Smart Manufacturing Today

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 […]

RegenerationHQ Perspective – Unpacking Productivity in New Zealand

From February issue, NZ Manufacturer – A view by John Luxton Productivity has long been a buzzword in political and economic discussions in New Zealand, often presented as a simple solution to complex problems. However, I am deeply unimpressed with people who rattle off the word “productivity” with no more thought behind what it actually means than “woke”. I believe it’s crucial to understand that productivity encompasses far more than what surface-level conversations suggest. Simplistic, bumper-sticker answers do not suffice when it comes to a topic as nuanced and multifaceted as productivity. Understanding Productivity – Productivity, in essence, is about maximising outputs while minimising inputs. It’s a measure of how efficiently resources like labour, capital, and technology are used to generate goods and services. A look at the world’s most productive countries – Switzerland, Luxembourg, Germany, Singapore, Netherlands, Norway, Denmark, Sweden and Hong Kong reveals a variety of approaches to achieving high productivity levels. The USA is in that mix, but with the size and scale of their economy, there is less for us to learn from their example. Myths and Realities – Common rhetoric blames unproductive workers, excessive taxation, and bureaucratic inefficiencies for low productivity levels. However, a closer look at the top productive countries shows a different story. These nations excel in areas like macroeconomic stability, resource utilisation, open trade, and advanced economic structures. Key Factors Driving Productivity – Several factors are critical to driving productivity in a national economy: Macroeconomic Stability – Low inflation and realistic interest rates create a stable environment for business planning. Natural Resources – Efficiently utilised resources significantly contribute to productivity. Open Trade – Free trade enhances productivity through diverse product/service offerings. Economic Structure – Moving away from agriculture toward a more diverse economy. Access to Capital – Essential for business growth and […]

Landmark carbon reduction project powers ahead

From February issue of NZ Manufacturer magazine. www.nzmanufacturer.co.nz Around 70% of world’s steel is produced from iron ore reduced in blast furnaces. Most of the remaining 30% is produced by minimills, which recycle scrap steel using electric arc furnaces – a proportion set to grow as companies seek to decarbonise their operations. Work is underway at New Zealand Steel to install an electric arc furnace: a move which will shrink the carbon footprint of its Glenbrook steel mill and place the company at the leading edge of low emissions steelmaking worldwide. As the company gears up to celebrate 60 years since it was founded, this crucial upgrade will secure steelmaking – and the corresponding jobs it supports – in New Zealand for the long term. Announced in May 2023, New Zealand Steel’s electric arc furnace (EAF) project will reduce Glenbrook’s carbon footprint by 800,000 tonnes each year and the country’s total annual emissions by 1% from day one. The carbon reductions – equivalent to taking 300,000 cars off the road permanently – will come from replacing the steel mill’s existing oxygen steelmaking furnace and two of the four coal fuelled kilns. Chief Executive New Zealand and Pacific Islands Robin Davies described the project as “a pragmatic response that not only sustains our critical domestic steel supply, but also provides a collaborative approach with public and private sector players to be world leaders in lower emissions steel.” The company is on track to be producing lower carbon steel as soon as 2026, having continued to hit project milestones such as the completion of a feasibility study, beginning to prepare the site for installation and the signing of new project partnerships since the May 2023 announcement. Already users of technologies such as robotics, automation, wireless sensors to collect real-time data and […]

Choose reuse as the new normal

From February issue of NZ Manufacturer magazine. Nada shares with us the vision of her company, Again Again, and even tells us what her favourite book is! Nada Piatek, Founder, CEO, Again Again. Again Again’s vision is to end single-use waste with a commercial, reusable container borrow system that makes it easy for everyone to choose reuse as their new normal. On a daily basis I am committed to that kaupapa and excited to be making inroads to achieving it. A societal shift like this is an enormous ask, and a slow burn. For many people in our community, even the understanding that each single-use packaging (SUP) unit is a part of a wider, enormous problem is missing. In fact the scale of this issue is massive: 400 million tonnes of single-use packaging waste is created each year around the world. Again Again’s key focus is to build the systems and infrastructure to facilitate brands designing out this waste and delivering food, beverages and grocery items in packaging that can be returned, washed, and used again for the same purpose. Changing people’s behaviour is also something Again Again can and does contribute to,but is the responsibility of our whole community. With regulations such as extended producer responsibility schemes (EPRs) and plastic taxes coming into force around the world, the economics of packaging is changing. In some regions, reuse is already close to cost parity with SUP over time – when one amortises the significant set-up costs – however, there are simply very few facilities that can deliver reusable packaging at all, let alone at scale. Legislation and consumer pressure demanding these systems is mounting and it is a solution that is increasingly coming into focus, for brands and retailers alike. A chicken and egg scenario exists. The wash infrastructure needs investment, but this investment is not […]

