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WHS Duties for Manufacturing Industry

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SafeWork NSW, the workplace health and safety regulator in NSW, acknowledges manufacturing as a cornerstone of a strong Australian economy. The regulator has an ongoing commitment to manufacturing which ensures a safe work environment for all workers — achieved by working with NSW businesses to reduce work-related fatalities, serious injuries, and illnesses. As part of its education outreach, the regulator will be attending Australian Manufacturing Week, given that the expo attracts diverse manufacturing industries and heavy steel fabrication companies. “It also attracts a large variety of WHS duty holders,” says Natalie Martin, Director of Investigations, Engineering and Enforcement at Safework NSW. “We want to connect and engage with the various WHS duty holders across manufacturing.”

Regulatory Priorities

SafeWork NSW’s Manufacturing Sector Plan was developed to influence safety improvements in NSW manufacturing. In 2023, SafeWork identified specific regulatory priorities across risk types and sectors which includes fire safety in manufacturing. Martin says, “Our regulatory priorities were designed to ensure employers and workers understand their WHS duties so all workers have healthy, safe and productive working lives.” SafeWork has been notified of multiple workplace incidents involving collisions between mobile plant, inadequate guarding, bypassing of safety devices and ineffective energy isolation. “We find there is usually more than one factor contributing to an incident,” says Martin. At the moment, the regulator has a strong focus on people and plant, with forklifts in the spotlight.

Duties and Obligations

All duty holders must be aware of their work health and safety duties, which are not transferable. One person may have more than one duty and more than one person can have the same duty. A strong culture of safety is integral for business. This is underpinned by strong leadership and a genuine commitment in promoting a safety culture in workplaces. “When Safework is making enquiries, we consider every duty holder, this includes designers, manufactures, importers, suppliers, installers and the end user”, says Martin.

Consultation and Hierarchy of Controls

Consultation is essential in managing WHS risks and is a legal requirement under the WHS Act. All duty holders need to collaborate to develop ways to manage risks. Designers, manufacturers, importers, suppliers, installers, officers and persons with management or control roles all have responsibilities to provide information to help other stakeholders minimize safety hazards in manufacturing and fabrication. When it is not reasonably practicable to completely eliminate risks, a ‘hierarchy of controls’ must be used by duty holders to minimise risks. Eliminating the hazard and risk is the highest level of control, followed by reducing the risk through substitution, isolation, and engineering controls. Reducing the risk through administrative controls and protective personal equipment (e.g., mining plant and equipment) is the lowest level of control as these controls’ effectiveness relies on human behaviour and supervision. Administrative controls are not enough on their own and should only be used to supplement higher level controls. “Some incidents indicate a lack of awareness of the hierarchy of control, often a control that’s too low level has been implemented, such as providing instruction, training and supervision only”, says Martin.

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The Future of Automotive Technology

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Technology is changing so much in our daily lives, including in how we get around. The electrification of vehicles, autonomous vehicles and connected systems within cities are no longer far off dreams, these technologies and a more connected automotive ecosystem are more of a reality in Australia than ever before. In the early 2000s, electronics accounted for less than 20% of the total cost of a vehicle. In 2020 it was up to 40% and we expect electronics to account for about half of the price of a new car by 2030. We are also expecting to see 300 million electric vehicles (EVs) on global roads by 2030. So, how do we ensure we are ready? How do private companies, cities and the people building the infrastructure to support this transformation come together to make this a reality? This blog will look to answer some of these questions.

