Smart Manufacturing Today

Apprenticeships vital to automated future

Now, more than ever before, it’s vital that school leavers choose a pathway that equips them to learn new skills for jobs that don’t yet exist in an automated future. And despite what many people think, automation is not a jobs killer – it’s creating new jobs and opportunity, says Competenz chief executive Fiona Kingsford. “Human jobs won’t disappear, they will change. The World Economic Forum predicts 75 million jobs will be lost in the next four years as companies automate, but at the same time, 133 million jobs will be created. “As parents and teachers, we are natural guides for our young people. But we need to accept the world of employment is undergoing a massive shift, and it’s happening right now. Our children must be equipped with the skills they need to meet change, and to find relevant, rewarding and adaptable jobs.” Outmoded thinking of what workplace learning and apprenticeships can deliver is an ongoing battle for Competenz, New Zealand’s industry training organisation for manufacturing and engineering. Modern food and beverage manufacturing plants, engineering workshops and other trades-based workplaces demand a high level of technical skill. Mechanical engineering apprentices are using artificial intelligence and robotics to facilitate the automation of a growing number of “doing”’ tasks. Today’s AI-enabled, information-rich tools are increasingly able to handle jobs that in the past have been exclusively done by people. “These shifts will produce massive disruptions to employment and, if we are going to meet this disruption and prosper from it, we need to address it now by helping our children choose the right learning pathway,” Kingsford says. The people needed for those 133 million new jobs will be responsible for gleaning insight and intelligence from the machines, fixing and maintaining them as well as quality assurance, among other things. “Various organisations have identified […]

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Safe and sound – Is your smart factory secure?

Alarms, cameras, locks and fences are all commonly recommended to keep burglars out of homes. Obtaining clear guidance for securing your smart factory isn’t quite as easy to come by. Here Jonathan Wilkins, marketing director at obsolete industrial equipment supplier, EU Automation, discusses smart factory security and what manufacturers should consider when protecting their facility. In a connected factory, manufacturers have access to a constant data stream from the shop floor, commercial operations and supply. The Internet of Things (IoT) generates a huge amount of data, gathered from machines and components, which can be accessed and analysed remotely. Though it brings a facility a number of advantages, connectivity also introduces a vulnerability in terms of cyber-security. With information technology (IT) and operational technology (OT) more closely connected than ever, systems are more vulnerable to attackers. The risk is increased by remote access or third-party access. According to Dark Reading magazine, the second most cyber-attacked industry after healthcare is manufacturing. With high profile ransomware attacks such as WannaCry disrupting large companies such as Honda, manufacturers know they must be vigilant. In the manufacturing industry, cyber-crime is usually a type of data theft, ransomware or data manipulation. Hackers can modify procedures to disrupt production processes, gain access to private patent data or cause system downtime, all of which can cause serious losses to a company. Engineering businesses must ensure that their operations, data and valuable intellectual property (IP) are protected. Businesses need to understand the limitations of their own capabilities and systems to form a well-rounded cyber-security strategy. For example, legacy equipment can be a target for cyber-criminals. Old equipment was not designed to be connected to the internet, which means that cyber security was not a priority during its design. Industrial control systems as well as programmable logic controllers (PLCs) have […]

What do your motors really do?