Material World: The Six Raw Materials That Shape Modern Civilization

by Ed Conway Sand, salt, iron, copper, oil, and lithium. These fundamental materials have created empires, razed civilisations, and fed our ingenuity and greed for thousands of years. Without them, our modern world would not exist, and the battle to control them will determine our future. The fiber-optic cables that weave the World Wide Web, the copper veins of our electric grids, the silicon chips and lithium batteries that power our phones and cars: though it can feel like we now live in a weightless world of information—what Ed Conway calls “the ethereal world”—our twenty-first-century lives are still very much rooted in the material. In fact, we dug more stuff out of the earth in 2017 than in all of human history before 1950. For every ton of fossil fuels, we extract six tons of other materials, from sand to stone to wood to metal. And in Material World, Conway embarks on an epic journey across continents, cultures, and epochs to reveal the underpinnings of modern life on Earth—traveling from the sweltering depths of the deepest mine in Europe to spotless silicon chip factories in Taiwan to the eerie green pools where lithium originates. Material World is a celebration of the humans and the human networks, the miraculous processes and the little-known companies, that combine to turn raw materials into things of wonder. This is the story of human civilisation from an entirely new perspective: the ground up.

Productivity Works

I The year ahead, NZ Manufacturer will be following closely the policies of the new government and will, of course, invite the Minister for Manufacturing, Andrew Bayly, to share his thoughts and explain how New Zealand companies can enhance on their current situation for a brighter future. We invite readers to share their journey and methods they are using for efficiency and growth, leading to better business outcomes. We can talk about Productivity as much as we like…however, that talk needs to lead to action for change.

New Zealand Steel: Landmark carbon reduction project powers ahead

Around 70% of world’s steel is produced from iron ore reduced in blast furnaces. Most of the remaining 30% is produced by minimills, which recycle scrap steel using electric arc furnaces – a proportion set to grow as companies seek to decarbonise their operations. Work is underway at New Zealand Steel to install an electric arc furnace: a move which will shrink the carbon footprint of its Glenbrook steel mill and place the company at the leading edge of low emissions steelmaking worldwide. As the company gears up to celebrate 60 years since it was founded, this crucial upgrade will secure steelmaking – and the corresponding jobs it supports – in New Zealand for the long term. Announced in May 2023, New Zealand Steel’s electric arc furnace (EAF) project will reduce Glenbrook’s carbon footprint by 800,000 tonnes each year and the country’s total annual emissions by 1% from day one. The carbon reductions – equivalent to taking 300,000 cars off the road permanently – will come from replacing the steel mill’s existing oxygen steelmaking furnace and two of the four coal fuelled kilns. Chief Executive New Zealand and Pacific Islands Robin Davies described the project as “a pragmatic response that not only sustains our critical domestic steel supply, but also provides a collaborative approach with public and private sector players to be world leaders in lower emissions steel.” The company is on track to be producing lower carbon steel as soon as 2026, having continued to hit project milestones such as the completion of a feasibility study, beginning to prepare the site for installation and the signing of new project partnerships since the May 2023 announcement. Already users of technologies such as robotics, automation, wireless sensors to collect real-time data and computer-aided engineering and design, Mr Davies says his teams […]

What is net zero?

