Smart Manufacturing Today

A powerful recipe for innovation & growth

Greg Balla, CEO, Aofrio. Adding software to hardware – AoFrio is a New Zealand technology leader that few local people know about. With deep manufacturing and hardware roots, the company has decades of experience supporting food and beverage companies around the world with their refrigeration. Now, the business has innovated beyond hardware and invented the world’s first Internet of Things (IoT) platform for commercial refrigeration. The combinations of hardware, like motors and fans, and smart IoT-enabled refrigeration controllers and sensors help customers sell more products, save costs, track assets, gain insights to do business better and save on energy and carbon emissions. AoFrio is growing into a hardware-enabled, software as a service (SaaS) provider. It’s their pathway to lifting recurring revenue (because they sell their solution ongoing to customers), to expanding in existing markets and exploring new regions around the world. But the path to getting there has been long and not without its challenges. In the words of Greg Balla, CEO of AoFrio: From where I sit now, it’s easy to see a future where hundreds of millions of refrigerators around the world are connected to AoFrio’s platforms, giving us data to drive powerful, purposeful outcomes for customers. But there are many moments in AoFrio’s history that plotted the way to becoming the company we are today. We’re now in the position where we can couple our hardware abilities with software and data-driven insights to give clear customer insights and actions that are impactful to their bottom line. One of the turning points for us is around 2012. The company was tired of purely competing on price. Deciding instead to design the best refrigeration motor in the world. We set a goal that our electronically controlled motor would be better than the competition in every single respect. Most […]

How to successfully deliver your CRM project with Clarity, Simplicity and Certainty

This is the 2nd in a series of 6 articles looking at how to successfully deliver your CRM project. The full series contains: The purpose of the Architecture is to help teams develop the technical capability on time and on budget whilst ensuring it solves the problem for which it was designed. The Architecture will build on the very high-level view purported in the Charter and will contain: Concepts – A conceptual view of the stack and its moving parts for communication and context Option Analysis – Platforms, Languages and Tools in light of the functional and non-functional requirements. High Level Design – Features, phases and solution requirements at a Function level Detailed Design – More definition around areas of complexity Non-functional requirements including – Security, Performance, Maintainability, Scalability, Reliability, Usability and Risk The expected outcome is that both the business and technical requirements have been incorporated into a Solution. Specific technologies may be selected, short listed or used as examples as the Architecture develops over time. The Architecture is neither a Process Diagram nor the detailed User Requirements, which will be developed in the next phase of the project. 3 x Critical Success Factors These are CSFs for the Architecture, not the Project: Match the Solution to the Business Environment This is important in all major technology solutions but even more so with CRM deployments due to its role in supporting all customer facing interactions and integrating to all other teams. The Architecture must take a strategic view of the specific functional requirements and then the significance and importance of potential reliance’s on and impacts to other teams and their processes Desire vs Reality The simple approach of Why, What and How (Before When & Who) will assist in addressing this challenge: Why: The justification of the need for […]

igus unveils world’s first urban bike made from recycled plastic

No maintenance, no corrosion- the igus:bike sets new standards in sustainable mobility With its expertise in plastics for movement, Treotham is making the concept and components available to all bicycle manufacturers on the new igus:bike platform. The first model should be available by the end of the year. The world is drowning in plastic waste. The huge piles in landfill sites are growing fast. Some of this plastic ends up in the ocean, enters the food chain, and becomes a danger to marine, animal and human life. Therefore it is most urgent to move away from the traditional linear economic model and migrate to a fully circular economy. To help this transformation, igus the motion plastics specialist has been developing and investing in ideas for recycling plastics for many years. The company recently presented a world first: The concept of a robust, durable urban bike made entirely of plastic, from frame to bearings to toothed belt. One special feature of this new bike is that the recycled version will be primarily made of reused plastics originally “single use”. “The plastic in rubbish dumps around the world is becoming a valuable resource,” explains Frank Blase, igus CEO. He first had the idea of a bicycle, now known as the “igus:bike”, on a beach while on holiday. In conversations with employees of a bicycle rental company on the beach, he found out about their major problems with beach bikes. These were continuously exposed to sand, wind and saltwater and sometimes only lasted three months before they had to be replaced. Maintenance and replacement are often expensive and time-consuming in this industry. “The igus:bike does not rust.” The igus:bike is easier to own than any other bike. Owners can leave the single-speed bike outdoors in all weather and clean it in seconds with […]

Are you still using Manual Time Sheets to record Staff time on Jobs?