Vehicles of the Future

There are many ways technology has improved how we get around, the efficiency in which we do so and the safety of our cars. These are exciting advancements and they are changing and improving transportation globally in the following ways: –

  • Eliminating the need for a human driver – To maintain a competitive edge, many companies are looking toward driverless vehicles to cut costs and increase efficiency. With autonomous capabilities, we will see material transport and rideshare services operating with nobody in the driver’s seat.
  • Battery Optimization – Similar to how AI learns your phone use, patterns and behaviours and charges your phone accordingly to best utilize your battery and increase its longevity, this is expected to be possible with car batteries in the future. Electric vehicles are creating new opportunities and batteries are expensive, and an important factor that dictates the lifespan of a car, and these advancements will help keep EVs on the road for longer.
  • Predictive maintenance – This is the ability to estimate, or predict, when maintenance should be performed on a vehicle. There are already sensors within cars and trucks, and it can be expected to leverage pipe fabrication while monitoring the different parts of a vehicle – like the engine, brakes, and any other moving component. If problems can be detected early and repairs can be made, this avoids costlier, and often time-consuming, catastrophic failures down the line.
  • IoT and Cars – With the rise of automation and intelligent integration, IoT is poised to make a significant impact in the automobile industry. When you bring your car to a mechanic, they will be able to connect to it via their phone, getting a full rundown of what is going on before ever opening the hood of the car. They can start diagnosing problems faster and more efficiently.

Fully Connected Automotive Ecosystem

The ability for vehicles to connect not just with each other, but also with mobile devices and smart ecosystems (smart cities, smart infrastructure, etc.) is an exciting prospect. Rather than rely solely on machine vision systems to perceive what is around them, key objects within communication range can provide feedback to reduce computational burden and increase confidence in what the vehicle “sees”. These objects could include smartphones to identify pedestrians, traffic lights to manage traffic flow at intersections, and road signs to enforce traffic laws. Furthermore, smart infrastructure has the potential to streamline how autonomous vehicles navigate from point A to point B. Beacons staggered along roads and streets can broadcast location data for vehicles to utilize when GPS signals are weak or lost entirely (e.g., when driving through tunnels or amongst tall buildings). Smart parking meters can charge vehicle owners directly, based precisely on how long the space was occupied. Streetlights can increase their brightness as vehicles approach them to increase visibility and decrease their brightness the remainder of the time, to conserve energy. The possibilities are truly endless.

Conclusion

It can be observed that there is immense potential for automotive technology to develop going forward. With the rise of EVs and a fast-growing automotive ecosystem as tailwinds, automotive technology led by heavy steel fabrication companies looks poised to take great strides. It is time to embrace this technology globally – especially in countries where battery vehicles are already prevalent in large numbers.

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Jebsen and Jessen Buy Major Shareholding in Safetech

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Industrial conglomerate Jebsen and Jessen Group is acquiring a majority share in Australian dock and lifting products company Safetech as part of a strategic partnership which the two family businesses say will benefit the Australian materials handling industry. Jebsen and Jessen is an ASEAN-focused conglomerate with businesses spanning manufacturing, engineering, and heat induction bending services and 11 manufacturing facilities in Indonesia, Malaysia, Myanmar, Singapore, and Vietnam. Its core businesses are cable and other technology, ingredients, life sciences, and packaging. Safetech invented the successful Palift pallet leveller in 1984 and the company has since developed a range of world-class materials handling equipment which includes dock products, freight hoists, scissor lifts, pallet loading and mining plant and equipment, and vehicle lifts. Today, more than 80% of Australia’s supermarkets use Safetech equipment as do manufacturers, warehouses, miners, and commercial builders.

Safetech and Jebsen and Jessen will combine their expertise to provide a broader product range and exceptional customer service in materials handling. The deal is expected to be completed on 28 March 2024. The partnership builds on Jebsen and Jessen’s growth strategy which saw the acquisition of MHE-Demag’s Industrial Products (IPD) business in February 2023 (MHE), as well as Electro-Mechanical Services (EMS) in Australia — the two together form Jebsen and Jessen’s material handling division. ​The partnership creates further synergies for Jebsen and Jessen’s materials handling division in Australia. It will bring together product portfolios from MHE, EMS, and Safetech’s established sales, engineering, and structural metal product manufacturing operations in Australia, as well as access to Safetech’s Australian-designed and manufactured products for Jebsen and Jessen’s key markets, including Indonesia, Malaysia, the Philippines, Singapore, Thailand, and Vietnam.

