Smart Manufacturing Today

Swim school purpose-built for champions

New Zealand’s prestigious AquaGym facility was purpose-built in 1988 by two of New Zealand’s leading Elite Swim Coaches: Brett Naylor and Clive Power. Brett and Clive have for many years coached New Zealand Swim Teams to Olympics, Commonwealth Games and World Championships. Until Brett’s retirement from National Swimming in 2000, AquaGym has placed a swimmer and coach on every International, Commonwealth and Olympic Games Team. AquaGym is now fully owned by Brett and Colleen Naylor, and whilst the competitive swimmers are still showing strength at all levels, an enormous amount of energy has been put in to its Learn to Swim Program. Top of the range instrument controller The Naylor’s needed a reliable, high-quality automatic controller that would help maintain hygienic water for their new 16m x 10m water babies and pre-schoolers swimming pool. “We required remote off-site access via the internet along with a low maintenance automatic chlorine and acid testing solution,” Colleen explains. “The entire system also needed to be sealed tight to withstand the harsh environment of the equipment plant room where temperatures fluctuate and there’s high levels of humidity and chlorine.” Waterco’s Chemflo PRO is equipped with the capability to connect up to four sensors of any type with appropriate analogue outputs and relays. Equipped with data logging as standard and multiple PID loops as options, the Chemflo PRO is able to control complex water treatment processes at a fraction of the cost of other controllers. Key product features and benefits include: Free chlorine, total chlorine and hydrogen peroxide reading through amperometric sensors. Chlorine range goes from 0.05 to 10.00ppm and hydrogen peroxide from 5 to 500 ppm Open overflow flow cell for sensors Superior patented gel-filled glass pH electrode Large easy to read colour LCD screen Capabilities for 4 inputs (expandable up to 16) and 4 outputs […]

mWL.cs mechatronic calotte loader unveiled

A fully automated stand-alone system for transferring wafers between cassettes and calottes, the mWL.cs provides integrated device manufacturers (IDMs) an opportunity to increase yield and improve process traceability at a high throughput. Evaporation process tools often utilise spherical carriers and rings to meet uniformity and defectivity targets. However, the design of these tools has made it challenging to introduce automated wafer handling in this step of the manufacturing process. IDMs invariably default to manual wafer loading, which has resulted in yield degradation and an increased risk for misprocessing. Automating the wafer loading and unloading system for evaporation type metal deposition is a step that bears much potential. By eliminating human error from the equation, the system enables manufacturers to achieve higher yield and reduce damage to wafers. Enhanced process traceability also supports quality improvement measures to meet the conformity requirements of critical customer industries. Key features of the mWL.cs mechatronic calotte loader include: Superior handling accuracy and repeatability — hand-off position measurement and auto-teaching capabilities (<50µm) Improved process traceability — host notification of Wafer ID, Cassette ID, Segment ID, and position in the segment Redundancy — 2 loading areas for continuous processing Impressive transfer times — high throughput of up to 240 wph that enables ROI within two years Dual size handling — customizable to handle 4”, 6”, 8”, or 6” & 8” (dual size) Small footprint — less than 7 m2 A specialist in fully automated handling systems for non-standard substrates and handling requirements, mechatronic recognizes and addresses the semiconductor industry’s need for the handling of ultra-sensitive substrates used in modern new wafer fabrication technologies. The company’s deep expertise and proprietary technologies provide manufacturers with safe, reliable systems that handle non-standard substrates with ease and confidence.

