EFFECTIVE SAFETY TRAINING CAN NOT ONLY SAVE LIVES BUT ALSO AID PRODUCTIVITY
ACCIDENTS, NEAR MISSES AND OTHER HEALTH AND SAFETY INCIDENTS NOT ONLY HAVE THE POTENTIAL TO CAUSE SERIOUS HARM TO WORKERS, BUT THEY CAN ALSO SERIOUSLY IMPACT ON THE PRODUCTIVITY AND EFFICIENCY OF A WORKSITE.
Having to close a section of your plant or halt work due to an incident; conduct investigations and complete incident reports; or more seriously – work through treating and rehabilitating an injured worker – are all serious and stressful tasks that also impact on productivity.
In recent years, the introduction of more comprehensive health and safety legislation; advances in technology and design of personal protective equipment; and increased awareness around health and safety procedures has gone a long way towards improving health and safety in New Zealand workplaces. But despite these measures, many sites still lose time and money as a result of health and safety incidents.
Many of these incidents could have been easily avoided if staff had been competently trained to use safety equipment and follow applicable procedures. Whilst many people employed in a health and safety role are trained, it is critical that all employees – frontline workers, supervisors, managers and even company owners – receive training.
As well as improving your workplace health and safety practices, effective training will provide you with a better understanding of the law and your legal obligations; help you avoid severe penalties; allow for improved management of your business; reduce workplace insurance costs and of course; increase efficiency.
NZ Safety Blackwoods Worksafe Training has been operating as a specialised training organisation, with a philosophy focused on the areas of health, safety and the environment, since the introduction of health and safety legislation in 1993.
Each specialised trainer is fully qualified, both academically and practically, and can provide both industry expertise and educational experience across a wide range of training areas – including, but not limited to emergency response, elevating work platforms, forklifts, height safety, lockout/tagout, hazardous substances, spill response and contractor management.
NZ Safety Blackwoods Worksafe Training also recognises that not all workplaces are the same, and it is often beneficial to customise and tailor training packages to a specific site or situation. Experienced trainers will consult with you and identify your specific training requirements from both a regulatory and an occupational health and safety aspect, then deliver cost-effective training packages tailored to your specific environment.
As well as dedicated training venues in Auckland, Tauranga, Wellington and Christchurch equipped with classrooms and purpose-built facilities; training can also be conducted on your worksite, to both minimise downtime and provide practical experience within a relevant environment.
Implementing regular and effective health and safety training for all staff will help ensure day-to-day operations, maintenance work and shut down activities are completed safely – not only ensuring compliance – but also minimising downtime and driving efficiency.
Engage with the experienced team at NZ Safety Blackwoods Worksafe Training so they can assess your requirements; pull together the best team to meet your training needs; and implement cost-effective, customised workplace training to minimise costs, reduce downtime, and most importantly, keep your team safe at work.
NZ Safety Blackwoods Worksafe Training is an independent Private Training Establishment (PTE) registered by the New Zealand Qualifications Authority (NZQA).
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MAZAK TOOLS YOU UP TO BE COMPETITIVE
Victor Hydraulics recently installed a Mazak HCN 4000 horizontal with multi pallets and tool hive with 312 tool locations.
This was driven by the need to be focused on how to keep competitive. In the past, Victor Hydraulics also bought ‘like for like’ machines for “standardisation reasons,” but then realised over time they were not getting any gains from new technology and were stuck in a rut.
“This need for standardisation was constraining our thinking,” says manufacturing manager Darryl May. “But the constraints are mainly in the mind, because we tell ourselves this is the way we have always done things, by doing this we were seriously limiting ourselves.”
So, Victor Hydraulics sent out specification requirements to four different suppliers; the overall offering that met Victor Hydraulics’ vision for the future in terms of size, controller, tool hive, pallet system and market support was Mazak.
“There was quite a bit at stake and the specifying and install process was very smooth – no-one cut any corners and I am very comfortable with the support we are getting from the team. From a commissioning point of view, it was well coordinated with good communication in advance so there were no surprises,” he says.
No-one attends the machine during the night shift. The tool hive allows the Mazak to run unmanned using the tool monitoring and there are enough tools in the machine to call back up tools. Without the hive Victor Hydraulics would not have a chance of aiming for this goal.
“The technology and configuration allow you to achieve delivery nimbleness. This machine gives us zero set-up time by the ability to set up pallets while another is being machined, our spindle cut time is very high and the smooth controller is super impressive and very intuitive.”
Even with adding more operations to the part being machined, within two months Victor Hydraulic have doubled production rate and halved labour content, and throughput per hour has gone up considerably – the machine is now running 21 hours per day.
With any machine tool investment, the quality of the after sales service is a huge decider in which direction the purchaser will go. When put to Darryl, he says: “Victor Hydraulics realised that while NZMT is a new agent for Mazak, its associated company Iscar Plus was not going to put their cutting tool business with us at risk with poor service, and we realise that Iscar have been in the industry for a long time. Victor Hydraulics trust they will get it right.”
Director John McCallister adds: “Victor Hydraulics are focused on through-put, that’s our main measure”, we have added value by adding to our capability which appeals to our clients and we can also offer design improvements because of the new capabilities.”