Net zero is an ideal state where the amount of greenhouse gases (GHGs) released into the earth’s atmosphere is balanced by the amount of GHGs removed. Decarbonisation efforts are needed to reach net zero. If you follow sustainability and climate topics, you have probably heard the term net zero thrown around. Still puzzled? A net-zero gain of GHG in the atmosphere is achieved when the level of GHG emissions released into the atmosphere is equal to the amount removed. This is also referred to as carbon neutrality. CO2 is a gas found in the Earth’s atmosphere—and it’s part of the planet’s air, along with nitrogen, oxygen, methane, and other gases. CO2 helps to trap heat, but too much of it can cause problems, such as heat waves or flooding. It occurs both naturally and as a byproduct of human activities such as burning fossil fuels. All industries—not just the energy sector—must achieve net zero to avoid a permanently warmer planet. Read on to learn more about what net zero means, and how it can be achieved. What is decarbonisation? Decarbonisation is the mitigation, cessation, or reduction of carbon in the atmosphere. It is achieved by switching to energy sources or materials that emit less carbon, often from high carbon-emitting fossil fuels and by counteracting any carbon that is emitted. Keeping global warming to 1.5°C above preindustrial levels by limiting the buildup of atmospheric GHGs will be necessary to prevent permanent warming of the planet and catastrophic consequences. Those efforts are referred to as decarbonisation. Many companies, countries, and organisations have pledged to decarbonise, or to make the net-zero transition, in the coming years. The power, oil and gas, and transport industries are frequently cited as the biggest emitters, but all industries need to work toward decarbonisation to achieve net zero. Getting to net zero is most significant […]

Women in Business: Peri Drysdale

Tell readers what you do? I am the Founder/CEO of Untouched World Ltd, established in 1981 ( formerly called Snowy Peak Ltd). We are a sustainability focussed lifestyle company, we manufacture here in NZ (mostly in Christchurch); we design, develop, produce mainly knitwear but also woven clothing. We wholesale in NZ and Australia and in lesser amounts to seven countries around the world, sell online globally reaching over 49 countries, and have our own retail concept stores in NZ for the Untouched World brand. We also have our own café attached to the flagship store in Christchurch which has won best CHCH café for the last two years. We have the Merinomink brand too which is wholesale only. We are acknowledged for founding the highly successful possum merino industry in NZ. We won the Common Objective best global Sustainable Fashion Brand award this year ( there are 650,000 C.O. member brands worldwide) – ahead of Stella McCartney and Gucci who were also in the finals. We were the first fashion company in the world to be acknowledged by the UN for sustainability and invited to put the UNDESD logo in our clothing for the duration of the Decade for Sustainable Development. A lot of our materials for our knitwear, all natural fibres, come from within New Zealand, we buy most of our finest merino direct from Glenthorne Station in Canterbury. I also Chair the Untouched World Foundation which since 2002 concepts and runs Leadership for a Sustainable Future Programmes for Young Adults. We have now put 3000 students through these groundbreaking programmes. What other companies have you been involved with? I have been in this company since setting it up as a cottage industry in 1981. How are you finding current business conditions? 2023 has been a softer year for us and our […]

Navigating energy intensity and energy efficiency in manufacturing

-By Insa Errey In advanced manufacturing, the concepts of energy intensity and energy efficiency play crucial roles in influencing both operational costs and emissions profile. While both terms are interconnected, they represent distinct parts of energy management. Understanding these dynamics is crucial as businesses seek to balance production demands with the imperative of sustainable energy use. Energy Intensity in Manufacturing: A Measure of Production Impact Energy intensity is a measure of the energy consumed per unit of output, such as the energy required to produce a certain quantity of goods. Typically expressed in terms of energy units per unit of physical output. Energy intensity provides insight into the overall energy consumption patterns within a manufacturing facility. High energy intensity in manufacturing suggests that significant energy resources are being used to manufacture a product. High energy intensive processes may use a disproportionate amount of energy to achieve their production goals, signalling inefficiencies that can impact both costs and emissions. On the other hand, low energy intensity indicates a more efficient use of energy resources. Trending this even monthly will enable visibility of process operations, signalling if processes are running differently and have shifted. Energy Efficiency: Improving Manufacturing Practices Energy efficiency, on the other hand, focuses on optimising the utilisation of energy inputs to maximise output. It is the ratio of useful energy out to the total energy in. In manufacturing, energy efficiency measures the effectiveness of processes in converting energy resources into final products, emphasizing the opportunities to reduce loss and waste. Energy efficiency in manufacturing involves optimising processes and technologies to minimise energy consumption while maintaining or enhancing productivity. Improving energy efficiency in this context includes adopting advanced machinery, implementing effective energy management systems, and embracing best practices. Often invest is required such as conducting energy audits, energy transition plans […]

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