Jebsen and Jessen’s Group CEO Per Magnusson said the partnership aligns with the company’s ‘advance and build’ strategy, to drive accelerated growth and its presence in Australia. “Building upon the foundation laid by the acquisition of EMS last year, our strategic partnership with Safetech will significantly enhance our footprint in Australia’s dynamic and thriving market and deliver enhanced value for customers.” Karl Tilkorn, Regional Director of Jebsen and Jessen’s materials handling business said Safetech is a major force in Australia’s material handling industry. “And our ambition is twofold – to empower its growth by utilising Jebsen and Jessen Group’s resources and to uncover synergies across the material handling business in Australia and beyond.”

In a joint management structure, Lindsay Wakefield, Founder and Managing Director of Safetech, will retain a stake in the business as a minority shareholder and continue to serve in the business. “From Safetech’s founding, we have continually invested in Australian engineering and manufacturing. Our journey — from a single outsourced product to 180 staff with four factories in regional Victoria — has been driven by the ingenuity and creativity of a talented team and a strong belief that Australia needs local steel manufacturing. Safetech’s partnership with Jebsen and Jessen will help us maintain that legacy as we continue to grow and strive to provide our customers with outstanding products backed by national service and support,” added Lindsay Wakefield. Safetech’s commercial operations, personnel, offices, and factories will remain after the deal is finalised. Honouring its long heritage of Australian-based engineering and manufacturing capacities, Safetech’s branding will continue to market its Australian-designed and manufactured products.

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Funds to Future-Proof Regional Steel Manufacturing

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The future of Australian steelmaking is up as the federal government spends $200 million in grants to steelmakers and projects which will help transform the energy system and keep Australian producers internationally competitive while creating jobs. In the first round of the Powering the Regions Fund (PRF) has granted $136.8 million to BlueScope Steel in New South Wales and $63.2 million to Liberty Steel Australia in South Australia. BlueScope will put the funds towards relining and upgrading its No. 6 Blast Furnace at the Port Kembla Steelworks to maintain domestic production, reduce emissions, and support pathways to producing even lower-emissions steel. Liberty’s funding will go to the purchase and commission of a low-carbon electric arc furnace (EAF) to replace its existing traditional blast furnace at the Whyalla Steelworks. The new state-of-the-art EAF will support the manufacturing of green steel and help achieve Liberty’s aim of carbon neutrality by 2030.

The Minister for Climate Change and Energy Chris Bowen said the $200 million investment in the steel sector aimed to secure its long-term future. “Steel is essential for our energy transformation and there are multiple benefits of using local Australian steel companies. Ninety percent of the materials that go into making a wind turbine are steel and cement, and we are going to need a lot more of it. Total steel demand for the energy transformation from 2022 to 2050 will be almost 5 billion tonnes, accounting for 75% of the total material requirement – and that steel will increasingly be green steel.” The Minister said the government wants to make sure products vital to Australia’s economic future, such as green steel are made here, but this will require innovation (such as old tyres and boots used in steel manufacturing) and new ways of processing iron ore that decarbonise the steel industry. “Regions like the Illawarra and Whyalla have been industrial powerhouses for generations, making the steel used in building our houses, infrastructure and industry while creating jobs, and we want to see this continue.”

BlueScope will add about 250 workers to its site during the blast furnace upgrade and will help secure the local workforce over the long term, including the thousands of jobs at the Port Kembla Steelworks. Liberty’s shift to green iron and steel will increase its workforce by around 24% over five years and help provide many existing employees with retraining and new skills in steel fabrication. Australian Workers’ Union National Secretary Paul Farrow said the AWU has long argued that Australia is ideally placed to become a global, green-steel powerhouse of the 21st century. “But to realise that exciting future we need strategic investment today. Thankfully that is what we are finally seeing through the government’s Powering the Regions Fund,” he said. “The decision to fund projects at BlueScope and Liberty is a testament to our nation’s readiness to embrace a clean steel future.”

