Smart Manufacturing Today

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 […]

Adoption of Industry 4.0 paves the way for growth in manufacturing

by Dr Troy Coyle, CEO, HERA Our world is changing. Climate change and pandemics have garnered much attention but there is another revolution underway. One that is likely to change the very fabric of the way we live and work. It is called Industry 4.0 and is the next stage of the industrial revolution. In 1794, the industrial revolution forever changed manufacturing with the introduction of the mechanical loom. Things changed fast. A mere hundred years later the first production line enabled mass production. Jump forward another hundred years and we witnessed the birth of industrial robots, that together with advances in electronics and IT have automated much of the manufacturing process. Today, we are entering a new age – Industry 4.0 – the age of cyber-physical systems; the marriage of physical production, and smart digital technology. It is not sci-fi. It is not the realm of filmmakers and futurists. Change is happening now and promises to transform industry as much, if not more so than, the introduction of water, steam, and electricity did in the past. What is Industry 4.0? In essence, Industry 4.0 enables companies to have better control and understanding of their business. The new technologies save time, boost productivity, and reduce waste. A panacea for considerable and sustainable growth. A quick search of the internet will provide you with a mountain of anachronisms – IoT, IIoT, CPS, AI, Big Data – to explain Industry 4.0. It is a catch-all term that encompasses all the technologies that enable businesses to collect and analyse data to help automate and streamline their systems and processes. It promises faster response times, increased efficiency and profits, and better quality products at a lower cost. Impact of new technology HERA’s latest report in collaboration with BERL, ‘Modelling the potential economic impacts of […]

EECA building energy use picture amongst NZ food and beverage businesses

The Energy Efficiency and Conservation Authority (EECA) is building a picture of energy use in the NZ Food and Beverage sector (not including dairy, meat and seafood). Importantly, the findings of this project will help EECA to design effective programmes to support energy efficiency and decarbonisation for the Food and Beverage sector. To participate in the study – a simple survey, which is due in by the end of October – should take 15-20 minutes and can be completed online at: https://www.surveymonkey.com/r/MTPVXPP

What is Speedglas Generation 5?

Generation 5 is the latest collection of Speedglas welding helmets that showcase a truly groundbreaking array of never-before-seen features. Each helmet is designed from inception to be uniquely tailored to a specific application, from heavy-duty welding in hard-wearing environments to critical precision TIG work. However, this is not to say these helmets are rigid in their capabilities. On the contrary, the Generation 5 series has been built on the premise that any high-performance welding helmet should be fully customisable to the preferences of each individual welder. The result, after extensive input from professional welders, is an elite welding helmet range that manages to be both highly specialised and versatile in equal measure. Speedglas G5-02: a new world standard in precision viewing As with past 3M Speedglas designs, the concept for the Speedglas G5-02 Welding Helmet originated from consulting professional welders. When it came to creating a helmet specifically for TIG welding, the feedback from TIG welders was unanimous: a wide view rated significantly higher than a taller view. The only way to achieve these exponentially wider views without the compromise of making the helmet wider was to invent a curved welding lens: and now, after dedicating two decades to this goal, Speedglas have delivered the world’s first curved auto-darkening lens! This groundbreaking new arrival has been designed to follow the shape of your head and maximise your natural range of vision by 100% when compared to a conventional flat lens. The curved G5-02 lens also provides highly advanced electronics, with four arc sensors that will detect an arc down to an industry-leading 1 Amp. This in turn ensures the lens can reliably react to the extremely stable arcs offered by the latest high-end inverter based TIG machines. Bluetooth enabled, so you can securely pair your smartphone to your welding lens […]