In 1969, the first home security system was born, consisting of four peepholes and a camera that could be moved to look through any of them, broadcasting the images to a monitor. Nowadays, we can now stream and view a feed of our home security cameras on our mobiles, giving homeowners greater piece of mind. Here, Markus Brettschneider, of ABB’s food and beverage program, explains how food plant managers can add a similar level of connectivity to retrofit most motors with smart sensors to bring their plants to the digital age. Industry as a whole is utilising technologies and solutions enabled through the industrial internet of things (IIoT). Gartner predicts that 25 billion devices will be connected to the internet of things by 2020, with some agencies predicting even double this amount. This presents plant managers with a conundrum. Most food manufacturing and processing plants currently have motors powering essential equipment such as mixers, conveyors and packaging machines. These motors are just motors and do not play in the same league as the other intelligent devices in their factories. With years of service often left in the motors, it’s difficult for plant managers to justify replacing motors that work effectively for the sake of an upgrade with any smart features. However, there are alternatives to a complete overhaul in order to connect motors to the IIoT. Instead of investing in new, more intelligent or smart equipment, plant managers should invest in sensors that provide similar functionality to connected devices. For example, ABB offers smart sensors, which can be fitted to almost any standard low voltage induction motor. The pocket-sized sensor, dubbed ABB Ability Smart Sensor, is directly attached in a couple minutes to the motor’s frame, without wiring. By using sensors that feed performance data to the cloud through a […]

The critical role of IIoT in the future of food processing

Michael Cahill, Rockwell MES Technical Consultant As the old adage goes, an ounce of prevention is worth a pound of cure. New Zealand food companies, that often produce high value-add product that is exported around the globe, value their brand and reputation. Things are changing. Customer expectations for food safety and quality are unprecedented. Expectations from regulatory authorities are increasing to meet ever growing market regulation. Demand for high safe products is driving growth at an unprecedented rate. The reality is the number of food recalls has been steadily increasing over the last decade, according to FSANZ’s 2009-2018 reporting. The lack of visibility in the early stages of production is leading to an increased amount of inedible product and is posing serious food safety compliance risks. With headline after headline, product traceability from paddock to plate is becoming more and more important. Any deviation in quality in the product line will involve significant wastage and financial burden on the organisation. A sustainable approach to maintain the highest standard of production quality is sought to meet these customer, regulator and growth challenges. Connecting the dots The rise of the Industrial Internet of Things (IIoT) has emerged as a solution to this problem. IIoT platforms and advanced analytics now enable users to fuse multiple data sources to provide contextually relevant historical and real-time data. Add in AI and machine learning and food manufacturing is more predictive and intelligent than ever before, giving workers uncanny insight into how to solve issues and predict problems before they happen. The problem isn’t a lack of data but a lack of connectivity from food companies. IIoT has provided the tools to better verify quality, establish batch genealogy and capture meaningful processing data from beginning to end. It’s now the job of manufacturing plants and farms to […]

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3D printing the next generation of machinery

By Ben Murton and Associate Professor Don Clucas, Dept of Mechanical Engineering, University of Canterbury While metal 3D printing is regularly used for components such as brackets, rocket parts and turbine fuel nozzles, it is rarely used as the major manufacturing process for an entire mechanical system. In a world first, students from the University of Canterbury developed an operational 3d printed titanium ethanol fuel injected internal combustion engine, showcasing the possibilities and limitations for the process. The team took their engine to Singapore and won the innovation award at the Shell Eco-Marathon event, a global competition on for students to compete with highly efficient vehicles. This was all done in one academic year, so a highly accelerated design process was required. To test and visualise ideas quickly, concepts were modelled and refined using cheaper and easier to post-process polymer 3D printing. The titanium parts that were optimised for efficiency, not machining constraints, were then printed and post-processed. Post processing proved to be the biggest headache. It is often said that 3d printing can create anything, but in reality it has its limitations and drawbacks. An example is the almost organic shape of the cylinder head that required little post processing, while the rather basic cylinder required complex support material. Using a laser sintering process that melts and fuses layers of very fine titanium powder has its complications. Thermal contraction of thin features would distort the part, much like MIG welding distorts steel, so support material is required. Removing the support required many hours EDM wire cutting, machining, and finally sand blasting. Before and after cutting the part off the build plate, thermal stress relief was required. Good Design for Additive Manufacture, DfAM, was essential to avoid or reduce the support material, ease support material removal, and reduce distortion. […]