Farrow said the transition is more than just an environmental imperative. “Sustainability is a buzzword in steel manufacturing and it is an economic opportunity for Australia to become a clean steel leader in Asia and globally. We tend to hear a lot of doom and gloom about manufacturing in Australia, but the fact is the future looks extremely bright if we seize our opportunities.” The two grants are the first under the PRF’s Critical Inputs to Clean Energy Industries program, which supports hard-to-abate sectors so Australia can keep making the things that are vital to the energy transition, including electricity and rail infrastructure such as wind towers, solar farms and energy transmission, and the construction of energy-efficient buildings using heat induction bending services. The Albanese Government has also committed $200 million in grant funding for the hard-to-abate cement and lime, and alumina and aluminium sectors, with successful projects to be announced in the coming months.

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2023 Trends in Australian Manufacturing

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As we say goodbye to 2023 and step into 2024, it is a good time to reflect on the year that went by and what it meant for the Australian manufacturing sector. It was a transformative year for the industrial landscape as it navigated through numerous challenges throughout the year. 2023 saw many ups and downs and witnessed evolving technologies, stronger sustainability imperatives, and a greater demand for resilience. Let us take a look at the top trends that shaped the Australian manufacturing industry this year and how the momentum can be carried forward into 2024.

Revolutionising Operations

2023 witnessed smart factories becoming the norm, not just in Australia but beyond, with the rise of real-time monitoring and agile operations on many shop floors. Industry 4.0 technologies and top manufacturing technology trends, like Internet of Things platforms, big data analytics and advanced algorithms, the digital twin, and 3D printing, continued redefining manufacturing processes throughout the year and show no signs of slowing down. Australian heavy steel fabrication companies are also recognising the importance of upskilling their workforce in digital transformation and automation.

Sustainability Takes Centre Stage

Manufacturers are increasingly embracing eco-friendly practices all over the globe. In doing so, they are not only reducing their environmental footprint but also future-proofing their pipe fabrication operations against continuously evolving regulations and consumer preferences. This year, many Australian companies turned to digital and electrified technologies, from artificial intelligence to electric vehicles, to promote sustainability and combat the climate crisis. A report released this year by Schneider Electric revealed that 82 per cent of businesses in the country believe that the advantages of adopting sustainable technology far outweigh the associated costs. In an era where environmental consciousness is crucial, sustainability is in the spotlight for many Australian companies as a key element in driving the industry towards a more eco-friendly and resilient future.

Reshoring and Onshoring

Supply chain disruptions and geopolitical uncertainties continue to plague the global industrial landscape, making it more crucial for Australia to revive manufacturing and claim its position by reshoring and onshoring operations. In 2022, the Australian government introduced a $15 billion landmark bill that would support, diversify, and transform Australia’s industry and economy and position the nation as a country that manufactures. The National Reconstruction Fund (NRF) was welcomed by business leaders across all industries in the country, with the local manufacturing sector in particular set to receive a major boost from the funding. This investment is expected to help cement Australia’s position as a world leader in innovation and manufacturing and help to unlock the potential of local Australian steel companies. The NRF board held its inaugural meeting in September, officially launching the corporation that will help enhance Australia’s local manufacturing prowess.

Upskilling

Upskilling has emerged as one of the most vital catalysts for growth and innovation. With the rise of Industry 4.0, the need for a new paradigm that prioritises upskilling and re-skilling workers has never been more important. This year, the federal government rolled out the Artificial Intelligence Adopt Program, a new initiative that would help Australian businesses integrate artificial intelligence safely into their workplaces. Through the program, the government aims to create a network of industry-specific centres that will highlight the innovative capabilities AI can bring (such as AI video surveillance in manufacturing) and provide specialist training to help develop skills to manage AI. It has been proven time and time again that upskilling efforts not only empower individual workers but also propel the entire industrial sector towards a future defined by innovation, sustainability, and resilience.

Final Thoughts

The Australian manufacturing industry has been fortified by many challenges and innovations in 2023. As we enter the year ahead, it is important to remember that change is the only thing that is constant and will always be present every step of the way. Thus, embracing the transformative forces that defined 2023 may hold the key to staying competitive in this industry!