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SPOTTING WARNING SIGNS – THAT HYDRAULIC HOSES NEED SERVICING
LMR Truck & Trailer Mossvale’s James Haddow with a newly serviced truck
Heavy transport and fleet operators are all too familiar with the importance of having fully functional and safe hydraulic hoses and fittings. A single fault can be deadly.
But since hydraulic hoses wear out at different rates, depending on usage and the environment in which they operate, it’s impossible to give a time-frame for when a service should be undertaken.
Instead, users of machinery that relies on hydraulic power should look out for early warning signs, says Shane Sutton, service technician, LMR Truck & Trailer Mossvale, who works closely with James Haddow as one of more than 100 authorised Hydraulink dealers across Australia.
Fixing problems during programmed maintenance is far cheaper and more efficient than expensive breakdowns causing downtime, and environmental damage.
Through its network of trusted distributors, Hydraulink provides high quality, tested and compliant hydraulic hoses, adaptors and fittings to industries such as transport, mining, earthmoving and civil contractor, agriculture, OEM manufacturers, materials handling, utilities, recycling and waste management.
SHANE’S TOP TIPS FOR HYDRAULIC HOSE SERVICE
LMR Truck & Trailer services a range of heavy vehicles, such as powder tankers, agitators and tippers, and Shane says that even though you can’t specify a time when they’ll need a service, there are a few signs to look out for:
1. The most common fault with hydraulic hoses, is wear to the outer cover. This can be caused by the hose rubbing up against something, or not properly located in a clamp or bracket. The outer cover of the hose is there to protect the reinforcement which is the strength of the hose assembly. If you see a worn cover, it is a lot easier to change that hose then, rather than wait for it to fail in the field.
2. Are there leaks at the ends of the hose? This can be from the fittings being loose, or an ‘O’ ring deteriorating. It could also be that there is a poor seal between the hose and fitting due to high temperatures or the hose being aged.
3. Exposed wires, usually caused by wear, will rust easily, or fail. Companies should not only replace these hoses, but look for a way to prevent future wear.
4. Make sure hoses are not kinked or twisted. Kinked hoses prevent flow, and a twist in a hose will rapidly reduce its life.
“For major companies with large fleets of vehicles, it’s often best to have a preventative maintenance programme in place, to stop normal wear and tear turning into a major fault.
“As a diesel mechanic, Hydraulink products make my job safer and easier,” says Mr Sutton, who has nearly a decade of experience in hydraulic service.
After using hydraulic products from a range of suppliers, LMR Truck & Trailer is now one of more than 100 authorised Hydraulink dealers in Australia.
Mr Sutton says the Hydraulink range is ideally suited to diesel mechanics, due to its broad range of parts and locally available stock.
“Whether it’s a turbo hose for a diesel truck, an oil-resistant hose for high temperature applications or a general-purpose fuel hose for low pressures, Hydraulink has it covered. Their products can handle any pressure.” says Mr Sutton.
“Even if we need a braided supply hose from the compressor down to the tanks, Hydraulink has the exact product, fully standards compliant and ready to go. It really puts our mind at ease.
“Hydraulink hoses are always manufactured to top quality and safety standards. They have the pressures easily labelled on the hoses to avoid any confusion,” says Mr Sutton.
“When servicing hydraulic hoses, fittings and adaptors, mechanics need to be spot on, every time. A faulty hose or incorrect fitting can have dire consequences when operating at high pressure (typically 3,000 – 7,000 PSI in mobile applications).
“One of the big advantages of using Hydraulink products is that there is an extensive amount of experience and capability built up under the one brand, so customers know that all Hydraulink branded products will be delivered to the same high-quality standards. This consistency and quality is very important to customers with diverse and multiple sites who want traceability and uniformly high standards of service and safety delivered across their organisations.”
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PORTS OF AUCKLAND USES 24/7 SOFTWARE SERVICE FOR NEW AUTOMATED CRANES
Ross Clarke, left, programme manager, terminal automation, Ports of Auckland; and Mario van den Heuvel, director, technical support, port service, Konecranes.
The newly signed software service level agreement (SLA) with Konecranes includes 24/7 software technical support once the new equipment goes live.
The equipment covered by the software service level agreement includes 27 new Konecranes Noell automated straddle carriers (A-STRADs) and 21 retrofits to manually operated Konecranes Noell straddle carriers that would make them fully automated.
“Our upgrade to automated straddles is essential to increasing our capacity so that we can handle the future freight needs of a rapidly growing Auckland city,” says Ports of Auckland chief executive Tony Gibson.
“In order to deliver for the city, we need to have confidence that any problems with the automation software will be resolved quickly and efficiently. This SLA gives us that confidence,” he says.
Mario van den Heuvel, director, technical support, Konecranes Port Service, says, “We very much appreciate the trust of POAL in our automated straddle carriers and software. The software agreement comes as part of the Konecranes automation solution in order to provide support under the most critical circumstances, and also, to provide piece of mind when changing, upscaling or transitioning from manual to automated operation. With around the clock access to our experts and minimum failure response times, the transition becomes easier.”
Under the SLA, Konecranes will provide a 24/7 expert hotline, continuous access to its service desk, and the latest updates of all the system software. Konecranes will be able to react and resolve software issues fast, as hotline staff will establish a secure remote connection to the POAL Konecranes Noell straddle carriers from anywhere in the world.
