Manufacturing Matters July 2021 - Issue 3

July 2021 | Issue 3 A publication of the Singapore Institute of Manufacturing Technology FEATURE LIGHTWEIGHT AND HIGH STRENGTH CUSTOM AUTOMOTIVE ALLOY WHEELS SUSTAINABILITY MATTERS SKILLS MATTERS RESEARCH SPOTLIGHT 2 NEW SGUNITED SKILLS (SGUS) ARE REUSABLE FACE MASKS ENVIRONMENTAL PROGRAMMES TRULY SUSTAINABLE? SUSTAINABILITY THROUGH GREEN COMPASS

FEATURE LIGHTWEIGHT AND HIGH STRENGTH CUSTOM AUTOMOTIVE ALLOY WHEELS Manufacturing of high-performance custom alloy wheels using Liquid Forging Technology There is an increasing consumer interest in custom light weight alloy wheels in the alloy wheels aftermarket, demanding for better car performance with appealing looks. These custom alloy wheels are popular among car enthusiasts who are willing to pay high prices to get them. Meisterform Pte Ltd, a start-up established in 2017, provides custom alloy wheels for premium car owners in the automotive aftermarket. The company began its journey by importing standard aluminium alloy wheel preforms from overseas and machined them into final wheel designs. To allow for lighter alloy wheels with optimisation for more complex designs, Meisterform would require further customisation of alloy wheel preforms to cater for aggressive spoke structures with optimum concavity. As a start-up, Meisterform faced several challenges such as limited choice of alloy wheel preforms as a result of low volume, high cost, and long procurement lead time from overseas. Hence, Meisterform could only obtain mass produced ready-stock preforms which are low pressure cast cum spin formed A356 wheel performs. However, compared to hot forged cum spin formed A6061 wheel preforms, these cast preforms have lower performance due to poorer mechanical properties and the presence of porosities. 2 MANUFACTURING MATTERS | July 2021

FEATURE Hot forged cum spin formed A6061 With SIMTech’s support and process trial. The team from Meisterform wheel preforms are known to have the the commendable effort of provided design optimisation through best performance, but they are limited Dr Chua Beng Wah and his utilising their simulation solution to in fitment size selections and are very team on the Liquid Forging optimise spoke structure by maximising expensive due to the high production process, Meisterform has concavity and strength. cost. achieved its goal of being The liquid forged alloy A6061 and To overcome these challenges and to the first and only one in A7075 wheel preforms are produced enable them to offer more custom wheel Singapore to manufacture with various hubs and thicknesses to designs at competitive costs, Meisterform, high performance wheels. cater for a variety of concavities of the supported by Enterprise Singapore (ESG), This is testament to the spoke designs, and subsequently hot collaborated with SIMTech PECOI on full support SIMTech spin formed to various barrel heights for the Liquid Forging (LF) technology for has provided, allowing different wheel offsets, allowing further high performance alloy wheel preforms. Singapore companies to design variability. The preforms are The Liquid Forging process is a hybrid still be competitive with subjected to further heat treatment to process of casting and forging and the right business models achieve optimum mechanical properties can produce pore free structural parts complemented with the before the final machining and coating with comparable properties to forge right technologies. processes. The optimised alloy wheel is parts after heat treatment. Through this lighter and can reduce unsprung weight collaboration, SIMTech provided the Mr Bryan Wong, Managing Director, of the car, thereby improving traction Liquid Forging process know-how and Meisterform Pte Ltd for better road handling and safety. system design, spin forming process, heat As a result of this collaboration, treatment process and pilot production Meisterform is the first in Singapore to have successfully acquired the Liquid Forging manufacturing capability enabling them to produce high performance custom lightweight alloy wheels for the automotive aftermarket. Car enthusiasts in Singapore are now able to enjoy high performance lightweight custom wheels at an affordable price. In addition, with this new capability acquired, Meisterform can now expand into other product innovations such as high performance composite disc brakes and heat spreaders. For enquiries, please contact Mr Tan Chee Tat, Director, PE COI Email: [email protected] Web: www.a-star.edu.sg/SIMTech-PECOI Scan for more information on Precision Engineering Centre of Innovation 3MANUFACTURING MATTERS | July 2021

