Automation/Industry 4.0

In an Australian manufacturing success story, Ellume is in the process of automating the high-volume production of its rapid COVID-19 home test using the latest technologies from Bosch and Rockwell Automation.  The COVID-19 pandemic has rapidly spread to all parts of the globe. There have been more than 395 million cases [1] around the world and this figure continues to rise rapidly. Healthcare systems are overwhelmed and continue to face a multitude of challenges as they work to manage demand while providing high-quality care. Communities, governments and industry around the world are now recognising the importance of minimising the requirement for widespread lockdowns and travel restrictions, which have been the main line of defence against COVID-19 since the start of the pandemic. As countries around the world move towards a new post-pandemic normal, rapid diagnostic testing has an integral role in reducing disease burden, managing outbreaks and community transmission, and reducing pressure on healthcare systems. Ellume, a Brisbane-based digital diagnostic company, has recently developed a rapid COVID-19 home test which detects the SARS-CoV-2 antigen and complies with Centers for Disease Control and Prevention (CDC) reporting requirements. Accurate results are provided within 15 minutes, providing users with quick results, and helping communities to return to a ‘new normal.’ With a growing list of orders, predominantly from the United States, ensuring supply was a key priority for Ellume. Scaling up production To meet the consumer demand for COVID-19 home tests, Ellume has invested in new manufacturing lines for their facilities in both Australia and the U.S. “COVID-19 isn’t going away anytime soon and as communities and economies continue to open up there will be increased need for rapid antigen tests which is why automating our production is vital to meet a surge in consumer demand,” said Sean Parsons, founder and CEO, Ellume. Ellume called on Bosch Australia Manufacturing Solutions (BAMS), a leading supplier of factory automation for the medical device industry, to automate the high-volume production of its COVID-19 diagnostic tests. This involves 27 new production lines in total – three new lines for Ellume’s facility in Brisbane, Australia and 24 production lines for their facility in Maryland, U.S. “We are providing Ellume with 18 fully automated assembly lines for manufacturing the home COVID-19 analyser unit. This also includes an end-of-line test system which communicates to the analyser unit over Bluetooth and completes a functional check to ensure the quality of the part,” said Bradley Trewin, Programme Manager, BAMS. “BAMS is also manufacturing nine lines for the production of the ‘dropper’ which will fully automate the assembly and packing of this product,” he added. Next generation technologies The Bosch manufacturing experience and factory automation know-how has benefited this project immensely. The production lines are being manufactured at Bosch’s headquarters in Clayton, Victoria. More than 160 robots are being utilised on this project, there are also 200-plus vision systems which are cameras that inspect and evaluate the line, and more than 60 programmable logic controllers (PLCs).  “We are delighted to bring the BAMS automation expertise to support Australian med-tech manufacturing for a global market – a real positive for local manufacturing, and a positive for the testing and medical diagnosis of COVID-19,” said Gavin Smith, President of Bosch Australia. An Australian manufacturing success story Ellume’s technology addresses the unprecedented global demand for accurate and rapid diagnostics as accessible, reliable, and fast diagnostics become increasingly critical to the COVID-19 response. Given the widespread supply shortages resulting from the pandemic, Rockwell Automation has prioritised their global supply chain to applications and machines that can help in the fight against COVID-19. “Our priority is to support local manufacturing, helping to ensure that we are able to provide much needed assistance to those requiring it urgently,” said Anthony Wong, regional director, Rockwell Automation.  “By working with local innovative companies such as BAMS and Ellume, we can deliver next generation technologies to help mitigate the risks of COVID-19 while also strengthening the Australian manufacturing industry,” he said. The new Ellume manufacturing facility will be one of the largest of its kind in the Southern Hemisphere. The production lines for Ellume’s Brisbane facility are undergoing final testing and likely to be operational by the end of February, whilst the first U.S. lines departed in November 2021.  The final lines for the US are expected to be installed and operational in mid-2022. Once complete, the production capacity across the whole Ellume project will be nine parts per second. “We’ve spent the last decade perfecting our technology, and now, in the midst of the COVID-19 pandemic, the role of rapid, accurate diagnostics has never been more important. Ellume is pleased to be working with Bosch to bring their world-leading automation know-how to our manufacturing process. This will allow Ellume to manufacture best-in-class diagnostics that can be relied on in a health crisis,” said Dr Parsons.”