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PLAIN SAILING: COOL SOLUTION TO NAVY OVERHEATING PROBLEM
More than $250,000 in annual fuel savings for two of the Royal New Zealand Navy’s (RNZN) fleet will be possible, thanks to a unique engineering solution developed by the RNZN and its fleet maintenance partner Babcock (NZ).
Offshore patrol vessels HMNZS Otago and HMNZS Wellington were designed to run mostly using just one of their two main engines and propeller shafts. The speed generated by one engine is generally enough for their operational requirements.
But the issue with this, RNZN Logistics Commander Maritime Captain Andrew Nuttall says, was that the trailing shaft, even though not powered by an engine, still turned because of the wind-milling effect of the propeller through the water, which subsequently generated heat in the gearbox.
“The pump to supply coolant to remove the heat was driven by the engine,” Captain Nuttall says. “But because this was shut down in the case of the trailing shaft, the result was that various components began overheating.
“To avoid that, both engines were required to be running most of the time, even though only one was technically required to power the vessel.”
HMNZS Wellington’s engineering officer Lieutenant Tim Johns and Babcock’s senior mechanical engineer Patrick Clissold view the coolant transfer system.
This meant that $200,000 of essentially wasted fuel was required for every 1,000 hours of running. Having both engines operational also required increased maintenance and It also meant that marine technicians had to manually adjust the cooling system at all hours of the day and night to ensure the ship’s safety.
The RNZN and Babcock combined engineering design team developed a unique solution that cross-connected the cooling system, so that when an engine was shut down the propeller could still rotate, while the heat generated was cooled through diversion of coolant.
The solution developed by the team would result in significant financial benefits, Captain Nuttall says.
“The saving in fuel alone is impressive. Combine that with the reduced maintenance costs and this solution represents an excellent example of the value our engineering team can add.”
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Kaeser Compressors launches new website
Kaeser Compressors New Zealand launched its new website last month, along with a fresh appearance and a simplified navigation, with the new website designed to be user- and mobile- friendly.
The new Kaeser website was created with the end-user in mind. A simplified navigation now divides the website into just four sections; products, solutions, services and company. In addition, a responsive design ensures that whether a visitor is viewing the website from a PC, tablet or smart phone, the website will adapt to suit the device.
The upgraded product section features extensive product range information and now also includes quick access to technical specifications and in many cases 360-degree product views and videos. There are also a myriad of compressed air resources available to Kaeser website visitors including:
• Kaeser toolbox calculators. From a unit conversion calculator to calculating pressure drop, air receiver size and leakages – the Kaeser Toolbox includes a number of practical online calculators.
• Whitepapers. Kaeser regularly writes and presents in-depth reports on compressed air topics such as energy efficiency, as well as advisory articles to assist compressed air users in – for example – selecting the right compressed air equipment for their application. All current whitepapers can be easily accessed from the upgraded Kaeser website.
• Compressed air engineering handbook. Visitors to the new website can also access the Compressed Air Engineering handbook. Following an in-depth introduction to the field of compressed air technology, this handbook covers a series of practical tips for system operators and compressed air users.
Visit www.kaeser.co.nz to see the new site.
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Sunny outlook for fountain thanks to 3D printing
Citycare property supervisor Doug Peek (right) and Wade Peek, from TWP Design in front of the restored Sunnyside fountain.
Innovative 3D printing technology, alongside archived images from the 1970s, were used to help Citycare restore Christchurch’s historic Sunnyside fountain to its former glory.
The fountain was created as a feature in the hospital grounds more than 150 years ago. It is located in what’s now the Sunnyside Heritage Garden on Annex Road – the only remaining part of the once vast complex of 19th century buildings and grounds that comprised Sunnyside Hospital, Christchurch’s first mental health facility.
Vandalism and the theft of its valuable brass fittings left the fountain in a state of demise for nearly 10 years.
Citycare’s property team, led by Citycare property supervisor Doug Peek, was charged with repair and restoration – a challenging task using only historical images as a guide.
“We didn’t have anything in the way of an original template or design, just some grainy photos depicting what the fountain used to look like,” says Doug.
“It was difficult to re-create the missing finial and nozzle due to the quality of the photos and the algae covering what remained.”
TWP Design, a Christchurch-based prototype and product development firm run by Doug’s sons Wade and Travis Peek, was contacted for its 3D printing capabilities.
Prototypes of the fountain’s missing nozzle and ornamental finial were 3D printed using measurements calculated from the photos and existing structure. The prototypes were assessed for fit and authenticity, before the final product was manufactured and then fitted to the fountain.
Citycare maintains and keeps the fountain clean, as part of its water feature maintenance contract.
“The rejuvenated fountain has been met with appreciation with many positive comments from members of the community who spoke to the team whilst renovations were underway,” says Doug.
“One lady mentioned that she has lived in the area for about 10 years, and she had always wanted to see the fountain restored and running so that she could sit and enjoy it and the ambience of the gardens.
“My team and I are thrilled to be part of its restoration, using innovative technology to achieve a task that for many years was left unattended, possibly due to the challenge it presented.”
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Parents urged to take trades seriously
ATNZ has recruited 105 apprentices this year, and still has another 50 apprenticeship vacancies to fill across the country.
Parents and teachers of school leavers need to start taking careers in trades seriously as teens are missing out on genuine opportunities to avoid student loans and get ahead.
Fiona Kingsford, chief executive of industry training organisation Competenz, says while around 60,000 teenagers leave school each year, just 4% of them go straight into trades training.