SUCCESS STORY Picture taken before Covid-19 SINGAPORE’S FIRST ELECTRIC MOTORCYCLE SIMTech T-Up secondee contributed to design and fabrication of Singapore’s first EV Motorcycle Turning concepts into products, Together with EST staff, Reza At the end of his T-UP, Reza decided to nurturing young talents to pursue implemented Advanced Process Quality join EST as the Chief Operating Officer. careers in Science, Technology, Planning (APQP), which increased When asked for the reason why he Engineering and Mathematics (STEM), the efficiency and effectiveness of would leave a big R&D Organisation and creating something remarkable the product development process by like SIMTech for a startup, he said “I get were the three things that Muhammad integrating inputs from engineering, to do the same things that I enjoyed Taureza (Reza) finds joy while working production, sales and marketing into doing while I was at SIMTech, which was in SIMTech. His secondment stint one platform. Reza also rolled up his turning dreams into real products! I am at Eurosports Technologies (EST), a sleeves to work on Computer Aided also thrilled because in many ways I get startup working on Scorpio Electric Designs and Finite Element Analyses to decide what the company makes.” brand of electric motorcycle, was no primarily on the frame or chassis of the different except that it operates on motorcycle. In addition, he would lead We can’t build Singapore’s a slightly different level. Joining a the team to work on materials selection, first electric motorcycle if company still at its infancy then, as process and product specifications, as we don’t invest in our the Head of Operations, Reza focused well as testing requirements. people and our Singapore on putting the basics right so that the During the T-Up, Reza witnessed factory. T-up has allowed company has a solid foundation in the strong growth of the company, my company to access the Research & Development (R&D) and despite being affected by the COVID 19 expertise and the Manufacturing. pandemic. The company’s staff count resources we need to Targeting on the increasing affluence had grown from 17 to 25 by the time deliver the product and to of the European and Asian middle he ended his T-Up, and most of the new build the brand! class, EST plans to provide options hires were working in R&D. The outcome for premium electric two-wheeler was EST’s launch of its first electric Mr Melvin Goh, Chief Executive Officer, products; riding for daily use, whilst at motorcycle prototype, called Scorpio X. Eurosports Technologies Pte Ltd the same time appealing to the new It immediately garnered attention from generation of buyers who perceive the local media. One notable example is motorcycles as a high-tech gadget CNA’s documentary, Factories Making and statement in supporting a cleaner the Future, which featured Scorpio X. environment. FACTORIES MAKING THE FUTURE For more enquiries, please contact Mr Lee Hock Wee, at THE FUTURE OF VEHICLES [email protected] Note: T-Up is a joint initiative by A*STAR and Enterprise Singapore to help local SMEs through the secondment of R&D talents from A*STAR’s research institutes. 4 MANUFACTURING MATTERS | July 2021

SUSTAINABILITY MATTERS ENVIRONMENTAL SUSTAINABILITY THROUGH GREEN COMPASS Transform your business by embracing environmental sustainability A*STAR SIMTech, JTC, and TÜV SÜD stakeholder loyalty and advocacy; After companies have chosen signed an agreement at the Energy and it will empower companies to be the environmental sustainability Innovation event, on 23 July 2021, to future-ready for sustainability-oriented dimensions of relevance, the respective develop a Green Compass initiative that regulations and industry trends. assessment questions will be generated; offers a set of software assessment tools, Through the Green Compass initiative, and upon its completion, the results methodologies, and training workshops companies can: will highlight and prioritise areas of and courses to help businesses across • Assess how environmentally improvement with the biggest financial sectors transition to more sustainable and strategic impact (Figure 1). and resilient business models. sustainable they are Businesses are invited to register for a As per Minister of State Low Yen Ling’s • Conduct a gap analysis to find free trial of Green Compass and provide opening speech at the event, she feedback to build industry confidence encouraged companies to adopt Green out what to do to achieve their on the usefulness of it. Government Compass “to navigate towards greater sustainability goals agencies or affiliates are also invited sustainability. Sustainability is not just • Prioritise areas for improvement to to use Green Compass as a tool to a good to have, but can be turned into maximise financial and strategic incentivise and recognise companies a competitive advantage and have impact who are making huge investment and strategic impact”. Green Compass • Develop a roadmap to become efforts to improve their sustainability will enable companies to adopt new more environmentally sustainable performance. The free trial is limited and sustainable business approach The Green Compass initiative will to the first 20 signups by 31st August to help them reduce their cost of consider a company’s practices 2021. Scan the QR code to register now. doing business by improving resource holistically in areas such as its product efficiency; to enhance their company’s life cycles and management of energy, Or visit brand reputation that enables them water, carbon emissions, materials, and https://bit.ly/3ermaZb to secure future earnings through waste. For enquiries, please contact Dr Ng Sum Huan Gary, Acting Director, SEAC Email: [email protected] Web: www.a-star.edu.sg/SIMTech/SEAC Figure 1. Green Compass Transformation Journey Scan for more information on Sustainability & Emerging Applications Centre 5MANUFACTURING MATTERS | July 2021