Global e-grocery disruptor, Rohlik, has invested in Swisslog automated micro-fulfilment centre (MFC) solutions to boost pick productivity threefold, and deliver 60% more storage space. Rohlik has added two new projects, which are part of a $66m AUD (45m Euro) automation investment, as the company plans to deliver faster service more than 850,000 customers, with the flexibility to effectively manage demand peaks. The same automation technologies are providing benefits to e-grocery and retail customers in Australasia, after being proven in the U.S. for years. “Automating e-grocery fulfillment enables significant productivity improvements compared to picking products from store shelves, and it also eliminates in-store picker congestion,” says Mr Francis Meier, Managing Director, Swisslog Australia and New Zealand. “Automated micro-fulfillment centres help to reduce delivery costs and shorten the last mile and the time to consumer. They are also an ideal solution for fulfilling online orders for curbside pickup,” he said. Rohlik’s latest automation projects will deliver a threefold increase in picking productivity, over 60% more storage space in its fulfilment centres, and a streamlined replenishment and inventory process, says Swisslog. Shift in consumer behaviour The pandemic has brought a major shift in grocery shopping patterns, with research suggesting that up to two-thirds of consumers changed their grocery shopping behaviour. Now, industry analysts and grocers are projecting that for a significant percentage of the market, these initially short-term adaptations will translate into long-term behaviour changes. “The right automation solutions are enabling e-grocery providers to operate with the sustained throughput they need, while also providing operational flexibility to accommodate demand peaks,” says Mr Meier. “Having sold or implemented several e-grocery projects in recent years, we are ideally placed to now support Rohlik on their growth journey with flexible and temperature controlled automation.” “We are proud to be a main partner for Rohlik with our large and committed team, which has ideal expertise in software, AutoStore, and integrated logistics solutions.” Multi-million dollar automation projects The first project for Rohlik involves a fulfillment centre in Prague, Czech Republic, and is due to be completed by the end of 2023. The e-grocery operations will utilise AutoStore technology, the Swisslog CycloneCarrier Shuttle solution and Swisslog QuickMove conveyor system, all supported by Swisslog’s SynQ Software. The second project is for an e-grocery fulfillment centre in Vienna. This facility will also use Swisslog’s SynQ Software and AutoStore technology, combined with Swisslog’s QuickMove modular conveyor system. E-grocery experience Swisslog has a well-established and growing reputation for successfully implementing automation projects across the burgeoning e-grocery sector. In the US, The GIANT Company recently opened its new, state-of-the-art GIANT Direct E-commerce Fulfillment Centre (EFC) in Philadelphia, US. This new, 124,000 square foot facility is powered by AutoStore and optimised by Swisslog’s SynQ software. “Swisslog has also partnered with H-E-B in San Antonio, Texas, to deploy a number of automated micro-fulfilment centres to support the chain’s curbside pick-up and delivery business. In the recent months, we have also received orders and implemented new e-grocery projects for customers in Italy and the Middle East,” explains Mr Meier, highlighting the growing e-grocery automation business on a global scale. In Sydney, Australia, Swisslog is currently underway building a new automated micro-fulfillment centre with 24/7 click and collect for e-commerce order fulfillment specialists, SKUtopia. A spokesman for SKUtopia said, “Swisslog’s solution provides flexibility to grow as SKUtopia grows, and as our customers grow, which means all companies can stay agile and responsive to growth or changes in product or offering.” “The automated solution has also increased efficiency, accuracy and throughput, allowing us to deliver products to customers faster. The system provides an average increase of 1200% (12 times) compared with a manual warehouse,” he said.