“We need to triple that. More than half of New Zealand’s apprentices and trainees have already been to university or another tertiary institute and many of them have clocked up student debt. But they could have avoided that debt altogether and started an apprenticeship straight away.
“Research shows that because apprentices start earning earlier, they can buy a house earlier and pay off a mortgage earlier, which puts them financially ahead of university graduates for most of their working lives, and at about the same financial position when they’re ready to retire.
“Our mission is to educate not only school leavers about their opportunities, but also their parents and careers advisers too.”
Competenz works with apprentices and trainees across 36 sectors including mechanical engineering, one of New Zealand’s biggest growth areas.
Ms Kingsford says: “Infometrics data shows that we’ll need 5,500 more workers in the mechanical engineering sector between now and 2022 to fill new jobs and replace workers who retire or leave. That’s just one sector, and with such a small number of school leavers going into the trades, employers are all competing for the same pool of people.
“We need to get more school leavers into trades now, or the skills shortage will only get worse.
“A lot of the decision-making is aided by parents and family members and a lot of the time it’s what mum and dad know of those industries. But we need our young people to be aware of all the opportunities out there.”
Genuine opportunities
Competenz works closely with Apprentice Training New Zealand (ATNZ), the country’s largest employer of mechanical engineering apprentices. “ATNZ has recruited 105 apprentices this year, and still has another 50 apprenticeship vacancies to fill across the country. “Auckland employs one third of mechanical engineers, and coupled with strong future population growth, the region still holds good prospects for those entering the sector. That said, rents and house prices are sky rocketing in Auckland, so working in smaller regions allows people to easily relocate and enjoy a higher quality of life. “There are genuine opportunities throughout the country.”
Cost me five grand
Maintenance engineer Tautalafua Mata’afa went to university when he left school, but it was a costly mistake.
“I went to uni for one semester after high school and that cost me five grand. That’s when I realised I wasn’t really into just studying, I was more into practical work and working with tools.”
He spent the next few years as a labourer in various sectors in New Zealand and Australia before starting an ATNZ apprenticeship in maintenance engineering at Pacific Steel in Auckland. He’s now a qualified tradesman working at Steelpipe in Onehunga.
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Academic warns: Soon it will be ‘Just in time to be too late’
Few organisations are equipped to respond to the challenge of reducing their emissions when the new Zero Carbon Bill becomes law, says a carbon and energy management specialist who is helping the country’s largest organisations build capacity by training a new breed of managers for the changes ahead.
Norman Smith, an academic/consultant hybrid, has for 25 years been developing and delivering post-graduate level capacity building programmes for all sectors of the New Zealand economy and Government.
A principal problem, he says, is senior executives do not yet understand the need to re-structure to achieve the trifecta of benefits awaiting;
• increased productivity/performance
• reducing their carbon footprint
• saving (lots of) money by saving energy
“They are staying with organisational silos which separate strategic/corporate objectives for sustainability from operational goals involving operational/energy use activities.
“This fails to realise the game has changed – forever – and these activities must become integrated in order to deliver overarching decarbonisation targets.”
As a result, there is invariably an internal disconnect and conflict between managers occupying head office based ‘staff’ roles but with no authority and budget and others in positions with the ability to effect change but no mandate to develop strategic initiatives.
“It’s going to get worse as pressure builds to ‘walk the talk’, not just measure their footprint but do something about it.
“The people employed to lead these programmes will come from a wide variety of backgrounds and will be up-skilled leaders – perhaps engineers, perhaps not – with diverse backgrounds. Their intrapreneurship and soft skills of internal advocacy and building internal coalitions will be critical to success.”
Once the Zero Carbon Bill becomes law it’s likely, he says, that the Government will lift its own game; right now while hospitals and universities are building capacity and developing carbon reduction programmes, larger departments appear to be slower off the mark.
Local government on the other hand was investing in staff training on the Carbon:Energy course delivered through the Energy Management Association, as were larger companies such as Fonterra, Oji Fibres, Winstone and Downers. (http://www.emanz.org.nz/energy-and-carbon-manager-professional-training)
He says overseas deep retrofits had proven many times the potential to cost effectively reduce energy costs by well over 50% – not just the 15% New Zealand companies generally settled for – while delivering productivity, decarbonisation and many other benefits which went straight to the bottom line.
www.tinyurl.com/GreenbizRetrofitProjects
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STRATALIGN LIFTING SYSTEMS: ROBUST AND DURABLE SOLUTIONS
Workstation gantry’s, jib and davit cranes are unique lifting devices for industrial and manufacturing environments.
The Erikkila ProSystem design is very durable with its closed profile design. The systems surface is treated with impact resistant powder coating or galvanised finish is also available. Each system is carefully designed to suit your unique workshop size and shape that can either be ceiling mounted or freestanding.
Thern davit cranes provide lifting solutions to water and wastewater treatment plants. From lifting submersible pumps and mixers, to raising filter screens and positioning hopper cars, Thern provides the right equipment to get the job done. Like all Stratalign products, they’re made to meet the conditions of their particular environment with corrosion-resistant finishes in powder coat paint, galvanised or stainless steel construction.
Vacuum lifting is increasingly being recognised as the ideal method of lifting almost any item in a safe, gentle and effective manner. Steel sheets, timber panels, glass, bags/sacks, cartons, drums, and every other conceivable item, airtight or porous, can be moved around the production area single handed with ease.