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MoU Signed for Queensland Wind Farms

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The global energy trend is towards cleaner energy as evidenced by the UK strategy for greater energy independence. A deal for Queensland that expects to plant the seed for more renewable energy projects and boost and support innovative industries in the region.  There have been Memorandums of Understanding (MoU) signed on wind energy world-wide, such as the MoU between API and OOC. Now, a MoU has been signed by Stanwell Corporation and RWE to deliver Stanwell’s 9 – 10GW pipeline of renewable energy assets across Queensland. The MoU has identified RWE’s Theodore Wind Farm (TWF) near Biloela and a second wind farm in the early-stage development in Southern Queensland.

With the thrust on greater clean energy forming the backbone, this partnership between publicly owned energy Stanwell and global company RWE is to commence with the development of two new wind farms in Central and Southern Queensland by 2029. Together, these two developments will add an additional 1.8GW back into the regional communities. The partnership will now enable negotiations on public ownership, equity, and offtake models for the projects. TWF is set to be built on a 46,000-hectare site 30 km east of Theodore and 40 km southwest of Biloela in Queensland. TWF proposes to include 160 wind turbines on the site as well as a battery storage facility with the potential to host a solar farm.

The wind farm will have the capacity to generate enough electricity to power around 410,000 Queensland homes. When given the green light to start major works, the structural steel fabrication project is expected to take up to four years to complete. TWF is expecting to require up to 500 jobs at the peak of construction and a further 50 ongoing jobs over its projected 35-year operational life. RWE is committed to prioritising local employment and engagement with Queensland businesses whenever possible. The second renewable energy project identified through the MoU will be a 720MW wind farm in its early-stage development. No further information has been released on this second project. The proposed wind farms to be developed under the MoU are expected to be completed by 2029.

Source: https://www.projectory.com.au/article/mou-signed-for-two-wind-farms-that-will-boost-renewables-and-jobs-in-qld

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Development Progresses on NT Mining Project

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In August, Projectory reported that a Northern Territory rare earth mining project is inching ahead thanks to a NT Government grant – now the latest update is that the drilling campaign is commencing. MetalsGrove Mining is currently undertaking a phase two soil sampling program at the Arunta Project’s Bruce Prospect in the Northern Territory. This follows the recent discovery of high-grade rare earth element mineralisation. Aeromagnetic and surface geochemistry work identified a 1,000-metre by 600-metre intrusive system considered as highly prospective for rare earth mineralisation.

The testing is the early part of a 2,000-metre drilling campaign, which will soon commence with appropriate mining plant and equipment to test the property’s best-looking targets and will involve a broad conductor and a substantial intrusive system measuring 1,600 metres by 600 metres. MetalsGrove’s program director Sean Sivasamy has been contacted for comment and said in a statement that the company is fast-tracking its exploration in the region. “Both the sampling and drilling programs completed so far have been extremely encouraging and point to a potential high-grade REE mineralised system within our tenure,” he said.

“This next phase of sampling will look to build on the recent drilling success and further refine our next suite of drill targets, as we move quickly to assess and unlock the potential of our prospects within the Arunta region.”  The phase 2 soil sampling program will leverage steel fabrication in mining by testing remaining outcrops and geophysical anomalies along the 9-kilometre carbonatite corridor. All things going to plan, the company aims to commence the next phase of drilling using advanced drilling technologies at the end of the third quarter. The Bruce REE Prospect covers an area of about 17,722 hectares and is located within the central desert region of the Northern Territory.

Source: https://www.projectory.com.au/article/development-progresses-on-nt-rare-earth-project

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Growth of Medical Manufacturing in Australia

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Australia has an expanding medical manufacturing industry with pharmaceutical giants such as Astra Zeneca, CSL, GlaxoSmithKline, Merck, Novartis, and Pfizer engaging Australian contract development and manufacturing organizations (CDMOs) in development of therapies. It has been setting global standards for innovation and quality and its medicines are much in demand. Medical manufacturing is part of Australia’s diverse and dynamic manufacturing sector which has been growing in different areas and making quality end products. It leads to the question – what is the secret sauce which enables Australia’s manufacturing to be so highly regarded? Let us explore this question further in this blog.

