Smart Manufacturing Today

Lubrication systems enhance reliability

Hydraulink mobile service brings its expertise on-site or through a network of well-equipped branches extending throughout New Zealand Ensuring fixed plant and mobile machinery is properly lubricated keeps money in the pocket of owners and operators, as under-lubrication is a major cause of machine unreliability and downtime due to bearing damage and failure. Ensuring the best and correct systematic application of grease can sometimes be a challenge when the machinery in question is required to be available 24/7 and worked continuously on remote, difficult sites with few breaks. One answer to this issue is automatic centralised grease lubrication systems from Hydraulink, which is New Zealand agent for high quality Lincoln Lubrication pumps and components. Hydraulink’s many branches throughout NZ are experts at installing these handy controllers that enable automatic systems to meet all applications requirements. Hydraulink is ideally placed to provide guidance on best industry practice in lubrication through its 24/7 network – with hundreds of service points throughout the country, including both mobile units and Hydraulink regional branches throughout the country. Key industries locally now drawing on Hydraulink services include agriculture, construction and infrastructure, civil engineering, forestry, farming and primary industry, public works, manufacturing, mining, machinery transport and machinery OEM and rental and other industries. These industries depend on Hydraulink’s prompt, expert service coupled with strong supply of quality branded hydraulic hoses, fittings, adaptors and accessories vital to optimising machinery reliability and safety while avoiding costly downtime.

3D print of human heart with tissue and vessels unveiled

Scientists in Israel have unveiled a 3D print of a heart with human tissue and vessels, a first and a “major medical breakthrough” that advances possibilities for transplants. Scientists hope one day to be able to produce hearts suitable for transplant into humans as well as patches to regenerate defective hearts. The heart produced by researchers at Tel Aviv University is about the size of a rabbit’s. It marked “the first time anyone anywhere has successfully engineered and printed an entire heart replete with cells, blood vessels, ventricles and chambers. People have managed to 3D-print the structure of a heart in the past, but not with cells or with blood vessels. But the scientists said many challenges remain before fully working 3D printed hearts would be available for transplant into patients. Journalists were shown a 3D print of a heart about the size of a cherry, immersed in liquid, at Tel Aviv University as the researchers announced their findings, published in the peer-reviewed journal Advanced Science. Researchers must now teach the printed hearts “to behave” like real ones. The cells are currently able to contract, but do not yet have the ability to pump. Then they plan to transplant them into animal models, hopefully in about a year. Maybe, in 10 years, there will be organ printers in the finest hospitals around the world, and these procedures will be conducted routinely. However, hospitals would likely start with simpler organs than hearts.

Callaghan Innovation support for innovating business

A new tool for start-up businesses will encourage innovation, says BusinessNZ. Chief Executive Kirk Hope says innovation is critical for businesses to stay competitive and attract new customers. “But research & development is costly, and many New Zealand businesses struggle to gain the investment needed to develop new products, services or processes. “The Scale-UP NZ platform launched by Callaghan Innovation today will help innovating companies to network, gain introductions, collaborate and attract investment.” Mr Hope said the digital platform, modelled on successful platforms in other countries, would help businesses and the New Zealand economy benefit from their intellectual property and creative ideas.

Synlait embarks on business transformation for growth and diversification

Synlait has chosen Infor CloudSuite Food & Beverage to support its supply chain and manufacturing operations and growth as part of a five-year business transformation plan. The goal is to modernise and streamline operations for the integrated dairy business, one with over 150,000 metric tonnes of annual sales volumes across domestic and international markets including Asia, Africa, Middle East, and Australasia. An existing Infor customer, Synlait is looking to improve employee engagement and increase operational efficacy and efficiency by aligning to best dairy industry practices. This will be facilitated and enabled by Infor’s food and beverage dairy industry specialised CloudSuite software-as-a-service (SaaS) enterprise solution. “The foundation of our business is all about partnering with other businesses and people who share our passion and commitment to excellence, integrity, and quality,” said Chris France, director of strategy and business transformation, Synlait. “Infor is a strategic partner for our business transformation plan with its ability to help us leverage dairy industry expertise, data insights and real-world knowledge via its innovative Infor CloudSuite F&B solution.” “Infor understands the unique challenges of the food and beverage industry in the Australia and New Zealand markets, and is committed to continue delivering finely-tuned industry-specific solutions in the cloud to help our customers maximise efficiencies and accelerate growth,” said Helen Masters, Senior Vice President and General Manager, Infor Asia Pacific and Japan.

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 […]

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