Contact Stratalign on 09 263 7725 or email sales@stratalign.co.nz
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EFFECTIVE SAFETY TRAINING CAN NOT ONLY SAVE LIVES BUT ALSO AID PRODUCTIVITY
Having to close a section of your plant or halt work due to an incident; conduct investigations and complete incident reports; or more seriously – work through treating and rehabilitating an injured worker – are all serious and stressful tasks that also impact on productivity.
In recent years, the introduction of more comprehensive health and safety legislation; advances in technology and design of personal protective equipment; and increased awareness around health and safety procedures has gone a long way towards improving health and safety in New Zealand workplaces. But despite these measures, many sites still lose time and money as a result of health and safety incidents.
Many of these incidents could have been easily avoided if staff had been competently trained to use safety equipment and follow applicable procedures. Whilst many people employed in a health and safety role are trained, it is critical that all employees – frontline workers, supervisors, managers and even company owners – receive training.
As well as improving your workplace health and safety practices, effective training will provide you with a better understanding of the law and your legal obligations; help you avoid severe penalties; allow for improved management of your business; reduce workplace insurance costs and of course; increase efficiency.
NZ Safety Blackwoods Worksafe Training has been operating as a specialised training organisation, with a philosophy focused on the areas of health, safety and the environment, since the introduction of health and safety legislation in 1993.
Each specialised trainer is fully qualified, both academically and practically, and can provide both industry expertise and educational experience across a wide range of training areas – including, but not limited to emergency response, elevating work platforms, forklifts, height safety, lockout/tagout, hazardous substances, spill response and contractor management.
NZ Safety Blackwoods Worksafe Training also recognises that not all workplaces are the same, and it is often beneficial to customise and tailor training packages to a specific site or situation. Experienced trainers will consult with you and identify your specific training requirements from both a regulatory and an occupational health and safety aspect, then deliver cost-effective training packages tailored to your specific environment.
As well as dedicated training venues in Auckland, Tauranga, Wellington and Christchurch equipped with classrooms and purpose-built facilities; training can also be conducted on your worksite, to both minimise downtime and provide practical experience within a relevant environment.
Implementing regular and effective health and safety training for all staff will help ensure day-to-day operations, maintenance work and shut down activities are completed safely – not only ensuring compliance – but also minimising downtime and driving efficiency.
Engage with the experienced team at NZ Safety Blackwoods Worksafe Training so they can assess your requirements; pull together the best team to meet your training needs; and implement cost-effective, customised workplace training to minimise costs, reduce downtime, and most importantly, keep your team safe at work.
NZ Safety Blackwoods Worksafe Training is an independent Private Training Establishment (PTE) registered by the New Zealand Qualifications Authority (NZQA).
The post EFFECTIVE SAFETY TRAINING CAN NOT ONLY SAVE LIVES BUT ALSO AID PRODUCTIVITY appeared first on NZ Engineering News.
MAZAK TOOLS YOU UP TO BE COMPETITIVE
This was driven by the need to be focused on how to keep competitive. In the past, Victor Hydraulics also bought ‘like for like’ machines for “standardisation reasons,” but then realised over time they were not getting any gains from new technology and were stuck in a rut.
“This need for standardisation was constraining our thinking,” says manufacturing manager Darryl May. “But the constraints are mainly in the mind, because we tell ourselves this is the way we have always done things, by doing this we were seriously limiting ourselves.”
So, Victor Hydraulics sent out specification requirements to four different suppliers; the overall offering that met Victor Hydraulics’ vision for the future in terms of size, controller, tool hive, pallet system and market support was Mazak.
“There was quite a bit at stake and the specifying and install process was very smooth – no-one cut any corners and I am very comfortable with the support we are getting from the team. From a commissioning point of view, it was well coordinated with good communication in advance so there were no surprises,” he says.
No-one attends the machine during the night shift. The tool hive allows the Mazak to run unmanned using the tool monitoring and there are enough tools in the machine to call back up tools. Without the hive Victor Hydraulics would not have a chance of aiming for this goal.
“The technology and configuration allow you to achieve delivery nimbleness. This machine gives us zero set-up time by the ability to set up pallets while another is being machined, our spindle cut time is very high and the smooth controller is super impressive and very intuitive.”
Even with adding more operations to the part being machined, within two months Victor Hydraulic have doubled production rate and halved labour content, and throughput per hour has gone up considerably – the machine is now running 21 hours per day.
With any machine tool investment, the quality of the after sales service is a huge decider in which direction the purchaser will go. When put to Darryl, he says: “Victor Hydraulics realised that while NZMT is a new agent for Mazak, its associated company Iscar Plus was not going to put their cutting tool business with us at risk with poor service, and we realise that Iscar have been in the industry for a long time. Victor Hydraulics trust they will get it right.”
Director John McCallister adds: “Victor Hydraulics are focused on through-put, that’s our main measure”, we have added value by adding to our capability which appeals to our clients and we can also offer design improvements because of the new capabilities.”
The post MAZAK TOOLS YOU UP TO BE COMPETITIVE appeared first on NZ Engineering News.