Solar giant Q CELLS enters New Zealand market

Globally renowned solar technology leader and total energy solutions provider, Q CELLS, is entering the New Zealand energy market for the first time in response to local demand for its high-quality, affordable products. The move comes as New Zealand establishes itself as one of the most exciting emerging renewable power markets in the world, reflecting the country’s strong commitment to a more sustainable future. According to state-owned energy supplier Transpower, over the next five years to 2025 New Zealand’s solar market is expected to more than double, making up 0.5% of the Country’s total power output. With New Zealand’s commitment to being carbon-neutral by 2050, household solar power is expected to play a key role in helping the country achieve its ambitious target. Established in Germany in 1999, Q CELLS is amongst the oldest and most well-known solar manufacturers in the world. The company is internationally recognised as a key player in solar panel innovation that focuses on high-quality, and is expanding its business area into integrated energy solutions. Part of Hanwha Group, Fortune Global 500 Company and the 7th largest conglomerate in South Korea, Q CELLS maintains its Technology and Innovations Headquarters in Germany with manufacturing facilities operating in the USA, Korea, Malaysia, and China. The first New Zealand solar installer to join Q CELLS’ Q.Partner program, a preferred network of vetted and trained Q CELLS suppliers, and be officially recognised as a supplier of Q CELLS solutions is Think Solar, comprising Wanaka Solar, Queenstown Solar and Dunedin Solar. Q CELLS is a leading supplier for residential and commercial solar in Germany, the USA, South Korea and Japan, where it is trusted for the quality of its manufacturing and is renowned for its research and development expertise. Mr Bae said that the partnership with Think Solar reflected Q CELLS […]

Is NZ’s Covid response world class?

By Ian Walsh, Managing Director, Intent Group Limited The re-emergence of Covid-19 in our community has got me thinking, as I am sure it has many of you. Of course, our normal reaction is to leap to solutions to ‘solve’ or eliminate the problem we’re facing, including measures such as shutting the borders, denying travel and so on. Upon reflection, I’m certain we are thinking the wrong way about how we manage returning New Zealanders. Is it our objective to fill the available managed isolation capacity to maximise the number of people per capita returning? If so, we’re probably succeeding. Great! We’re truly world class. But, if our objective is to ensure that everyone who leaves managed isolation is COVID free, then we’re not so successful. There is a significant difference between a world class mindset and the ‘also-rans’. A world class company identifies its core objective and aligns all systems and processes to achieve this objective. Inputs, variables and outputs are measured and anything impacting the goal is eliminated. All leading indicators of failure are addressed. A great example which springs to mind is Alcoa. Paul O’Neil changed the focus of the organisation from output, to safety, with a goal of zero incidents. He was relentless in leading this approach and transforming the organisation, and achieved outstanding safety improvements and exceptional business outcomes, as a result. This leadership lesson is inspirational. I had the privilege of visiting Alcoa’s centre of excellence in Davenport, Iowa, a few years ago, and their culture of safety clearly underpinned everything. It still does. We can think of managed isolation as a processing facility very similar to a manufacturing or processing plant. The goal is not to maximise capacity, but to deliver quality (by being COVID free). If you were producing food, let’s say […]

When EMEX 2021 comes to town

-Doug Green, Publisher, NZ Manufacturer In the 1860’s – way back then – New Zealand entered the world market as a trader, primarily through the agricultural sector. Growing things. Since that time, a lot has happened. Now, in 2021, we are celebrating the 40th anniversary of EMEX, the prime manufacturing trade fair in New Zealand being held at ASB Showgrounds, Geenlane from 15-17 February. Over those 40 years New Zealand manufacturers have appeared at the show all with enduring stories of success to share. These include Addington Engineering, Tait Electronics, Buckley Systems, Gallagher Engineering, Fletcher Steel, Brown Brothers Engineering, A & Price. Suppliers of equipment such as Techspan, Enerpac, Weldwell, Total CNC, Lucas Machinery, Tasman Machinery, Chevpac Machinery. Industry support has come from Callaghan Innovation, HERA, The Manufacturers Network, MBIE, EMA and the Chamber network. All groups working with the shared passion of making business better for their members. Exhibitors have come from Australia, Asia, Europe and the United States. Trade representatives from countries such as Australia, Germany and China work closely with XPO Exhibitions Ltd to share information and provide opportunities for trade between their countries. The strength of EMEX – apart from the enduring support of manufacturers and suppliers – is also seen in the speaker series which provide valuable insights and discussion into trends in the marketplace, regulations and assistance for manufacturers, forward thinking and vision- building pictures for the future (and direction) of manufacturing in New Zealand. And, of course, to inspire aspiration. In these times of the virus, we look at the future of manufacturing and what it means for a country like New Zealand, parked just above Antarctica and Stewart Island. It is essential that manufacturers, suppliers, decisionmakers have an EMEX to focus on, make business connections and working together to build on the […]