Support from Government

The Australian government has been facilitating conditions for growth, innovation, and further investment in medical manufacturing. Making medical products and medicines requires state-of-the-art, skilled, advanced manufacturing and sheet metal fabrication processes. Governments and industry must work hand in hand to make the most of the opportunities. The Liberal National Party’s Modern Manufacturing Strategy, developed in close consultation with industry, set a solid foundation to build up Australia’s industrial base. The Coalition’s Modern Manufacturing Strategy provided a long-term vision to support the scale and competitiveness of medical manufacturing. It outlined opportunities for Australian businesses based on strengths, emerging industry trends and market potential. A roadmap was laid out on how industry and government, together, could capture opportunities and address barriers to scale. This plan was backed with investment to support companies that want to grow their manufacturing locally. Building up Australian medical products and medicines manufacturing requires specific things from governments: they must ensure they build a skilled workforce so the sector can commercialize technologies and advanced manufacturing capabilities. Governments are the main customers for many medical products so government procurement must function well so that SMEs have the opportunity to provide services and products.

Asian Market and Complementary Medicine

Demand for health therapeutics in Asia is growing in line with its ageing population. The share of the population aged 65 years and over is expected to increase by nearly 2.5 times in the next decades. Treatments for the two leading causes of death – cardiovascular disease and cancer – will be welcomed. Australia’s proximity to and close business ties with Asia offer trade opportunities, including trade benefits as a result of steel manufacturing. Medicines manufactured in Australia can be exported across the region. Australia has free trade agreements with Asia’s largest economies, including China, Japan, and Korea, as well as fast-growing ASEAN countries. Australia also has strong relationships with Asia’s leading universities and research institutions, opening up possibilities for R&D collaborations. As the booming populations of south and south-east-Asian middle classes grow, Australian-made medical products should be their first port of call.

Australia are world leaders in manufacturing complementary medicines. They are known for great produce, innovation, and quality-assured products — this is doubly so in medicine and preventative health. Complementary medicine manufacturing is a high-demand and high-growth industry. The medical products and medicines sector today supports 30,000 workers across the supply chain, and more than 2,500 manufacturing workers. It is a sector that needs to hit the highest of benchmarks for quality and safety. However, globally recognized regulation needs to balance safety and trust with market access. Government must support businesses as they navigate new markets so they can compete globally.

Final Thoughts

The medical manufacturing sector has been a priority for Australian governments and this approach is expected to continue in the future. The government is expected to announce further grants and incentives to heavy steel fabrication companies to support medical manufacturing and partnerships and collaborations are predicted to grow as well. A highly developed medical innovation ecosystem is to be leveraged on the back of Australia’s strong manufacturing base – and the future looks bright for this sector!

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South32 Warns Against IR Changes

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South32 chief executive officer Graham Kerr has joined other mining executives in warning industrial relations (IR) reforms, including the ‘same job, same pay’ policy, would potentially harm the industry. “I think the industrial relations reforms are going to probably set back productivity and not take it forward,” Kerr said. The Australian Government’s ‘same job, same pay’ legislation law will require host employers to pay labour hire workers the same rate as direct employees performing the same job. A number of mining companies have expressed concern that the legislation, which is set to be enacted by the end of 2023, will put additional pressure on what is already a fragile labour market. After releasing its financial year (FY23) results yesterday, South32 said it expects production costs across its global operations to increase over the coming financial year – which is likely to impact financing required for manufacturing growth as well.

In addition to increasing costs, Kerr believes the IR changes ran the risk of dampening Australia’s attractiveness to foreign investment. He said the company invests in its workers, offering fair pay. South32 is the latest company in the Australian mining industry to warn against the reforms, with the Minerals Council of Australia (MCA) calling for the legislation to exclude service contractors. “The Government must listen to the legitimate concerns of all businesses, given the impacts of this proposal reach into all corners of the economy,” the MCA said.