PRODUCTIVITY MATTERS Picture taken before Covid-19 COLLABORATE & EXCEL Driving productivity of precision engineering companies The Precision Engineering (PE) industry Mr Steven Koh, Executive Director, Table Event on 5th May 2021, and a total is the backbone of Singapore’s SPETA commented that “enhancement of 14 SPETA YET (Young Entrepreneurs manufacturing industries as it supports of productivity is the one and only way Team) member companies had Electronics, Chemical, Biomedical, to increase workers’ earnings while attended the Roundtable Event to Transportation and other manufacturing maintaining product cost. We work very provide their valuable feedback. industries. Based on the 2019 MIT closely with SIMTech MPTC to target To embrace future challenges and Economic survey, PE Industry annual 3 key areas to enhance productivity changes in the industry, we strongly manufacturing output is about S$38.7B, - Driving appropriate allocation of encourage and welcome more which is 11.4% of Singapore’s total resources, improving its utilisaton, and companies to come on board, work manufacturing output. enhancing efficiency together with SIMTech, SPETA and our Currently, Singapore’s over-reliance on These 3 key areas are being executed SI partners for the adoption of advanced the 1.2M foreign labour with suppressed through our 6A processes, namely: manufacturing digital technologies. low wages has discouraged small-SMEs • Creating Awareness via Model in the PE industry to automate and Enhancement of digitalise for increased productivity and Factory visit, coupled with webinars productivity is the one capital per worker. As Singapore aims to and other outreach programmes and only way to increase increase manufacturing output by 50% • Assessment on companies’ gaps workers’ earnings while within the next 10 years with advanced and readiness maintaining product manufacturing technology and fewer • Advisory on planned adoption cost. foreign workers, many SMEs would be • Adoption Gantt chart and actions severely affected. Hence, it is essential • Postmortem Analysis Mr Steven Koh, Executive Director, SPETA for SMEs to start to explore automation • Awards and accreditation with and digitalisation so that they can SIMTech For enquiries, please contact improve their productivity and be more To elaborate further, Adoption would Mr Rick Yeo, Director, MPTC competitive. cover both digital technology adoption Email: [email protected] As a joint effort, SIMTech Manufacturing and skills training programmes such Web: www.a-star.edu.sg/SIMTech-MPTC Productivity Technology Centre (MPTC) as SIMTech Digital Transformation & has started collaborating with Singapore Innovation (DTI™) programme, Smart Precision Engineering & Technology System Framework™ (SSF™) programme Association (SPETA) to drive adoption of and modular TIPS (Technology Industry 4.0 digital technologies in the PE Innovation Productivity Solution). industry for productivity improvement As part of our Awareness creation and and business growth, as well as to engage outreach programme, SIMTech MPTC more System Integrators (SI) and transfer and SPETA had co-organised a Round SIMTech’s matured digital technologies. Scan for more information on Manufacturing Productivity Technology Centre 6 MANUFACTURING MATTERS | July 2021