Transforming the manufacturing industry with Internet-of-Things

By Mike Russell COO Central Innovation In a highly competitive global marketplace, businesses are searching for and adopting revolutionary technology and processes to stay relevant. According to the latest IDC Worldwide semiannual Internet of Things Spending Guide[1], New Zealand shares the second highest position with Australia in APAC region when it comes to the IoT spenders per capita. The report further highlights that the top three industries spending most on IoT solutions in 2018 were discrete manufacturing ($43.9 billion), process manufacturing ($33.2 billion) and utilities ($20.1 billion). With the advent of automation and analytics, manufacturing is moving from mass production to mass customisation. The immense growth of IoT in the industry has resulted in factories being able to extract critical data on operations. By using big data and machine learning they are achieving more efficiency in their workplace as well as enhancing customer experience. Without a doubt, IoT is a clear investment area for the manufacturing industry particularly in the Asia Pacific Region which is among the world’s top regions for IoT adoption and usage[2]. To effectively work with new technologies, businesses must be prepared to think differently, adapt and invest to remain competitive. According to the MBIE report[3], Industry 4.0 is seen both as a threat and an opportunity for New Zealand manufacturers. The ministry believes that Industry 4.0 technologies have the potential to make a type of short run, customised production that will enable more specialisation to become efficient and profitable. This would be especially important for the manufacturing industry where it currently accounts for 12 per cent of New Zealand’s GDP value. This means there is untapped potential for New Zealand businesses to stand out from their competitors in the race to transform their businesses. Business productivity The bottom-line when adopting new technology is that it will […]

Point Pod latest start-up success story

A new innovative product that solves your household power problems has teamed up with Australia and New Zealand’s large distributor just six months after making its market debut. Point Pod finally solves the problem of not having enough power outlets in your kitchen by hiding a pop-up unit beneath your stone or timber bench top. Brisbane builder-turned-entrepreneur, Cameron Singer, developed Point Pod after being frustrated with the limited options on the market. “I developed Point Pod two years ago out of my own frustration of the limited power options available,” says Mr Singer. “After renovating my own house, I was disappointed with what was available to improve access to power for my island bench. There were products online, but they looked so cheap and flimsy in a kitchen we’d spent a lot of money renovating.” With a simple touch, Point Pod’s power points and USB sockets emerge for use. But unlike other power options, it blends seamlessly into your bench top, so it doesn’t comprise your aesthetics. The units are designed for any space where you would use power on a bench top, including the kitchen, bathroom, office and boardroom. After launching in August 2018, Point Pod has today announced its new partnership with Häfele, Australia and New Zealand’s biggest distributor. “I’m excited for Point Pod’s next phase, working alongside Häfele,” Mr Singer says. “Häfele’s commitment to innovation made them the number choice for our distribution partner.” “Häfele brings new innovative products to the market so their customers are always on the cutting edge of what’s available, and we’re excited to be part of it.” “Our distribution agreement gives us access to a larger chunk of the market, but it also means we can focus on manufacturing and developing further products.” Mr Singer says he’s been overwhelmed by the industry’s […]

Photo by: Visual Culture Ltd (www.visualculture.co)

SouthMACH 2019 what’s not new!

Entrepreneur’s development lab Local Canterbury businesses and organisations have created the ‘go to’ destination at this year’s SouthMACH! Motovated Design & Analysis, Brush Technology, ARA Mechanical Engineering, The Ministry of Awesome and Fab Lab have joined forces and created a unique environment for creativity and information sharing, building new knowledge, creating alignment and developing comprehensive solutions. Forward-looking firms, incubators, entrepreneurs, and agencies that collaborate with each other to develop cutting-edge products for the marketplace. The Entrepreneur’s Development Hub foster’s the growth of our future manufacturing technology business’, introduce them to the marketplace and facilitate networks for commercial success. NZ tech startup – the lab Innovation in the manufacturing technology space is advancing at record speeds. What is new today can be old technology tomorrow. More and more professionals and young entrepreneurs are pushing the boundaries of technology finding innovative solutions and creating new applications and products. SouthMACH is the place to discover these new gems at The Lab – an incubator for all the up and coming Kiwi tech start-ups to showcase their innovative ideas to a wide professional audience of Engineers, Manufacturers, Designers, Consultants and Investors, and be in the draw to win sponsored prizes to a value of over $10,000. 12 start-ups will be given the opportunity to display their innovative product designs during SouthMACH 2019 and access advice from product development consultants as well as other participants in the Entrepreneur’s Development Hub on all aspects of project design and market entry. Entrants will be able to connect with investors and gain understanding of what is required to attract potential investment. The innovation quarter The Innovation Lab is where the latest technology in Engineering and Manufacturing in New Zealand will be displayed. Exhibitors have the opportunity to display in the Innovation Quarter as the world looks to New […]