Konecranes has further enhanced its commitment to cybersecurity and the protection of its customer’s data through achieving ISO/IEC 27001:2013 certification for information security management.  The globally recognised ISO/IEC 27001 certificate demonstrates a commitment to proactively manage the information security of Konecranes’ digital services and ensure compliance with legal and customer requirements. Konecranes is one of the first companies in the lifting equipment and service industry to certify its digital services provided to customers.  “During the past few years, we have seen rising awareness in the industry for cybersecurity get to a point where having an ISO 27001 certification on our Information Security Management System was a natural choice. Certification is a common language for communicating security management practices with our customers,” says Timo Harjunen, Vice President, Digital Platform Development, Konecranes.  “This achievement is important for our customers in many industries, but especially in Ports, Power and Automotive, where security is a critical requirement when choosing a supplier,” said Mr Harjunen.  The certification applies to the development and delivery of the yourKONECRANES.com customer portal, productivity-enhancing mobile applications and the TRUCONNECT® suite of remote service products and applications for all Konecranes customers, including manufacturing and process industries, shipyards, ports and terminals.  “A strong focus on customers and a commitment to business growth and continuous improvement make Konecranes an industry leader. This is underpinned by investments in digitalization and technology, plus our work to make material flows more efficient with solutions that advance circularity and safety,” says Mr Harjunen  yourKONECRANES Portal  Konecranes’ customer portal, yourKONECRANES.com, provides quick and easy access to crane maintenance information, asset condition and usage data, and agreement details. The portal provides a transparent view of all maintenance activities, TRUCONNECT alerts, and even spend over any selected time interval. Aggregated data can be viewed, analyzed and shared quickly, for a single asset or an entire fleet.    TRUCONNECT® Remote Monitoring  TRUCONNECT is a suite of remote service products and applications to support maintenance operations and drive improvements in safety and productivity.  TRUCONNECT Remote Monitoring collects condition, usage and operating data from control systems and sensors on a crane and provides alerts of certain anomalies. Remote Monitoring data is used in maintenance planning and in predicting possible component or equipment failure.  TRUCONNECT data is accessible on the yourKONECRANES customer portal and includes:  Safety-related occurrences, such as brake service life, over-temperatures, attempted overloads and emergency stops  Pareto analysis of critical alerts and faults  Operating statistics, such as load spectrum, monitoring of hoist jogging, overloads, emergency stops, work cycles and running hours  Estimates of remaining Design Working Period (DWP) of selected components, such as the hoist, hoist brake, contactors and trolley  

Leading beverage distribution specialist, BevChain (a wholly owned subsidiary of Linfox), has further extended its commitment to work smarter for its customers, with the installation of a Swisslog PowerStore automated warehouse shuttle system. BevChain installed the highly customisable Swisslog PowerStore system at its facility in Auburn, NSW, which is conveniently located adjacent to the brewery of one of its major customers. “PowerStore is next generation warehouse automation. It has increased storage utilisation by around 60 per cent in the same building footprint, created a safer workplace for our people, and will deliver growth for our customers,” said Linfox President, BevChain, Misha Shliapnikoff. BevChain delivers tailored beverage supply chain solutions across Australia and New Zealand. It leads the industry with 22 distribution centres across six states, handling more than 2.5 billion serving units annually. PowerStore is ideally suited to applications seeking to achieve high throughput and optimal space utilisation, in industries such as fast-moving consumer goods (FMCG), e-grocery and pallet warehousing. PowerStore can also operate in a range of environments, from -30°C in frozen food storage up to 50°C, and can easily be retrofitted to warehouses with low ceilings or unusual shapes. Swisslog’s PowerStore solution for BevChain consists of vertical conveyors that accommodate fast and effective pallet movements between levels, RowCarriers that retrieve from, and deliver pallets to, transfer stations at the vertical conveyor, and AisleCarriers that use precision lasers to transport RowCarriers between the vertical conveyor and the designated row. Swisslog has more than 50 years of global experience in the design and implementation of pallet warehouses, and its PowerStore system complements a comprehensive range of highly customisable automation and Industry 4.0 solutions that Swisslog provides to retail, FMCG, food and beverage, logistics, transport, pharmaceutical and warehousing operations globally. “The new 24/6 facility includes over 30,000 pallet locations, with vertical conveyors transferring pallets to and from one of five levels. It has 20 satellite AisleCarriers and RowCarriers, one in each level of the four quadrants transferring pallets to and from their location. This is all pre-determined by Swisslog’s intelligent SynQ software,” said Mr Shliapnikoff. “This technology-driven facility is also giving our people the chance to gain new knowledge and skills in a warehouse of the future,” he said. Swisslog’s advanced SynQ software is fully integrated with BevChain’s warehouse management system and creates a seamless operation. It ensures full traceability and trackability including batch numbers and visibility on storage and throughput, using automation for receipt despatch. Swisslog Managing Director, Australia and New Zealand, Francis Meier, says the new PowerStore system provides safety and efficiency benefits to BevChain’s operations. “Replacing manual operations with an automated system increases the accuracy of picking and removes error, which leads to fewer returns, and greater profitability,” he said. “The solution has delivered productivity benefits and makes the warehouse safer and quieter. And, because we were converting an existing manual warehouse, our team worked closely with BevChain to ensure the go-live phase was carried out in stages, to minimise the impact during commissioning,” he said. “The working relationship with BevChain has been outstanding. Swisslog has been involved right from the beginning, in the ideas and design stages, and every step of the way, the two companies have worked together to achieve the best outcomes.” Dedicated on-site systems operations team To further enhance operational efficiency, and to ensure the system is always operating at optimal levels, BevChain partnered with Swisslog to bring on board a  highly trained Swisslog system operations team to work in collaboration with BevChain onsite. This core team strongly supports and works closely with BevChain to provide software support, training, condition monitoring and spare parts maintenance, to improve the overall lifecycle of the automation. They are focused on BevChain’s requirements and expertly maintain the complex task of maintaining continuous system performance. Swisslog Maintenance Manager, Paul Woodward, says the team is performing exceptionally well at BevChain. “The training, commissioning and handover stages went very smoothly, with the team working well as a unit. Members of the same team that helped build the PowerStore solution are now part of the system operations team, which means they have a huge advantage when it comes to problem-solving and troubleshooting in the future. Knowing how the system is connected – including parts that are no longer easily accessible – can save a lot of time when identifying issues in the future,” he said. Mr Shliapnikoff says, “we value the highly skilled, onsite Swisslog team who work in partnership with our people. They provide vital insights, immediate incident response and proactively monitor equipment to ensure maximum efficiency over its life span.” “This site represents BevChain’s commitment to work smarter for our customers. We continue to invest in their future with high performing supply chains and best-in-class technology.”