RESEARCH SPOTLIGHT ARE REUSABLE FACE MASKS TRULY SUSTAINABLE? Quantifying product sustainability using Life Cycle Assessment (LCA) Since the start of the COVID-19 not always true. Previous studies on especially significant when scaled by the pandemic, there has been an increase in reusable and disposable medical devices face mask consumption of Singapore’s face mask consumption as the general have shown that there is no definitive population. population is encouraged to wear a face version of a device that will have a lower In addition, the work also explores the mask beyond their domestic space.While environmental impact. environmental impact that arises from there is no denying in the importance of In this work, Life Cycle Assessment (LCA) different face mask usage habits and face mask usage during the pandemic, was used to quantify the environmental waste treatment processes through the there are concerns on the amount of impact of the EFL reusable face mask scenario analysis. The work has been plastic waste generated from single-use by calculating its entire life cycle from published in the journal Resources, surgical face mask usage. material extraction to incineration. The Conservation and Recycling under the Despite the potential environmental environmental impact categories that title “Life cycle assessment of single-use repercussions, the consumption of face were evaluated include climate change, surgical and embedded filtration layer masks is unlikely to recede in the new fossil fuel depletion, metal depletion, (EFL) reusable face mask”. norm. Therefore, the general population water depletion, freshwater ecotoxicity, can explore alternative face mask options freshwater eutrophication, marine that have a lower environmental impact ecotoxicity, marine eutrophication, to help alleviate the environmental human toxicity, and waste generated. burden of face mask usage. One such Using the environmental impact of option would be the embedded filtration single-use surgical face masks as a layer (EFL) reusable face mask. This face benchmark, the EFL reusable face mask mask was developed in Singapore at the is clearly the more environmentally start of the pandemic as an alternative friendly option. EFL reusable face masks face mask option to address the shortage will have a lower emission value of at least of single-use surgical face masks. 30% compared to single-use surgical Intuitively, the use of a reusable device face masks for climate change, fossil fuel would be naturally thought of as the depletion, metal depletion, freshwater greener alternative to the single-use ecotoxicity, marine ecotoxicity, and version of the device. However, this is waste generated. This reduction is REUSABLE Breakdown of carbon footprint by EFL reusable face MASK WILL mask vs single-use surgical face mask over 31 days BE WASHED For more information, please contact 29 TIMES Dr Jonathan Low, Sustainability & Life Cycle Engineering Division (SLED), at sclow@ Process map of EFL reusable face mask SIMTech.a-star.edu.sg 7MANUFACTURING MATTERS | July 2021

INDUSTRY ASSIST Collaborative Industry Projects (CIPs), Initiatives, Programmes and Ready-To-Go Technologies are Available to Industry Assist Picture taken before Covid-19 Automated Optical Inspection (AOI) Inventory Planning This programme aims to develop and co-develop advanced This programme aims to facilitate the decision-making and technologies that help the manufacturers improve their quality development of inventory policy.This is to control rightsized and productivity by transforming and upgrading the current inventory with the evolution of data & analytics techniques inspection process through latest advancement in optics and to optimise inventory performance. automation. For enquiries, please contact Mr Alex Tay Sheng Ru at For enquiries, please contact Ms Charlotte Lim at [email protected] [email protected] Resource Efficiency Monitoring & Collection & Delivery Management Analytics System (REMAS) System (CDMS) This programme helps companies implement Resource This programme aims to equip companies with a real-time Efficiency Monitoring and Analytics System (REMAS) to collection and delivery management solution with Cloud-based assess the equipment’s resource usage (for energy, water Mobile Apps. This supports courier/logistics industries in service and waste) in real-time and identify hotspots of excessive improvement at reduced cost and time to achieve information resource usage. These hotspots can then be analysed to accuracy, process efficiency and resource optimisation. derive quantifiable improvement. For enquiries, please contact Mr Chai Lai Sing at For enquiries, please contact Mr Joshua Thong at [email protected] [email protected] Last Mile Logistics Sensorisation & Machine Connectivity (S&C) A planning and tracking solution to improve the management of drivers/vehicles to effectively meet customer-imposed This programme helps resource owners identify hidden pickup and delivery requirements amidst resource constraints. capacities of their machines to improve manufacturing For enquiries, please contact Mr Gary Kwok at productivity. By tapping into the equipment in the shop [email protected] floor losses such as machine breakdown, machine slow- down and scrap parts, manufacturing companies can Real-time Dashboard optimise the Overall Equipment Effectiveness (OEE) of their existing equipment. A real-time dashboard that is customised to suit company needs and to connect to multiple sources for congregation and For enquiries, please contact Mr Wong Ming Mao at analysis of real-time data. [email protected] For enquiries, please contact Mr Gary Kwok at [email protected] Manpower Scheduling System (MSS) This programme aims to equip companies with a manpower scheduling solution that enables users to create schedules with one click, reassign tasks effortlessly and share scheduling changes with employees instantly. For enquiries, please contact Mr Gary Kwok at [email protected] 8 MANUFACTURING MATTERS | July 2021