igus heavy-duty rol e-chain for maximum service life

The new generations of cranes demand increasingly more from energy supply systems. Now an energy chain meets precisely these requirements for longer travels, higher accelerations and speeds as well as reliability. The new heavy-duty P4HD rol e-chain from Treotham is made of highly abrasion-resistant materials. Special side parts, newly designed joining links, roller links as well as a triple stop-dog system minimise wear and reduce the drive energy even further. All parts can be replaced in case of maintenance. To monitor the service life, smart plastics sensors can be integrated into the pin/bore connection. They are getting faster, longer and have to carry heavier fill weights: the energy chains in the new generations of ship-to-shore cranes. “Especially for these emerging trends in the world of cranes, we have already developed a new rol e-chain with the longest service life”, says Jörg Ottersbach, e-chains Business Unit Manager at igus GmbH. This is why igus has launched a heavy-duty version based on its P4 rol e-chain range. The chain is said to have a service life – depending on the application – of up to 15 years. For this purpose, igus relies on tribologically optimised high-performance polymers. In order to further reduce abrasion at all points of the chain, igus has come up with a few design refinements. Amongst other things, a triple stop-dog system and a symmetrical design. The integrated rollers reduce the required drive energy by 57 per cent compared to a gliding chain. The rollers run on top of each other in a staggered manner. The comb-like autoglide crossbars keep the chain in its track, increasing the safety of the system and reducing costly unplanned downtime. In the new pin/bore connection, igus uses its expertise from polymer plain bearing technology and relies on a proven iglidur material, which also […]

Blank conveyors on a blurred factory background. 3d illustration

Automation rises due to worker shortage

Faced with a growing shortage of workers, many business owners in New Zealand are looking towards automation, something of an irony after years of concern about the risks of structural unemployment. The national labour shortage looms as the most significant risk to our booming manufacturing sector. The latest Bank of New Zealand Performance Manufacturing Index (PMI) for July increased to 62.6, the second highest recorded, but also cited labour issues as the primary concern to industry players. Caleb Nicolson, General Manager of TMX New Zealand – Asia-Pacific’s leading business transformation consultancy – says the combination of a local worker shortage, an inability to bring in seasonal migrants during peak season, and increasing labour costs in New Zealand were making the business case for supply chain automation more attractive to a broader group of businesses. “These types of facilities are common-place overseas, in the US for example approximately 70% of new major warehouses are automated. New Zealand has been relatively slow to take up these smart technologies, until now. The labour shortages are challenging businesses to look differently at their supply chains and we’re now seeing even smaller companies starting to investigate automation, despite the relatively high upfront investment cost.” Many local businesses are looking at automating operations to create high speed, low-cost and higher capacity operations. COVID has undoubtably amplified the requirement to deliver operations with less human contact, automation provides a logical way to reduce this risk to your business model says Nicolson. To ensure businesses move with the times, Nicolson urges them to consider getting independent advice in relation to automation and make it a priority to consider the different software solutions and automation options that are available. Similarly, seeking advice on the procurement and implementation process can make a huge difference to business productivity. TMX has been […]

RMIT welcome RS Components as racing partners

RS Components are proud to announce their support of the RMIT Electric racing team in the legendary Formula SAE competition this year. Originally started by the Society of Automotive Engineers student branch at the University of Texas, Austin, in 1980, the Formula SAE competition now sees over 500 teams from universities worldwide, design, build and compete in their own Formula-style open-wheeled race car. The vehicles are judged on dynamics, design justifications, costing strategies and business presentation and apply rigorous STEM concepts to the build and design process. As the brightest young minds compete annually around the globe, the boundaries of innovation, technology and engineering are constantly redefined. The RMIT Electric Racing team took the competition to the next level in 2008, and entered the first-ever electric vehicle. They were confident they could produce a simple, electric counterpart for the combustion vehicle competition. Every year since, Formula SAE has seen a rapid growth in the number, competitiveness and performance of electric vehicles against their combustion rivals. A fact the RMIT Electric Racing team are infinitely proud of. Managing Director of RS Components ANZ Scott Philbrook said, “We are proud to support the next generation of innovators with the quality products RS Components has to offer. The team and I at RS wish these bright minds the best of luck in this year’s race.” Today the team counts over 50 passionate students across a dozen faculties who demonstrate innovative thinking, initiative and commitment to the real-life commercial project. And it’s little wonder the Formula SAE graduates are often headhunted for their unique combination of technical skills, strong communication abilities and project management skills. Christopher Carr, Business System Head for RMIT Electric Racing said, “Our project is dependent on the valuable investment by our sponsors who allow us to advance the research and […]