Large helium-filled balloons are used by filmmakers to provide even lighting for night scenes Lightweight self-illuminating balloons are often used by filmmakers to provide even overhead lighting for night scenes. Leading German supplier of these specially designed luminaries, blberlin, is using LAPP EPIC® connectors to ensure a lightweight and stable connection solution. “This impressive application shows the versatility of LAPP’s product range. In an application where every gram counts, EPIC’s lightweight design has a significant advantage,” says LAPP Australia General Manager, Mr Simon Pullinger. “The lightweight connectors are ideal for industrial applications and challenges where weight matters. LAPP EPIC® power cable connectors are regularly used in plant engineering applications, servo drives and servo assemblies, but are broadly applicable to any application requiring a high quality, lightweight and compact solution,” says Mr Pullinger Flying film balloons take flight The founder of blberlin, Fabian Friedrich was a trained carpenter by profession, but became fascinated with helium filled lighting balloons when he first saw them used by a French company in the 1990s. “At that time, it was a totally new way of lighting large surfaces at night. Finally, light had been set free and we could have a large self-illuminating surface floating above the set,” Mr Friedrich recalls. It was a method that an increasing number of camera operators liked, as they had previously had to use unwieldy cranes and aerial platforms for lighting. Mr Friedrich founded his company in 2001, bringing in components from France to recreate the solution for the German film industry. But because spare parts from France were expensive and the light intensity requirements for film productions were constantly increasing, in 2006 he started working with his electrician to develop his own lighting balloons for film sets. One thing was clear: All components had to be as lightweight as possible – including the connectors. “We needed the smallest possible lightweight connector that allows high current loads and can fly as part of the balloon. My electrician was familiar with LAPP. The advice from the local application engineer at LAPP was uncomplicated and we quickly found what we were looking for,” says Mr Friedrich. The EPIC® Power LS1 industrial connector was chosen, and is exceptionally robust against impacts and environmental influences. Since then, Mr Friedrich has remained loyal to LAPP’s connection solutions. “The quality of the products and the service are great,” he adds. Technically challenging lighting solutions The lighting balloons can rise to between 10 and 80 metres depending on requirements. The balloons consist of a special helium-tight and translucent special coating. Inside is the electrical unit with the illuminant. A plastic plate at the “south pole” at the bottom seals everything hermetically. This is also where the EPIC® Power LS1 connector is integrated. ÖLFLEX® ROBUST 210 power and control cables, which transmit 220 volts or even high-voltage power at 380 volts, ensure a reliable downwards connection. Mr Friedrich and his team develop and produce their helium balloons based on the relevant requirements on the film set such as lighting levels, light output and light colour. And precise calculations are always essential. Each cubic metre of helium generates 1.1145 kg of lift. This means that the weight of every component for the balloon – from the special translucent coating for the casing to the luminaire to the circuit board and the connector – has to be taken into account. The plastic casings alone are designed for six to 81 cubic metres of helium as required. “For us, every gram counts,” says Mr Friedrich. Finally, the wind load also has to be considered. The balloons must stay up even in windy conditions. They are approved up to a wind strength of four. For this reason, the current wind data from nearby airports is regularly retrieved on the film set. Now, blberlin has around 70 different balloon versions and around the same number of different control units with cables and connectors that can be installed in the balloons virtually “plug and play”. The flexible combination of balloons and control units means that a tailored solution is usually ready to hand. Depending on requirements, they can be used in artificial light, daylight and mixed light areas in and deliver a light output of up to 50,000 watts. Lighting up film stars Mr Friedrich had his most interesting contract on Lake Turkana in Kenya a few years ago. A film about child soldiers was made there over two and a half months. The Berlin-based company designed a helium balloon with a diameter of 5.5 metres and an output of 42,000 watts especially for this film. It had to float at a height of 80 metres above the landscape at the edge of the lake. “We developed our own prototype for the job and shipped it to Nairobi. We only had time to test it once, but thankfully, everything worked,” says Mr Friedrich. The entrepreneur rarely comes into contact with the film stars. When it does happen it’s by accident. On the Valkyrie film set in Berlin, he suddenly found himself standing next to Tom Cruise. Mr Friedrich says with a smile: “I didn’t even notice at the time, but my wife told me about it later on.” Working almost exclusively with freelance staff, blberlin does most of its business with the European film industry. Film balloons for night transmissions were followed by effective, fast and power saving illumination of blue and green screens. More and more balloons are also being used for outdoor transmission in sporting events, especially in open countryside, skiing, downhill and biathlon. At a G7 summit in 2015, balloons printed with a portrait of Barack Obama were even floating in the Bavarian sky as an art project. Future expansion plans Mr Friedrich is optimistic about the future. “At the start of the pandemic, business came to an almost complete stop. But everything began to return to normal again very quickly. Our team is always a long way away from the set and films are in demand more than