include integrating a control system into existing machines, setting up and commissioning robots, evaluating safety measures or, if there is simply no capacity, providing the capability of assembling machines on site. Experience Low Cost Automation […]

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