Kiwi technology receives Australian recognition

Cutting-edge technology aimed at minimising waste in the food processing industry has received major recognition at Australia’s largest agricultural technology event. Dr Matthew Jones, of Christchurch start-up company CertusBio, took home the top cash prize of $20,000 in the Investment Ready Pitch Tent competition of the inaugural EvokeAg event in Melbourne. The Christchurch-based innovator was one of five finalists from Australia, New Zealand and Israel. The participants pitched their agricultural challenges, solutions and business ideas over the two-day event to a panel of expert venture capitalist judges. Strong attendance of 1,100 delegates at the event showed an increasing international interest in new agtech technologies, including sensors, artificial intelligence, robotics and automation. Dr Jones’ winning concept is an automated technology that reduces industrial food waste by 40 per cent. CertusBio commercialised the solution, which was developed by the Lincoln University-owned multidisciplinary R&D company, Lincoln Agritech Ltd. Dr Jones said that with 2-3 per cent of all processed milk disappearing down the drain, the dairy industry loses a staggering NZ$12.8 billion per year globally. “CertusBio is transforming industrial food production to prevent this type of waste,” he said. “Our solution saves money for processors and helps them meet their social responsibility to safeguard the environment for future generations.” The technology includes a biosensor device that provides real-time insights into when food is wasted, a dashboard giving company managers unprecedented visibility on losses and a dedicated consultant to optimise food production. “The solution can be installed without interruption to existing processes,” Dr Jones said. “Other companies have been in the market a long time but do not provide accurate enough information to prevent this type of food waste.” Dr Jones said he developed CertusBio to combine two of his great passions – the reduction of waste and the development of great science. He […]

Predicting the future of maintenance

In 1927, Thomas Parnell set up the pitch drop experiment, which examines the viscosity of a tar-like substance by the speed at which it flows from a funnel into a jar. The test has seen just eight drops fall in as many decades and, despite the experiment being displayed in the University of Queensland’s physics department, no one has ever seen a drop fall. Just like this test, the need for factory maintenance often goes unnoticed. Here Gernut van Laak, group automation solutions leader of ABB’s Food and Beverage Program, explains how plant managers can budget for maintenance and ensure optimum efficiency for all processes. Paper to glass In terms of research and development, food and beverage is a leading industry because of its use of new, innovative technology. However, when it comes to maintenance, many companies find themselves keeping paper records. While regulation and compliance requirements historically drove these companies to work with paper, advancements in digital tools mean this is no longer the case. Unfortunately, once paper-based systems are in place, they can be difficult to eradicate. Companies become stuck in their ways, which leads them to ignore the significant cost savings, efficiencies and competitive advantages electronic systems can provide. The most important driving force for a company’s success is its employees. Today’s maintenance engineers have the computing knowledge to make the switch to digital. Providing them with a familiar interface that quickly connects employees across the organization allows staff to work faster and smarter, increasing productivity. Electronic records also eliminate time-consuming and error-prone data entries that are necessary with paper-based systems. While staff are the most important factor of any company’s success, the biggest cost of manual maintenance comes from people. Human errors that occur during manual record-keeping can result in redundant actions, rework and audits. […]

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