SKILLS MATTERS 2 NEW SGUNITED SKILLS (SGUS) COURSES Get paid to upskill while you look for a job! SIMTech’s Knowledge Transfer Office (KTO) will be adding 2 new SGUS specialisations, bringing a total of 9 SGUS courses through SIMTech’s partnership with the SkillsFuture Singapore (SSG). The 2 new specialisations are: • SGUS for MedTech Product Manufacturing • SGUS for Advanced Instrumentation and Quality Control through Digitalisation (to launch soon!) The Knowledge Transfer Office has also consolidated a series of webinars for each SGUS specialisation. You can access the recordings by scanning the QR code below to watch and learn more about each course: Scan to access our SGUS webinars on our Facebook Since the launch of the SGUS programme in May 2020, SIMTech has been upskilling Singaporeans and Permanent Residents affected by the economic impact of the COVID-19 pandemic. We have since graduated over a hundred participants who completed their 9 months of training with us. In his 2021 Budget Statement on 16 Feb 2021, Deputy Prime Minister and then Minister for Finance Mr Heng Swee Keat announced that the SGUS Programme will be extended for another year to 31 Mar 2022. SIMTech will continue to strive and give our strong support for this programme. Follow our social media channels to be updated on our upcoming launches of SGUS courses! For enquiries, please contact: Dr Fannon Lim, Deputy Director, Knowledge Transfer Office Email: [email protected] Web: www.a-star.edu.sg/SIMTech/KTO 9MANUFACTURING MATTERS | July 2021

EVENTS UPCOMING ACTIVITIES PE COI Conference 2021 20 September 2021 | 9.00am - 1.00pm | Webinar The PE COI Conference is an annual event to reach out to the precision engineering industry. The theme for 2021 is on “PE COI: Breaking Threshold and Accelerating Transformation to Thrive in the New Economy” where seasoned speakers from association (SPETA) and industry will share topics related to pushing technology boundaries and accelerating transformation to realise new innovations in Process, Product, Materials, Operations and Business Models needed for the new economy. Companies, in particular SMEs can learn how to leverage on the various available support in the local R&D ecosystem and hear from seasoned industry leaders sharing their experiences and journeys in overcoming technical challenges and transforming their operations and businesses to thrive in the new economy For enquiries, please contact Mr Goh Chee Chien at [email protected] Watch this space for more exciting upcoming events update for 2021! Scan for more events COURSES Graduate Diploma in Industrial Automation Graduate Diploma in Mechatronics Module 2 Module 4 23 August 2021 | 6.30pm to 9.30pm | Online via Zoom or 2 September 2021 | 6.30pm to 9.30pm | Online via Zoom or SIMTech, Fusionopolis 2 SIMTech, Fusionopolis 2 Graduate Diploma in Advanced Welding Technologies Master Class in Mastering Sales and Operations (S&OP) to Align Strategies for Operational Excellence Module 1 24 August 2021 | 6.30pm to 9.30pm | Online via Zoom or 13 September 2021 | 6.30pm to 9.30pm | Online via Zoom or SIMTech, Fusionopolis 2 SIMTech, Fusionopolis 2 Data-driven Energy Efficiency Management 25 August 2021 | 6.30pm to 9.30pm | Online via Zoom or SIMTech, Fusionopolis 2 For course details and registration, please visit https://www.a-star.edu.sg/SIMTech/KTO For general enquiries, please contact Scan for Tel: 6590 3193 or more courses email: [email protected] Editorial Committee About SIMTech Ms Veronica Chiu Advisor SIMTech is a research institute of the Agency for Science, Technology and Research (A*STAR) committed to serving the Ms Charmaine Goh Editor manufacturing industry to develop the human, intellectual, and industrial capital in Singapore. Ms Charlotte Lim Member Ms Cheryl Wong Member The vision of SIMTech is to be a world-class innovation partner in advanced manufacturing technologies, systems Mr Alex Tay Member and capabilities. It develops targeted high-value manufacturing technologies and human capital to enhance the Mr Hock Wee Member competitiveness of Singapore’s manufacturing Mr Darren Ong Member industry. It collaborates with multinationals and local Dr Fannon Lim Member companies in the precision engineering, medtech, Ms Tan Yee Shee Member aerospace, automotive, marine, oil & gas, electronics, Ms Nurul Ain Designer semiconductor, logistics, and other sectors. 10All rights reMsAeNrvUeFdA.CCToUpRyINriGghMtA©TTSEIRMSTe| cJhuly| 2S0i2n0gapore Institute of Manufacturing Technology, 2 Fusionopolis Way, #08-04, Innovis, Singapore 138634 07/2021 For enquiries, please contact us at Tel: 6590 3199 | Email: [email protected] | Web: www.SIMTech.a-star.edu.sg