BHP Australian President Geraldine Slattery recently told the American Chamber of Commerce higher pay is not sustainable when mining already offers some of the highest paid careers in Australia. “Australia has one of the highest labour costs in the world (including costs of mining plant and equipment) – around 12% higher than in the US,” Slattery said. “We are proud to be a high-paying industry. Changes to industrial relations policies are of particular concern, and like many businesses such as steel fabrication in the mining industry – we believe they will have a negative impact on Australia’s competitiveness and jobs.

Slattery raised concerns that pipe fabrication operations at BHP’s Olympic Dam copper mine in South Australia could be harmed by the reforms. “We believe ‘same job, same pay’ could increase the operating costs of our existing operations (in SA) by nearly $200 million per year and maybe up to $500 million in a worst-case scenario,” she said. “The hit to the value of any potential growth plans in SA could be anywhere up to $US2 billion ($2.98 billion) and this would make it much harder for any South Australian investment case that has to compete with alternative options in other parts of the world.”

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Can Cobots Resolve Australia’s Welder Shortage?

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With Weld Australia predicting that Australia will be short 70,000 welders by 2030, robotics companies are hoping to step in and help solve the skills gap by attracting Gen-Z with advanced welding technologies, including collaborative robots or cobots – small, flexible collaborative robots built to do tasks within a small footprint. The main beneficiaries would be small to medium sized businesses since larger industrial robots have been used for high-speed, heavy-duty welding for a long time and their size, safety and programming complexities mean they are generally inaccessible for small to medium sized production facilities. So, how can cobots fill the gap in Australia’s welding industry? Let us deep dive into this blog to find out.

Collaborative Benefits of Using Cobots

A cobot lowers the barrier to entry, potentially lowering the cost of safety devices to reduce machine risk, which ultimately also reduces the footprint of the machine. The smaller size of the cobots also means welders can more easily drive the robot by hand in order to teach them. Teaching a cobot, which resembles a giant arm, to do a TIG or MIG welding task is not as difficult as it seems – it is far easier than learning to weld. Traditionally, the problem has been having a combination of an experienced robot programmer who has minimal welding experience, and an experienced welder with minimal robot programming experience – cobots aim to bridge this gap.

In a typical setup, the welder would be the one programming the robot, setting up the jigs and running the robot until it is able to produce satisfactory results. From there the operator would then unload the completed parts and load in new pieces, locking in the jig and re-starting the robot. One welder might also be managing multiple robots and when there are new parts to weld, the welder then reprograms the cobot. The best practice to be followed is to teach the process experts how to use the robots and they can teach and adjust the cobot self-sufficiently.

Growth of Companies Using Cobots

Many Australian companies already use cobots to weld and perform other tasks such as machine tending, screwdriving, palletizing, pipe fabrication and materials handling. Cobot welding is one of the fastest-growing sectors, driven largely by the welder shortage in Australia now. The solution is particularly suitable for smaller SMEs and workshops that have high mix-low volume production and need more versatile options, as well as a level of independence in using their own personnel to adjust the robots rather than having to call in an engineer from a systems integrator. Regarding return on investment, it obviously varies according to application, and if it is welding, it also depends on the complexities and requirements for additional hardware/software. But commonly for Australia, the return on investment for customers has been reported to be on average approximately 1.5 years.

Closing Statement

It is clear that cobots may potentially resolve the welder shortage problem being faced in Australia, however there are other issues to consider in this regard. Welders need to be reassured that cobots will not take away their jobs, and in certain situations, it may be more beneficial to train welding apprentices than to invest in cobots. Thus, cobots are not a one-stop solution but a workaround to ensure that Australian heavy steel fabrication companies are not adversely impacted. Having said that, AI and robotics is poised to be the buzzword of the next decade – and the bandwagon is here to stay!

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