WRONZ launches Wool Source

Wool Research Organisation of New Zealand Inc (WRONZ) has announced its world-class research initiative with the Ministry of Business, Innovation and Employment (MBIE) to explore new uses for New Zealand’s strong wool has led to the development of unique wool particles, powders and pigments with global export potential for applications as diverse as cosmetics, printing, luxury goods and personal care. WRONZ unveiled the innovative wool products at an event to celebrate the achievements from its New Uses for Strong Wool programme, supported by research, industry and funding partners. WRONZ also announced the launch of commercial development company Wool Source to develop the new products and assess market demand for the strong wool innovation. WRONZ further announced the completion of its pilot production facility to manufacture its first deconstructed wool ingredients from 100 per cent biodegradable, renewable and sustainable New Zealand strong wool. The launch event also provided the opportunity to announce investment from the Ministry for Primary Industries to fund further product lines and commercial development as part of the wider New Uses for Strong Wool programme. MPI is contributing $1.95 million via its Sustainable Food and Fibre Futures (SFF Futures) fund alongside $2.92 million from WRONZ. The three-year programme aims to prove the commercial viability of the new deconstructed wool particle products. The goal is to develop more sustainable product ingredient alternatives for global manufacturers and consumers – while revitalising New Zealand’s strong wool sector, creating new value for our economy and communities. Additionally, The Strong Wool Action Group (SWAG) announced it was jointly funding Wool Source’s market engagement alongside WRONZ. SWAG chief executive Andy Caughey says, “We’re providing support for Wool Source to undertake a deep dive project into particles, powders and pigments markets to assess the scale and viability of the commercial opportunity. “New Zealand’s wool […]

Lubrication-free igus spherical balls from Treotham

In the picture:The lubrication-free and cost-effective solution: igubal spherical balls made of maintenance-free high-performance plastics in low-cost sheet metal housings replace metal bearings. Heavy dirt accumulation, dust and swarf are commonplace for pillow blocks and fixed flange bearings. Constant lubrication and maintenance is therefore necessary. With the injection-moulded igus spherical balls, customers can resort to a lubrication-free and maintenance-free solution for their metallic pillow blocks. igus has now developed new spherical balls made of the high-performance plastic iglidur J, specifically for cost-effective sheet metal housings. Metal and lubrication are found close together in mechanical engineering. igus proves that this does not always have to be the case. The motion plastics specialist has developed its igubal exchangeable spherical balls especially for pillow blocks and fixed flange bearings with metallic housings. These consist of the high-performance polymer iglidur J, which reduces costs since lubrication and maintenance are eliminated. The use of polymers prevents dirt and dust from settling in the bearing, which additionally reduces the sealing and prevents an unplanned machine downtime. The use of exchange bearings is also suitable in agriculture and farming, in the food industry or in plant and mechanical engineering. The igubal spherical balls come directly from injection moulding and are therefore cost-effective. Within a few seconds, they can be mounted in place of ball bearings in existing classic metallic pillow blocks and flange bearing housings and now also in low-cost sheet metal housings. The bearing system consisting of sheet metal housing and igubal spherical ball is available from Treotham. The plastic spherical ball has a high durability and its service life can be easily calculated online. Lubrication-free operation thanks to iglidur J The spherical balls made of iglidur J are not only cost-effective, but also have a very low coefficient of friction in dry operation. The […]

Inflation pressure triggers uncertainty and volatility for manufacturing sector

-Rebecca Reed Rapidly rising costs for businesses, a lack of skilled and unskilled workers, increasing inflation and shipping delays are putting huge pressure on New Zealand’s business environment and the consumer is about to feel it. The latest Hutt Valley Chamber of Commerce Business Confidence Survey found inflationary pressure is increasing and between a third and a half of all businesses are expecting to increase their prices in the next 3 to 12 months. It also found more than half of all businesses are expecting increased costs, yet less than 25% are expecting increasing profitability. Covid-19 economic impacts, growing concern around government policy and labour shortages are holding businesses back nationally. The survey shows labour shortages as the single biggest barrier to business for more than 60% of businesses. This is at unprecedented levels. “The business environment continues to be increasingly difficult – while the economy has rebounded strongly and demand continues to be strong, the ability for firms to deliver is fraught with a wide range of risks and cost increases. “These cost increases and risks are more widespread across business type and size as all companies try to adapt to the rapidly changing business environment,” said Helen Down, Chief Executive of Hutt Valley Chamber of Commerce. Down says she is hearing from businesses unable to commit to fixed prices or a delivery timeline due to the totally uncertain environment. “This time last year our survey found business owners were experiencing small increases in costs and holding prices but now costs are increasing rapidly, and the consumer is only just starting to feel it. The situation is set to deteriorate quickly when businesses are forced to not only increase prices but not even commit to a set price in the next six months,” said Down. The Wellington Electric Boat […]

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