The manual time sheet system for tracking staff time on jobs has been used by NZ manufacturers for over 100 years without change and without improvement. Manual time sheet reporting provides production information “too little, too late, too inaccurate and too expensive”. For example for a workshop of 10 staff the cost of manual time sheets is lost production time and administration time of $800 per week, therefore $40,000 per year. For a 20 workshop staff manufacturer the costs are $1,600 per week and $80,000 per year. By comparison, the technology of touchscreens on the workshop floor and a Labour Tracking and Management Software App subscription cost is substantially less than the cost of manual time sheets. Such Apps have 200+ screens and reports in real time and accurate production information, accurate individual staff times and job times, presented continuously throughout the day on 50 inch TV monitors in the office and on the workshop floor. If, as a NZ manufacturer with 10 workshop staff, you stopped using a 100 year old inaccurate manual system and instead used accurate new technology of touchscreens and TVs on workshop floor and the production App, you would save in excess of $650 per week and save $32,500 per year. One good Labour Management Software App option developed specifically for jobbing manufacturers and engineers involved in custom, bespoke and “one off” manufacturing is www.empowersoftware.co.nz – you will see a 20 year and 240 manufacturing clients’ track record of securing 20% to 40%+ reduction in labour times on Jobs and 20% to 40%+ reduction of labour cost on Jobs. This on a 10 workshop staff manufacturing site is 80 additional production hours per week and $6,400 additional revenue per week.

Cosmed Group – a byword for innovation, efficiency, quality and respect

For Cosmed Group, the upheaval of the last two years has been unexpectedly good for business. Based in East Tāmaki, it’s the leading New Zealand-owned contract manufacturer (OEM and ODM) for the skincare, cosmeceutical, cosmetic, baby care, hair care, pet care and personal care industries. Co-founder, Dr Olga Garkavenko, says the pandemic came into this world unexpectedly and changed the way society operates. “This has caused a lot of businesses to rethink their strategy. Not only are the established successful brands switching to us, but there’s also many new players too,” she says. Dr Garkavenko’s core strength is in Biotechnology R&D, but she says it is a team effort all round. “I’m proud of all of our dedicated and enthusiastic team members. We have more than 100 years of combined experience across all the services. “This includes Cosmetic Science Research, Ingredient R&D, Business Management, Quality Management, Environment Management, GMP Production, Cosmetic Care, Personal Care, Health Products, Consumer Products, Supply Chain, Engineering and Customer Services”. Who and what About eight out of ten of Cosmed’s clients are based in New Zealand. Most of these clients want help in developing formulation of their own brand, ensuring quality across each stage of the process. Cosmed Group creates a unique business package for each client, including VI Design, packaging solutions, product IP issues and registration. Sustainability and ethical sourcing A big selling point for Cosmed’s products are that they are made in New Zealand which has a good reputation overseas for its natural and sustainable products. The demand for natural ingredients in cosmetics is on the rise globally, and environmental issues are growing in importance, making sustainability, ethical sourcing and their related labelling schemes more prominent. Changes in consumer behaviour and lifestyles are also creating openings for natural ingredients. Cosmed Group is BioGro NZ […]

Southland businesses benefiting from investment in technology

Businesses from Southland to as far afield as Canterbury are benefiting from a new computer numerical control (CNC) laser cutter investment from Southland firm MPE Limited, the first of its kind in the region. MPE Managing Director, Chris Hughes, said offering this technological capability had been highly sought after given the current pressures on labour and the continued focus on increased productivity currently experienced by southern manufacturing industries. “We’re helping our customers where we can, by taking the manual work out of specific jobs that can sometimes take days or weeks to complete. The automated function of the laser saves time and money, leaving the staff to utilise their time and skills more efficiently to add real value elsewhere in our clients’ businesses,” he said. Not only is the new machinery the single largest investment MPE has seen in decades, it is also an investment for the general industry in the lower to mid-South Island, offering customers a new, intelligent automated option for their steel processing and engineering needs. Chris said there were several machines that cut flat plate and used similar technology, but no machines in Southland that could do this to various profiles of sections other than plate. The design software converts 3D files into a code format for the machine and then the computer’s numerical control process takes over and produces high precision parts at speed which are more efficient than traditional methods, thus saving time and resources. Not only does it cut steel sections, but it was also designed and manufactured to be able to cut through a range of different profile sections in various steel, stainless steel, aluminium, brass and other material types. Chris said that MPE had further integrated into their clients’ supply chain by performing this type of work which has allowed their […]

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Endeavour Fund awards more than $10m to HERA to build world-leading construction sector

HERA, the heavy engineering research association, has been successful in the 2022 round of the prestigious Endeavour Fund, which supports important scientific research projects seeking to address some of our biggest challenges. HERA has been awarded a grant of close to $10.3 million to support a four-year research project focused on transforming the construction sector in Aotearoa New Zealand using Construction 4.0 approaches. Fundamentally, it will improve productivity for the construction sector more broadly, with key outcomes including better economic performance, building and infrastructure affordability, and a larger workforce which is more skilled, innovative, and digitally literate. HERA CEO Troy Coyle says, “Our research team is both excited and thankful that the Science Board, assessors and the Minister of Research, Science and Innovation appreciate the significant contribution this project will make to the sector and New Zealand economy. “This programme not only addresses key challenges identified by our members and wider industry, but will be world-leading in creating data-driven decision-making for the future of construction. “Currently there is a profound limitation in the way we perform construction in Aotearoa New Zealand. Complex decisions are being made based on simple data inputs and in linear silos with little inter-connection or data-derived decision support. “This project will improve design to construction (and beyond) by bringing together industry and a team of global experts rigorously vetted, who will use complexity science to build upon developing nascent global Construction 4.0 knowledge. “We also recognise the Science Board’s focus on Vision Mātauranga as it is something that aligns strongly to our own commitment in this space. We see this as an opportunity to bring a more holistic approach to the key components of the program of Industry 4.0, sustainability and mātauranga Māori. Our linkages internationally, to industry, and to existing research programmes will ensure project […]

