Smart Manufacturing Today

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 […]

Automation in today’s economy

With labour shortages forecast to continue and predictions that up to 30% of the workforce may have to isolate in the coming months, businesses are increasingly looking to automation as a solution to reduce the impact of a tightening labour market. Over the last 18 months businesses have been grappling with a severe labour shortage, with unemployment dropping to 3.2 percent earlier this month, the lowest level on record. Caleb Nicolson, TMX’s New Zealand General Manager, says “the number of enquiries about automation have increased significantly across both our New Zealand and Australian businesses as organisations look for solutions to staff shortages. “Businesses are facing inflation, high wage costs, closed borders and now, the reality that staff may have to isolate for long periods of time over the next few months. Automation is increasingly being seen as a way to reduce the impact of these external factors.” “More businesses see automation as a way to increase efficiency and reduce their reliance on a shaky labour market – that trend is accelerating in a covid environment. Businesses are recognising that incorporating automation can also help protect their people and customers by freeing up space and reducing staff contact in warehouses,” says Caleb. He states that while traditionally automation was the domain of large corporates, there is now increased interest from small to medium sized businesses who are able to access automation at a lower price point. “Small to medium businesses are also the ones who are hit hardest by labour shortages and increased labour costs, so for them, an investment in automation is one which can pay dividends long term. “Automation doesn’t always have to be on a grand scale. There are a range of solutions available, from simple technology such as leveraging your existing WMS with pick and putwall processes, […]

RS Components webinar introduces new ranges to reduce MRO spend

Financial efficiency and saving time were the focus of the recent RS PRO Webinar held in late 2021, which attracted attendees from across the Asia Pacific. During the webinar, attendees were introduced to key RS PRO ranges and service offerings, including some of the recent range additions across Hand Tools, Sensors & Connectors, Automation & Control and Facilities Maintenance products. Decisions have consequences. And because every decision matters, every part matters. That’s why RS PRO offers an ever-expanding choice of over 60,000 quality-tested products engineered for demanding manufacturing and industrial environments. Scott Philbrook, Managing Director of RS Components ANZ said the webinar was a great success, showcasing our huge portfolio of quality-tested products for a range of industries and working environments. “With huge local stock holding of the RS PRO range across Asia Pacific you can get the products you need, when you need them.” He explained. “This webinar showcased our ever-growing range of RS PRO products, outlined the potential applications and gave us the ability to answer questions directly from industry participants.” Scott Philbrook said. The RS PRO range offers customers a choice where the combination of quality, performance and price create exceptional value. The range of more than 60,000 high-quality, competitively priced industrial products and electronic components can be as much as 30% on branded alternatives. To ensure customers have complete confidence in the RS PRO offering, all products and components are backed by the RS Seal of Approval, representing leading industry standards for audit, inspection, test and certification. “Our local portfolio has recently seen significant increase with thousands of new product lines added to complement our existing RS PRO offering. The expansion in the range is meeting demand in the Australian market for affordable options for engineers looking for choice” says Scott Philbrook, Managing Director of RS […]

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.

EMEX 2022

The long awaited EMEX 2022 expo runs from 31 May to 2 June 2022. With 200+ exhibitors already booked and many visitors expected, the show is looking to be one of the busiest to date. EMEX brings together the technological advancements over the past four years, including applications of the Internet of Things and an exceptional line-up of speakers, show features, new products and new suppliers. Exhibitors at the show include those specialising in Additive Manufacturing; (CNC) Machine Technology; Control and Instrumentation; Health and Safety; Industrial Automation; Industrial Engineering and Maintenance; Industry 4.0 and IoT Applications; Robotics; Tooling; and Welding, Forming and Cutting. Over the years EMEX has worked hard to deliver the best line-up of speakers, presenting on up-to-the-minute topics and 2022 will be no exception. Day 1 starts off with the hot topic, 3D printing, and EMEX presenters bring a range of information on leading edge additives and metal componentry. On Day 2 a stellar line-up of speakers and topics powered by Callaghan Innovation will frame up “what is Industry 4.0?” and how this set of advanced and connected technologies can help a business secure a bright future. Day 3 is all about innovation and how New Zealand companies succeed by doing things differently. With over 40 years hosting EMEX, the team at XPO Exhibitions are looking forward to reuniting the thousands of people in the engineering, manufacturing technology and electronics sectors. Many professionals in the industry won’t have seen each other for three to four years and the opportunity to catch-up with colleagues and technology makes this the most anticipated show ever. NZ Manufacturer has again partnered again with EMEX and you can expect to hear more about the up-and-coming show over the coming months. For those looking to exhibit, limited space is available by contacting Aad […]

Your 2022 sustainability workout programme!