Manufacturing in the age of sustainability

For companies to be truly sustainable, they not only need to limit the impact of the manufacturing process but create products that benefit society, writes Iain Hosie. Globally, the heat is on companies to continue to reduce waste and prioritise sustainability when developing or manufacturing products. Constantly fine-tuning processes and researching new, environmentally friendly methods is essential to making this change happen. So, using safer, less toxic solvents, or monitoring and changing production processes to reduce the amount of waste going to landfill, is great. But as a manufacturer, there is more to sustainability than being clean, green, and doing your bit for climate change. Key to being a sustainable business is creating a range of products and applications that make a difference in society – while also working to limit its impact on the planet. Companies and manufacturers also have an opportunity to influence and encourage sustainable customer behaviour through the way they design and produce their products. This needs to be an increasingly important consideration for manufacturers if they want to be taken seriously in the sustainability stakes. Take the unique technology behind Revolution Fibres’ nanofibre skincare product, ActivLayr, which uses collagen to deliver natural actives deep into the skin. This is in stark contrast to the excessive amount of chemicals found in traditional creams and serums. ActivLayr technology also has strong potential beyond the skincare industry. With the ability for different ingredients to be added to the ActivLayr formula it could one day enable a controlled drug dose to be delivered to a patient for more effective and efficient treatment. The beauty of nanofibre – a class of textile made from superfine fibres 1/500th the width of a human hair which can create vast changes in strength, reactivity, and absorbency – is that it can be used […]

Industry 4.0 Adaption to NZ Industry

Dr Mike Edmondson, Founder, Edge Robotics and Automation Ltd One thing I commonly find is the lack of widespread direction and grasping of “Industry 4.0” benefits in the context of NZ industry. The rapidly changing world is hard enough for technical experts, let alone for manufacturers to filter and identify how to use this potential. The drive for improvement from manufacturers and wider industries is certainly present and has been growing with the push from COVID. Here are three topics for our industry, with the hype removed and practical opportunities we could apply: Robotic Automation It is particularly surprising how big a disconnect there is between your typical production manager or GM and the actual costs and capability of robotic systems. Enquirers are often surprised at the modern cost of purchasing industrial robots let alone the opportunities offered with current state-of the-art. The total economics become even more prevalent when an integrator has the innovation skills to take a robot centric approach. This allows you to capture all the additional indirect benefits such as flexibility and reducing both the capital and operating costs. NZ has a great history of successful innovation and leading the world, however, part of the very fabric of that innovation mindset tends to hurt in scaling. Often, we do not value our time or get side-tracked away from our core business trying to reinvent the wheel. Industrial Robots are an easy way to scale and are highly advanced, flexible mass-produced units that come off a production line with 60 odd years of refinement. Leading brands have reliability statistics of 7+years between failure and depending upon the chosen manufacture local factory support. Then you factor in the indirect benefits such as being able to repurpose and reduce complexity of an overall system. The flexibility of robotics […]