SPOTTING WARNING SIGNS – THAT HYDRAULIC HOSES NEED SERVICING
LMR Truck & Trailer Mossvale’s James Haddow with a newly serviced truck
Heavy transport and fleet operators are all too familiar with the importance of having fully functional and safe hydraulic hoses and fittings. A single fault can be deadly.
But since hydraulic hoses wear out at different rates, depending on usage and the environment in which they operate, it’s impossible to give a time-frame for when a service should be undertaken.
Instead, users of machinery that relies on hydraulic power should look out for early warning signs, says Shane Sutton, service technician, LMR Truck & Trailer Mossvale, who works closely with James Haddow as one of more than 100 authorised Hydraulink dealers across Australia.
Fixing problems during programmed maintenance is far cheaper and more efficient than expensive breakdowns causing downtime, and environmental damage.
Through its network of trusted distributors, Hydraulink provides high quality, tested and compliant hydraulic hoses, adaptors and fittings to industries such as transport, mining, earthmoving and civil contractor, agriculture, OEM manufacturers, materials handling, utilities, recycling and waste management.
SHANE’S TOP TIPS FOR HYDRAULIC HOSE SERVICE
LMR Truck & Trailer services a range of heavy vehicles, such as powder tankers, agitators and tippers, and Shane says that even though you can’t specify a time when they’ll need a service, there are a few signs to look out for:
1. The most common fault with hydraulic hoses, is wear to the outer cover. This can be caused by the hose rubbing up against something, or not properly located in a clamp or bracket. The outer cover of the hose is there to protect the reinforcement which is the strength of the hose assembly. If you see a worn cover, it is a lot easier to change that hose then, rather than wait for it to fail in the field.
2. Are there leaks at the ends of the hose? This can be from the fittings being loose, or an ‘O’ ring deteriorating. It could also be that there is a poor seal between the hose and fitting due to high temperatures or the hose being aged.
3. Exposed wires, usually caused by wear, will rust easily, or fail. Companies should not only replace these hoses, but look for a way to prevent future wear.
4. Make sure hoses are not kinked or twisted. Kinked hoses prevent flow, and a twist in a hose will rapidly reduce its life.
“For major companies with large fleets of vehicles, it’s often best to have a preventative maintenance programme in place, to stop normal wear and tear turning into a major fault.
“As a diesel mechanic, Hydraulink products make my job safer and easier,” says Mr Sutton, who has nearly a decade of experience in hydraulic service.
After using hydraulic products from a range of suppliers, LMR Truck & Trailer is now one of more than 100 authorised Hydraulink dealers in Australia.
Mr Sutton says the Hydraulink range is ideally suited to diesel mechanics, due to its broad range of parts and locally available stock.
“Whether it’s a turbo hose for a diesel truck, an oil-resistant hose for high temperature applications or a general-purpose fuel hose for low pressures, Hydraulink has it covered. Their products can handle any pressure.” says Mr Sutton.
“Even if we need a braided supply hose from the compressor down to the tanks, Hydraulink has the exact product, fully standards compliant and ready to go. It really puts our mind at ease.
“Hydraulink hoses are always manufactured to top quality and safety standards. They have the pressures easily labelled on the hoses to avoid any confusion,” says Mr Sutton.
“When servicing hydraulic hoses, fittings and adaptors, mechanics need to be spot on, every time. A faulty hose or incorrect fitting can have dire consequences when operating at high pressure (typically 3,000 – 7,000 PSI in mobile applications).
“One of the big advantages of using Hydraulink products is that there is an extensive amount of experience and capability built up under the one brand, so customers know that all Hydraulink branded products will be delivered to the same high-quality standards. This consistency and quality is very important to customers with diverse and multiple sites who want traceability and uniformly high standards of service and safety delivered across their organisations.”
The post SPOTTING WARNING SIGNS – THAT HYDRAULIC HOSES NEED SERVICING appeared first on NZ Engineering News.
PORTS OF AUCKLAND USES 24/7 SOFTWARE SERVICE FOR NEW AUTOMATED CRANES
Ross Clarke, left, programme manager, terminal automation, Ports of Auckland; and Mario van den Heuvel, director, technical support, port service, Konecranes.
The newly signed software service level agreement (SLA) with Konecranes includes 24/7 software technical support once the new equipment goes live.
The equipment covered by the software service level agreement includes 27 new Konecranes Noell automated straddle carriers (A-STRADs) and 21 retrofits to manually operated Konecranes Noell straddle carriers that would make them fully automated.
“Our upgrade to automated straddles is essential to increasing our capacity so that we can handle the future freight needs of a rapidly growing Auckland city,” says Ports of Auckland chief executive Tony Gibson.
“In order to deliver for the city, we need to have confidence that any problems with the automation software will be resolved quickly and efficiently. This SLA gives us that confidence,” he says.
Mario van den Heuvel, director, technical support, Konecranes Port Service, says, “We very much appreciate the trust of POAL in our automated straddle carriers and software. The software agreement comes as part of the Konecranes automation solution in order to provide support under the most critical circumstances, and also, to provide piece of mind when changing, upscaling or transitioning from manual to automated operation. With around the clock access to our experts and minimum failure response times, the transition becomes easier.”
Under the SLA, Konecranes will provide a 24/7 expert hotline, continuous access to its service desk, and the latest updates of all the system software. Konecranes will be able to react and resolve software issues fast, as hotline staff will establish a secure remote connection to the POAL Konecranes Noell straddle carriers from anywhere in the world.