-thinkstep anz Is your business feeling carbon-heavy? Are your waste bins bulging? Is your product a bit out-of-shape? Then a sustainability tune-up’s in order! Here’s our four-step sustainability workout programme to help your business trim down, tone up, and stay in shape in 2022. (And if you already have a sustainability programme, early in the year is a great time to review it.) The good news: this programme is a business plan. So, while your efforts will help sustain the planet and its people, your business will be fitter too. You’ll spot opportunities for your products, uncover risks in your processes, and strengthen relationships with your team, customers, and suppliers. And you’ll become known as a manufacturer who’s doing the right thing. Let’s get started. Step one: build a plan Every sustainability programme needs a plan. Decide what ‘sustainability’ means for your business. The UN Sustainable Development Goals (SDGs) are a good place to start. These 17 inter-related goals form an urgent ‘call to action’ for companies to protect the environment, tackle climate change, and improve people’s lives. The good news? All these actions help businesses like yours get ahead too. You can’t tackle all 17 goals and you shouldn’t try. Instead, choose four or five SDGs that are relevant to your business: where can you have the greatest impact? Here are some SDGs which fellow manufacturers have chosen. Fisher & Paykel Healthcare has picked SDG 3 (Good Health and Wellbeing) as one of their goals. It’s relevant to their customers and their team. Seafood company Sanford is using SDG 14 (Life Below Water) as one of their goals, to focus their sustainability work. Trans-Tasman manufacturer Eagle Lighting has made SDG 12 (Responsible Production and Consumption) a priority goal. Focus on what matters. Identify your main stakeholders, like your team, […]

The Interview: Mike Hendry, chief digital officer, Steel & Tube

HERA member, Steel & Tube is one of the oldest and largest providers of steel products and solutions in New Zealand. It sources, processes and distributes steel products to customers across New Zealand through its national network and also makes steel products to order on a project basis. The company has expertise across a broad range of sectors, from residential to commercial construction, large infrastructure products, manufacturing, rural and bespoke design. HERA spoke to Chief Digital Officer, Mike Hendry, about the future of the steel and construction sectors and the opportunity and challenges the company faces. How are you finding current business conditions? While demand growth for steel has been strong, macro conditions have been challenging with global supply chain constraints, a higher pricing environment and Covid-19 lockdowns and restrictions. The key focus for our team has been to maintain availability of product and high levels of service for our customers while navigating the current market conditions. We have seen strong growth in demand over the past year across a range of sectors and are fortunate to have a significant pipeline of secured contract work in place across the country. The residential construction market remains strong, particularly in Auckland, and government investment is driving large infrastructure projects across the regions. Commercial construction activity has been increasing and manufacturing expanding which is also driving up demand for steel products and solutions. Market conditions look to remain positive. How has your company been impacted by the pandemic? Our scale, diversity across a range of sectors and the ability of our team to adapt to new working conditions have helped to offset the impacts of the pandemic and the current challenging market conditions. We are very proud of our team and their efforts which have ensured we can keep providing our customers with […]

Foster productivity growth for a strong recovery and better living standards

Strong government support to protect jobs and incomes in the face of the pandemic helped New Zealand recover rapidly from the severe Covid-19-induced downturn, but challenges remain to set the economy on a sustainable growth path, according to a new OECD report. The unemployment rate fell to its lowest level since 2007 while the employment rate rose to its highest level on record in the third quarter of 2021. However, inflation and house prices have picked up significantly and both household and government debt have increased. The latest OECD Economic Survey of New Zealand recommends that fiscal policy be adjusted in the near term to help stabilise the economy. Boosting productivity, particularly by making better use of digital technologies, would support further increases in living standards. Economic growth is expected to slow as capacity constraints bite and macroeconomic policies are tightened. Consumption growth is also expected to ease to a more sustainable pace as employment growth slows. After surging to 4.7% in 2021, New Zealand’s GDP is expected to rise by 3.8% this year before easing to 2.5% growth in 2023. “The near-term economic outlook is positive. The New Zealand economy has recovered strongly from the pandemic. The need for policy action is pressing in a number of areas to make economic growth sustainable. For instance, helping the digital sector to grow would help boost labour productivity.” OECD Secretary-General Mathias Cormann said, presenting the Survey alongside Finance Minister and Deputy Prime Minister Grant Robertson and Minister for the Digital Economy and Communications David Clark. “Linking pension eligibility to life expectancy and adopting long-term debt-to-GDP targets would help address the projected increase in government debt.” With affordability for first homebuyers at low levels and a buoyant housing market, it is important for the government to complete reforms to increase housing supply and […]

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 & […]

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