HandScanner saves four seconds per scan

Datalogic’s new HandScanner is non-intrusive, hands-free wearable and enhances efficiency and accuracy. The scanner’s low weight allows it to reduce the load lifted by a worker during every working shift by up to 1.5t. Capable of scanning from 10cm to 150cm, HandScanner is suitable for a broad range of tasks in transport, logistics, warehousing, manufacturing, retail, and healthcare industries. Weighing just 40g and measuring 50 x 45 x 16mm, this is the lightest and most compact hands-free scanner available to improve workplace efficiency. It saves four seconds per scan, with 33% less errors. The HandScanner complements Datalogic’s comprehensive range of advanced industrial scanning equipment designed to deliver efficiency, accuracy, reliability and ergonomic benefits to demanding industries. “Compared to ring scanners, the HandScanner is thinner and positioned on the back of the hand, therefore it is less intrusive and less exposed to hits than a ring scanner that stays on the fingers of a worker,” says Mr Stefano Pistis, Product Manager, Datalogic. “This durable, practical and ergonomic design results in up to a 20 per cent reduction in scanner damage,” adds Mr Pistis. A fully charged HandScanner battery can last almost two working shifts, running up to 15 hours and 10,000 scans. With a 2-slot charging station the battery can be fully recharged in 2 hours. Equipped with a megapixel sensor, the HandScanner captures 1D/2D bar codes and is available in two models: a standard range – designed for close range scanning between 10 to 80cm for manufacturing, retail and healthcare applications; and a mid-range model with a scanning range of 30 to 15cm, which covers applications in transportation and logistics such as warehousing, plant floors, docks, and stock yards. HandScanner’s non-intrusive and comfortable design result in up to a 20% reduction in scanner damage compared with ring scanners. The HandScanner […]

Hydraulink gives wings to hope in the America’s Cup

Hydraulink hydraulic hose and maintenance expertise will go on display to millions of people in 225 countries when the 36th America’s Cup begins in coming months. The defending champion Emirates Team New Zealand – and entire field of challengers which will fight it out to meet the Kiwis in the final – all use Hydraulink hoses and fittings to control their complex hydraulic systems, such as the vital foil cant technology. Rapid and sensitive hydraulic actuation of the foils is vital to the performance edge of each boat as it skims above the waves at speeds reaching 47-50 knots (90+kph) in what is expected to be a lightning-fast defence series from March 6-12. The super yachts demand quality products that perform where the absolute pinnacle of engineering standards and reliability is required, in the same way that Hydraulink protects the uptime and dependability of individual pieces of expensive machinery and multi-million-dollar mobile fleets and industrial plant. The event will be seen around the world by the biggest audience ever expected in the America’s Cup’s history, when the 36th America’s Cup begins with the Prada Cup Challenger from January 15-Feb 22. Preliminary races, including the Prada Christmas Cup, commence in December, with more than 120 broadcasters already signed up in the first wave of support announced in October. Digital platforms are expected to help make this the most widely accessible America’s Cup ever. Hydraulink’s introduction to involvement in the America’s Cup began when Hydraulink Director Lee Short was watching a race in the build-up to the NZ win in the America’s Cup in San Diego in 1995. “A hydraulic leak on the mast boom of Team New Zealand sprayed oil into the cockpit, causing a few issues. I thought, ‘We can do better than that’, so, when the team arrived back […]

What we said when the PM came to visit

– Sarah Ramsay, Chief Executive Officer, United Machinists The Prime Minister was so disappointed she couldn’t make United’s Hawaiian launch party, she dropped in for a visit a couple of weeks later with her own party of some 30 media, entourage and diplomatic police. We can confirm it isn’t an act – Jacinda Ardern in person is the real-deal, a people person that puts you at ease immediately and is genuinely interested. Thoughtful, curious and obviously read up before her visit, she was eager to discuss the operations of our workshop and our views on the contract manufacturing industry: How difficult is it to find skilled staff? What can be done to help push apprenticeships? What can schools be doing to draw attention to careers in engineering? Why is it important for NZ to retain manufacturing? What can the government do to help push this? We told her our vision was to bring sexy back into manufacturing – she had a good laugh at that. We told her that now is the time for a renaissance of hi-tech manufacturing in New Zealand. The time to redefine what manufacturing looks like. That it’s not a dirty old mill or lathe, with ‘you’ll get it when its good and ready’ service. It’s the ‘Machine Shop of the Future’ – a state of the art, temperature-controlled facility making highly intricate parts for industries such as medical, cinematography, marine and aerospace. Utilising the very latest in CNC, robotic and software technology available. But that investments into machine capacity will come to nought, if we don’t have the highly skilled people to run them. Of the seven qualified CNC machinists we have hired in the past 18 months, six have been from overseas. “Go hard & Go Early” – a motto often used by Prime […]

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