Manufacturing Association, HI Tech Manufacturing, Association Manufacturer, Victoria, Australia

AMT October 2009

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Lead story
Learning from Toyota’s secret weapon
By Steve Dow
“Lean Manufacturing” has replaced buzzwords like Total Quality Management, Business Process Reengineering and Just in Time as the latest concept for companies trying to gain a competitive edge. Lean has moved beyond its traditional manufacturing origins to logistics, distribution, services, retail, healthcare, construction, maintenance, and even government. Steve Dow from QMI Solutions explains what lean manufacturing means, concepts such as Kanban, 5S and the 4Ps and how they can be implemented…

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Legislation strengthens future of automotive industry
The Rudd Government last month welcomed the passage through Parliament of a key component of its $6.2bn New Car Plan for a Greener Future – the Automotive Transformation
Scheme Bill 2009…

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An Australian icon – GA & L Harrington
Celebrating 90 years, privately owned family company G.A. & L. Harrington sees a good future ahead with constant investments in technology, automation and lean manufacturing. Managing Director John Harrington has been running the business started by his grandfather and great uncle for the last 50 years.

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Engaging with industry
Bosch participates in Swinburne University’s Upskill project - a development program which provides hands-on work experience for TAFE teachers and students in manufacturing environments…

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Competitive manufacturing initiative to refine companies’ processes 
An outcome many businesses are seeking today is to refine their processes and operations to give better company returns and develop their workforce to be more productive. This has proven to be difficult to achieve for many companies, but through recent initiatives in training by Navitas Training Services, through their Business Improvement Program (BIP), this elusive goal has become a reality…

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Lean processes deliver quick order turnaround 
By introducing a lean production system into its manufacturing process, Australia’s leading manufacturer of steel personnel doors  - Larnec - achieved lead time  improvements of over 50%. MD Phil Joyce and Operations Manager, Leon Joyce had already been experimenting with lean manufacturing after having seen the potential for the lean approach at Innovation Insights factory visits. Larnec also did an Enterprise Connect Business Review with Vecci Business Advisor, Paul Szuster. This review reinforced Phil and Leon’s belief that Lean Enterprise might provide the answer to the challenge of achieving order lead times of less than five days with a make to order product. Larnec engaged TXM to assist in implementing lean approaches to reduce the lead time on steel doors. A Tailored Advisory Service Grant from Enterprise Connect also helped Larnec Doors to get underway. With coaching from TXM Consultants Tim McLean and Anthony Clyne, the Larnec team developed a future state map and action plan for the business…

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Making materials flow 
Getting materials to the right place in the right time and quantity is crucial to an efficient production process. Tim McLean, Principal TXM Pty Ltd, explains how an effective materials flow can be achieved. Manufacturers still suffer downtime, poor productivity and missed deliveries. The cause is the inability to get materials to the right place in the right time and in the right quantity. A value stream map will show the process steps and, critically, the information flows that trigger the movement of materials and production jobs from one process to the next. From this you can develop your future state map. It is at this point you will probably get introduced to some new concepts for managing the flow of production jobs and materials.

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MQL: Lean and Green 
While flood coolants have traditionally been used almost exclusively in machining operations, the concept of minimum-quantity lubrication (MQL) has been steadily gaining momentum during the last several years. MQL, also known as near-dry machining, is suitable for many types of machine tools and replaces flood coolant with a minute amount of high-efficiency lubricant applied precisely to the cutting tool/workpiece interface. The benefits of MQL are numerous, as explained by Chuck Boelkins,  President of Unist …

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Machining micro screws
By John McBride
The recently released Tornos MultiAlpha 8x20 multi-spindle turning machine, suitable for complex micromachining, provides Switerzerland’s Stryker Spine (the world’s leading manufacturer of orthopaedic and medical technology).with a high level of productivity and flexibility… 

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Ecoline meets medical demands 
By Phil Mitchell
Producing orthopaedic tools requires high-precision specialised equipment. Sydney-based MAC Surgical relies on Gildemeister machines to deliver the quality and efficiency its global customer base demands, which is why DMG produced its Ecoline range…

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Hydrostatic milling and grinding on one machine
By Rhys Williams
Amongst machine tool manufacturers, hydrostatic systems designed for axes and drives are rated as the finest technology available. Now, specialised milling expert Kern of Germany successfully demonstrates what potential this technology possesses for manufacturers. Kern recently launched its ‘co-ordinate or jig-grinding package’ now available for all customers specifying the Kern Pyramid Nano.…

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Keeping a hawk’s eye on tolerances 
Rowan Precision of the UK,  is using Vision Engineering’s Kestrel manual 2-axis and Hawk 3-axis fully automatic measuring systems to measure a wide variety of swiss machined components. Chris Kent, Director of Rowan Precision explains why he chose the Vision Engineering equipment. “We wanted to find a measuring solution that would work for our entire range of production, from complex connectors through to stainless steel and plastic medical devices,” …

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Adaptation is the key to success
By James Rehfisch 
For the Australian manufacturer, adapting to meet the changing needs of customers and the market is vital to remaining successful. The installation of a Mazak STX Champion 510 laser processing machine helped Australian company E.P. Draffin to create new products through added design flexibility and great prototyping opportunities. Before this installation, Draffin spent a significant amount of money sub-contracting laser cutting… Based on the volume and type of work sub-contracted, the team at John Hart knew that the latest laser processing solution from Mazak, the STX 510 Champion was the right solution to reduce the amount of outsourced work The Champion can process up to 12mm mild steel, 4mm aluminium, 4mm stainless steel and 2mm brass, in one setup and is designed to operate 24 hours a day …

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The Safety Show Sydney puts safety into action 
Manual handling, bullying, compliance and safe work at heights workshops plus acres of the latest workplace safety products and services await visitors to The Safety Show Sydney, when it runs from 27 to 29 October 2009.

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Nasa relies on laser tracker for Ares 1 Project 
Nasa Langley research centre, located in Hampton, Virginia, US, is facilitating the build-up of the Ares I crew module, the launch abort system and the separation ring assembly for its Orion crew exploration vehicle. With the high accuracy requirements when building these items, the research centre has turned to Faro laser tracker technology. The research centre chose the Faro laser tracker due to its cost, portability and accuracy. “We already had certain expectations
for what laser trackers should be able to do,” says Pete Veneris, Quality Assurance Specialist at Nasa Langley research centre...

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Commitment to quality 
Alfred Lewis Engineering adopts the latest industry-standard Faro Gage measurement technology for machine shop flexibility, productivity and enhanced levels of customer service. In order to sustain future growth and maintain its quality standards, Alfred
Lewis purchased a Faro Gage Plus and rolling cart - a portable on-machine measuring system from Hi-Tech Metrology in June 2008. After installation and training on the Faro Gage, provided by Hi-Tech Metrology, and subsequent follow-up training the Alfred Lewis team has been able to achieve widespread usage of the portable measuring system around the workshop…

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AMTIL FORUM
Finance : Securing finance for manufacturers 
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Law: Looking after your intellectual property 
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OHS: New OHS laws divide experts 
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Strategies: Len thinking comes before lean manufacturing 
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AMTIL INSIDE 
Message from the President and CEO 
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AMTIL celebrates 10 years 
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Education and member support high on the agenda 
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AMTIL – The Source will be back next year 
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Member Profile – Complete Machine Tools 
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