Manufacturing Technology

Meeting manufacturing’s cyber security challenges

Scott Leach, Vice President APJ at cybersecurity firm Varonis In February 2021, Security Intelligence reported a 156 per cent increase in ransomware attacks on manufacturers worldwide.Some of the biggest attacks included a demand for $US17 million from a Taiwanese laptop maker and another attack for $US34 million from an electronics manufacturer for Apple. Verizon’s 2021 Data Breach Investigations Report also found the manufacturing sector facing a significant increase in ransomware attacks. These accounted for 61.2 per cent of all breaches in the sector analysed by Verizon. None of these reports offered any reason for this surge in attacks on manufacturers. Still, it has been well-reported that the increasing interconnection of legacy operational technology (OT) and newer information technology (IT) systems has greatly increased the attack surface for manufacturers. OT can now be compromised to gain access to IT, and vice versa. To make matters worse, OT systems were historically isolated from the internet and therefore were not designed to face cyberattacks. Manufacturers must double down on security, and ensure their data is protected and managed safely. This is particularly important for customer data and intellectual property, which could be extremely valuable to a rival organisation. Taking a data-centric approach to security Traditional security measures rely on a ‘walled garden’ approach. Anyone within the walled garden–i.e., employees, contractors and those granted network access–are automatically assumed to be trustworthy, and not verified. Instead, a data-centric approach utilises a zero-trust model, where no-one is assumed to be trustworthy and every access attempt to sensitive data is verified. Typically, the identity of the accessor, the device they are using, their location and the data they are seeking access to are all checked against pre-authorisations. There are plenty of technology solutions available to implement a zero-trust policy. The hard part for any large organisation that […]

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 […]

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 […]

MHM Automation continues growth trajectory despite covid challenges

Increases in revenue, profitability and $40 million of forward-booked orders were among the highlights of the half year report released by MHM Automation recently. The NZX-listed automation company reported revenue growth of 19% to $29.5 million and EBITDA growth of 45% to $2.12 million for the six months to 31 December 2021. These results continue the momentum of growth the company has seen over the last two years, primarily driven by strong sales of its Milmeq chilling and freezing equipment to the Australian red meat sector. MHM Automation Chief Executive Officer, Richard Rookes said the growth was admirable, particularly given the challenges posed by Covid and border restrictions. “It is a real credit to the performance of our team. Our project managers and procurement teams have negotiated numerous logistics challenges, and our ability to continue to deliver projects to clients overseas was only possible thanks to the dedicated staff who were prepared to travel in uncertain circumstances,” he said. “We welcomed the news of the imminent re-opening of New Zealand’s borders, as this will significantly reduce our project risk and costs going forward,” he added. Key projects delivered during the year included a milestone 200th Milmeq plate freezer installation for a major Australian meat processor and a first-of-its-kind robotic de-boxing line for a leading meat processor in the US. Mr Rookes said the company’s continued success was a reflection of the world-leading status of its technologies, and its ability to innovate to resolve customers’ production challenges. “Take the universal robotic box cutter for example. It’s a robotic system that can open boxes of various shapes and sizes on the fly, without operator invention. Our client told us they could not find a system on the market that would fulfil this task, so we developed one to meet their needs,” he […]

Beckhoff automation solutions

Founded in 1980, by Hans Beckoff (pictured) as a one-man operation, Beckhoff implements open automation systems using proven PC-based control technology. Primary areas their product range covers include industrial PCs, I/O and fieldbus components, drive technology, automation software as well as control cabinet-free automation. Products that can be used as separate components or integrated into a complete and mutually compatible control system are available for all sectors. The company’s new automation technology stands for universal and industry-independent control and automation solutions that are used worldwide in a large variety of different applications, ranging from CNC-controlled machine tools to intelligent building control. Development of innovative products and solutions based on PC-based control technology is key to the company’s continued success. The company has recognised many standards in automation technology that are taken for granted and introduced to the market as innovations. Beckhoff’s philosophy of PC-based control as well as the invention of the Lightbus system and TwinCAT automation software are milestones in automation technology and have proven themselves as powerful alternatives to traditional control technology. EtherCAT, the real-time Ethernet solution, provides a powerful and future-oriented technology for a new generation of control concepts. Beckhoff is headquartered in Verl, Germany and there are 4,500 employees worldwide and 1,900 engineers. The company has 39 representative offices worldwide from an overall total of 75 representatives worldwide. The corporate headquarters of Beckhoff Automation GmbH & Co. KG in Verl, Germany, is the site of the central departments such as development, production, administration, sales, marketing, support and service. Beckhoff is represented in New Zealand with offices in Auckland. Technical training is available.

Panel Building: Everything you need to build and maintain your panel

RS PRO are experts in Industrial Control Panels. And for good reason. They are the control centre of countless industrial operations, and without them production stands still. This guide gives buyers, and experts alike, a quick guide to the ins and outs of control panels. Where to start? Panels are effectively the brains, containing the components necessary to control and manage devices, electrical systems, production plants and industrial machines. They function as the interface point between the machine operator and the production line, and transmit acoustic, visual, and video signals to ensure constant monitoring. The operator input commands can be completely digital (touch screen panel) or physical (buttons, switches) while the output signals (machine side) are sound and visual alarms, and video responses on how the plant is working. From the outside The meters on the outside serve as an interface with a machine-operator and employee. They display energy, temperature, counters, and voltmeters. The ammeters show the numerical values that the panel commands and switch to intervene on the machinery. This can turn the machinery on and off and use sounders & beacons to signal possible problems. The human touch RS PRO now boasts a human-machine interface (HMI) for the first time in its range. A user-friendly and interactive touchscreen panel displays the plant graphically, enabling users to operate and evaluate functionality via the software. The graphic interface can be programmed, and reprogrammed for different functions and in the case of modifications to the plant. Inside the Box A panel cannot exist without an enclosure containing all its components. Known as a wall box even if it does not hang exclusively on walls. The DIN Rail components contain everything from power supplies and contactors, relays, terminal blocks and Ethernet switches, to timer relays and axial fans. Connected by cables & […]

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 […]

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