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PLAIN SAILING: COOL SOLUTION TO NAVY OVERHEATING PROBLEM
More than $250,000 in annual fuel savings for two of the Royal New Zealand Navy’s (RNZN) fleet will be possible, thanks to a unique engineering solution developed by the RNZN and its fleet maintenance partner Babcock (NZ).
But the issue with this, RNZN Logistics Commander Maritime Captain Andrew Nuttall says, was that the trailing shaft, even though not powered by an engine, still turned because of the wind-milling effect of the propeller through the water, which subsequently generated heat in the gearbox.
“The pump to supply coolant to remove the heat was driven by the engine,” Captain Nuttall says. “But because this was shut down in the case of the trailing shaft, the result was that various components began overheating.
“To avoid that, both engines were required to be running most of the time, even though only one was technically required to power the vessel.”
HMNZS Wellington’s engineering officer Lieutenant Tim Johns and Babcock’s senior mechanical engineer Patrick Clissold view the coolant transfer system.
This meant that $200,000 of essentially wasted fuel was required for every 1,000 hours of running. Having both engines operational also required increased maintenance and It also meant that marine technicians had to manually adjust the cooling system at all hours of the day and night to ensure the ship’s safety.
The RNZN and Babcock combined engineering design team developed a unique solution that cross-connected the cooling system, so that when an engine was shut down the propeller could still rotate, while the heat generated was cooled through diversion of coolant.
The solution developed by the team would result in significant financial benefits, Captain Nuttall says.
“The saving in fuel alone is impressive. Combine that with the reduced maintenance costs and this solution represents an excellent example of the value our engineering team can add.”
The post PLAIN SAILING: COOL SOLUTION TO NAVY OVERHEATING PROBLEM appeared first on NZ Engineering News.
Kaeser Compressors launches new website
The new Kaeser website was created with the end-user in mind. A simplified navigation now divides the website into just four sections; products, solutions, services and company. In addition, a responsive design ensures that whether a visitor is viewing the website from a PC, tablet or smart phone, the website will adapt to suit the device.
The upgraded product section features extensive product range information and now also includes quick access to technical specifications and in many cases 360-degree product views and videos. There are also a myriad of compressed air resources available to Kaeser website visitors including:
• Kaeser toolbox calculators. From a unit conversion calculator to calculating pressure drop, air receiver size and leakages – the Kaeser Toolbox includes a number of practical online calculators.
• Whitepapers. Kaeser regularly writes and presents in-depth reports on compressed air topics such as energy efficiency, as well as advisory articles to assist compressed air users in – for example – selecting the right compressed air equipment for their application. All current whitepapers can be easily accessed from the upgraded Kaeser website.
• Compressed air engineering handbook. Visitors to the new website can also access the Compressed Air Engineering handbook. Following an in-depth introduction to the field of compressed air technology, this handbook covers a series of practical tips for system operators and compressed air users.
Visit www.kaeser.co.nz to see the new site.
The post Kaeser Compressors launches new website appeared first on NZ Engineering News.
Sunny outlook for fountain thanks to 3D printing
Citycare property supervisor Doug Peek (right) and Wade Peek, from TWP Design in front of the restored Sunnyside fountain.
Innovative 3D printing technology, alongside archived images from the 1970s, were used to help Citycare restore Christchurch’s historic Sunnyside fountain to its former glory.
The fountain was created as a feature in the hospital grounds more than 150 years ago. It is located in what’s now the Sunnyside Heritage Garden on Annex Road – the only remaining part of the once vast complex of 19th century buildings and grounds that comprised Sunnyside Hospital, Christchurch’s first mental health facility.
Vandalism and the theft of its valuable brass fittings left the fountain in a state of demise for nearly 10 years.
Citycare’s property team, led by Citycare property supervisor Doug Peek, was charged with repair and restoration – a challenging task using only historical images as a guide.
“We didn’t have anything in the way of an original template or design, just some grainy photos depicting what the fountain used to look like,” says Doug.
“It was difficult to re-create the missing finial and nozzle due to the quality of the photos and the algae covering what remained.”
TWP Design, a Christchurch-based prototype and product development firm run by Doug’s sons Wade and Travis Peek, was contacted for its 3D printing capabilities.
Prototypes of the fountain’s missing nozzle and ornamental finial were 3D printed using measurements calculated from the photos and existing structure. The prototypes were assessed for fit and authenticity, before the final product was manufactured and then fitted to the fountain.
Citycare maintains and keeps the fountain clean, as part of its water feature maintenance contract.
“The rejuvenated fountain has been met with appreciation with many positive comments from members of the community who spoke to the team whilst renovations were underway,” says Doug.
“One lady mentioned that she has lived in the area for about 10 years, and she had always wanted to see the fountain restored and running so that she could sit and enjoy it and the ambience of the gardens.
“My team and I are thrilled to be part of its restoration, using innovative technology to achieve a task that for many years was left unattended, possibly due to the challenge it presented.”
The post Sunny outlook for fountain thanks to 3D printing appeared first on NZ Engineering News.
Parents urged to take trades seriously
ATNZ has recruited 105 apprentices this year, and still has another 50 apprenticeship vacancies to fill across the country.
Parents and teachers of school leavers need to start taking careers in trades seriously as teens are missing out on genuine opportunities to avoid student loans and get ahead.