To Trace or not to Trace, that is the question

EMA As our Smart Factory Showcase continues building momentum in the Industry 4.0, manufacturing and technology space, it’s time to share some insights into what we’ll be covering. Each showcase covers several key areas of operation at Nautech Electronics. These include sales and planning, systems, connectivity, research and development, production, testing, facilities, smart business models and implementation strategies. Industry 4.0 and the showcase are all about highlighting how a range of digital technologies enhance manufacturing performance, output, monitoring and control, keeping businesses globally competitive. Today, we’ll look at all things Traceability and help you decide whether implementing a traceability system might work to keep your business globally competitive. What is Traceability? In manufacturing, Traceability, or “Trace” and “Ability”, is the process of gathering and managing data related to your manufacturing processes. It allows you to effectively track all parts and products involved in manufacturing operations including history, location, status. It provides visibility and transparency from the moment raw materials enter your factory through to tracking your final products as they are exported, sold or shipped. Traceability systems use technologies such as QR codes, barcodes, sensors, IoT (internet of things), RFID (radio frequency identification) to trace the products or parts and relay the information back to a centralised system. There are two perspectives when it comes to product traceability, these include: Chain traceability This is forward and backward product traceability – This means that manufacturers can easily track products from raw material to the distributor, which ensures the distributors or consumers can understand where the product came from. In some sectors such as food and beverage, it is a requirement to trace at least one step forward and one step backwards in the supply chain. Internal traceability This is about monitoring the movement of parts and products within a limited […]

NanoLayr’s sustainability roadmap charts the way

Article from Dr.Barbara Nebel,CEO, thinkstep-anz www.thinkstep-anz.com Want to make your manufacturing business more environmentally and socially sustainable? When you’re a busy manufacturer, investing in a sustainability roadmap can be the difference between talking about sustainability and making it happen. In this article we explain what a sustainability roadmap is and why your business needs one. We also talk with Auckland-based functional textile manufacturer NanoLayr about the benefits it’s seeing from theirs. What is a sustainability roadmap? A sustainability roadmap charts the course your business plans to take to become more environmentally and socially sustainable. Think of it like a Google map. Plug in your destination (a more sustainable manufacturing business) and Google offers up a host of ideas to help you with your journey. Street names and directions? These are the high-level sustainability actions you need to take to reach your destination. In a manufacturing business they may include sourcing renewable materials or tackling waste in your packaging. Alternative routes? Think of these as your options and trade-offs. There are many ways to become more sustainable. You’ll need to assess different projects and prioritise them. Distances and different modes of transport? These are the resources you’ll need to commit and the people you’ll need to involve: team members with clear responsibilities, external stakeholders such as suppliers, and (probably) some budget. Journey times? They’re the high-level timelines you’ll work to. Map your sustainability actions into blocks of time. You may be able to complete some within six months to a year. Other activities will take longer. Assign them over the medium term (say one to two years) and longer term (say two years plus). Bring this ‘journey’ information together and you have your sustainability roadmap: a summary of your sustainability goals and the projects, resources and timetable that will help […]

How to successfully deliver your CRM project with Clarity, Simplicity and Certainty.

-Scott Fuller, Exception. Article 1 :: Project Charter – Universal Buy-in This is the first in a series of 6 articles looking at how to successfully deliver your CRM project, the rest of the series will look at: Architecture and Integration – The Big Picture Partner Selection – A Vendor vs A Partner Data; Data; Data – The Devil is in the Detail Project Management – Quality, On Time, On Budget Users, Usability and Usage – First, Last and Always The purpose of the Project Charter is to engage all interested and/or potentially affected parties, solicit feedback and gain a mandate to move to the next phase. It is a Pre-liminary Business Case, a succinct document preferably with an equally succinct presentation containing: Purpose: Definition and those Responsible Benefit: Objectives and KPIs, including indication of costs Resources: Key Players and Roles (RASCI Model), including external parties if known Architecture: Technology added, impacted or replaced Scope: Deliverables and Key Milestones The expected outcome is that everyone in the business is at least informed of the project scope and impact and those Responsible for the Delivery and Accountable for the Benefits are ready to drive the Project to its successful conclusion. The introduction of this Project ‘Vision’ gives many parts of the business an opportunity to participate in its inception and contribute to the direction. It should always be a 2-way engagement to create valuable buy-in and support. 3 x Critical Success Factors These are CSF’s for the Charter, not the Project: Multi-level and multi-functional buy in At the initiation of any project it is easy, and safer, to confine the visibility to the immediate user group and line management. However a customer management solution to be successful will require the commitment of all parts of the organisation, from Board to Basement, […]

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