Fiona Kingsford, chief executive of industry training organisation Competenz, says while around 60,000 teenagers leave school each year, just 4% of them go straight into trades training.
“We need to triple that. More than half of New Zealand’s apprentices and trainees have already been to university or another tertiary institute and many of them have clocked up student debt. But they could have avoided that debt altogether and started an apprenticeship straight away.
“Research shows that because apprentices start earning earlier, they can buy a house earlier and pay off a mortgage earlier, which puts them financially ahead of university graduates for most of their working lives, and at about the same financial position when they’re ready to retire.
“Our mission is to educate not only school leavers about their opportunities, but also their parents and careers advisers too.”
Competenz works with apprentices and trainees across 36 sectors including mechanical engineering, one of New Zealand’s biggest growth areas.
Ms Kingsford says: “Infometrics data shows that we’ll need 5,500 more workers in the mechanical engineering sector between now and 2022 to fill new jobs and replace workers who retire or leave. That’s just one sector, and with such a small number of school leavers going into the trades, employers are all competing for the same pool of people.
“We need to get more school leavers into trades now, or the skills shortage will only get worse.
“A lot of the decision-making is aided by parents and family members and a lot of the time it’s what mum and dad know of those industries. But we need our young people to be aware of all the opportunities out there.”
Genuine opportunities
Competenz works closely with Apprentice Training New Zealand (ATNZ), the country’s largest employer of mechanical engineering apprentices. “ATNZ has recruited 105 apprentices this year, and still has another 50 apprenticeship vacancies to fill across the country. “Auckland employs one third of mechanical engineers, and coupled with strong future population growth, the region still holds good prospects for those entering the sector. That said, rents and house prices are sky rocketing in Auckland, so working in smaller regions allows people to easily relocate and enjoy a higher quality of life. “There are genuine opportunities throughout the country.”
Cost me five grand
Maintenance engineer Tautalafua Mata’afa went to university when he left school, but it was a costly mistake.
“I went to uni for one semester after high school and that cost me five grand. That’s when I realised I wasn’t really into just studying, I was more into practical work and working with tools.”
He spent the next few years as a labourer in various sectors in New Zealand and Australia before starting an ATNZ apprenticeship in maintenance engineering at Pacific Steel in Auckland. He’s now a qualified tradesman working at Steelpipe in Onehunga.
The post Parents urged to take trades seriously appeared first on NZ Engineering News.
Academic warns: Soon it will be ‘Just in time to be too late’
Norman Smith, an academic/consultant hybrid, has for 25 years been developing and delivering post-graduate level capacity building programmes for all sectors of the New Zealand economy and Government.
A principal problem, he says, is senior executives do not yet understand the need to re-structure to achieve the trifecta of benefits awaiting;
• increased productivity/performance
• reducing their carbon footprint
• saving (lots of) money by saving energy
“They are staying with organisational silos which separate strategic/corporate objectives for sustainability from operational goals involving operational/energy use activities.
“This fails to realise the game has changed – forever – and these activities must become integrated in order to deliver overarching decarbonisation targets.”
As a result, there is invariably an internal disconnect and conflict between managers occupying head office based ‘staff’ roles but with no authority and budget and others in positions with the ability to effect change but no mandate to develop strategic initiatives.
“It’s going to get worse as pressure builds to ‘walk the talk’, not just measure their footprint but do something about it.
“The people employed to lead these programmes will come from a wide variety of backgrounds and will be up-skilled leaders – perhaps engineers, perhaps not – with diverse backgrounds. Their intrapreneurship and soft skills of internal advocacy and building internal coalitions will be critical to success.”
Once the Zero Carbon Bill becomes law it’s likely, he says, that the Government will lift its own game; right now while hospitals and universities are building capacity and developing carbon reduction programmes, larger departments appear to be slower off the mark.
Local government on the other hand was investing in staff training on the Carbon:Energy course delivered through the Energy Management Association, as were larger companies such as Fonterra, Oji Fibres, Winstone and Downers. (http://www.emanz.org.nz/energy-and-carbon-manager-professional-training)
He says overseas deep retrofits had proven many times the potential to cost effectively reduce energy costs by well over 50% – not just the 15% New Zealand companies generally settled for – while delivering productivity, decarbonisation and many other benefits which went straight to the bottom line.
www.tinyurl.com/GreenbizRetrofitProjects
The post Academic warns: Soon it will be ‘Just in time to be too late’ appeared first on NZ Engineering News.
STRATALIGN LIFTING SYSTEMS: ROBUST AND DURABLE SOLUTIONS
The Erikkila ProSystem design is very durable with its closed profile design. The systems surface is treated with impact resistant powder coating or galvanised finish is also available. Each system is carefully designed to suit your unique workshop size and shape that can either be ceiling mounted or freestanding.
Thern davit cranes provide lifting solutions to water and wastewater treatment plants. From lifting submersible pumps and mixers, to raising filter screens and positioning hopper cars, Thern provides the right equipment to get the job done. Like all Stratalign products, they’re made to meet the conditions of their particular environment with corrosion-resistant finishes in powder coat paint, galvanised or stainless steel construction.
Contact Stratalign on 09 263 7725 or email sales@stratalign.co.nz
The post STRATALIGN LIFTING SYSTEMS: ROBUST AND DURABLE SOLUTIONS appeared first on NZ Engineering News.
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