Manufacturing Matters Issue 2, April 2020

April 2020 | Issue 2 A publication of the Singapore Institute of Manufacturing Technology FEATURE MAKING BUSINESS SENSE OF SUSTAINABILITY PRECISION MATTERS ADVANCED MACHINING DYNAMICS: NO MORE CHATTER PRODUCTIVITY MATTERS BIG IMPACT WITH LEAN INDUSTRY ALLIANCE SIMTech INNOVATION FACTORY

FEATURE NOTE FROM EDITOR... Dear Friends and Industry Partners Sustainability, not something new, is gaining wide recognition. It is becoming increasingly clear that we must start taking actions to meet the needs of the present without compromising the sustainability of the environment. Globally, over 36 bainlldionthtiosnnnuesmobfeCr Ois2 was emitted in 2017 still increasing. At this rate, the world is not on track to meet its agreed target of limiting warming to within 2oC (Source: Our World in Data, CO₂ and Greenhouse Gas Emissions, May 2017). More countries and businesses are MAKING BUSINESS SENSE OF adopting sustainability initiatives such SUSTAINABILITY as going plastic-free and promoting green manufacturing. For example, China SIMTech uses technology to help businesses achieve balance has launched the “Made in China 2025 between profitability and sustainability initiative” to develop their manufacturing into a high-tech, automated industry. Driven by a vision of building a sustainable future where businesses make Under this initiative, the country is also profits while making a positive impact on people and the planet, the investing in the creation of sustainable Sustainability & Life Cycle Management Group’s (SLMG) R&D focuses on two manufacturing (Source: ET2C, Sustainability key areas. in Manufacturing: Made in China 2025 and the BRI, 9 December 2018). Firstly, the Eco-Operations and Design looks at how waste as well as materials and energy consumption can be minimised to improve resource efficiency As a small nation with finite resources, it across a business operation. Secondly, the Industrial Ecology examines how is imperative for Singapore to ensure that flows of resources can be facilitated within and across industries to enable sustainability is an integral part of our daily circularity of resources. lives and businesses. Collaborating with researchers across A*STAR, from the universities, and Targeting the rising need of building a the industry, R&D outcomes are translated into capabilities and tools in the sustainable future, the Singapore Institute domain applications of Life Cycle Analysis, Energy Management, Water of Manufacturing Technology (SIMTech), a Management and Waste-to-Resource Management. These tools enable research institute of the Agency for Science, companies to improve their resource efficiency and support them in the Technology and Research (A*STAR), set up transition towards a low-carbon and circular economy. the Sustainability & Life Cycle Management Group (SLMG), to help businesses achieve balance between profitability and sustainability. How does this research group support businesses in this sustainability journey? Find out more in our Feature. Ms Yap Yi Jin Editor, Manufacturing Matters Email: [email protected] 2 MANUFACTURING MATTERS | AApprriill22002200

FEATURE For instance, the Energy Efficiency the environmental impact of food in Monitoring and Analysis System Singapore. Findings also show how (E2MAS) was deployed by LHT to assess shifting to a lower meat consumption its equipment’s energy efficiency in diet helps in reducing greenhouse gas real-time and identify hotspots of emissions. excessive energy usage. Through the power meters installed at the pallet Different future scenario analyses assembly and polishing machines, the highlight how the opportunities system analyses energy data for the recommended may scale down the hotspots and derives potentials for environmental impact in Singapore by energy efficiency improvement. This 2030. These insights will help inform enables LHT to understand day-to-day policy makers and businesses in the energy usage in its manufacturing line, F&B space on less environmentally and adopt best practices in energy burdensome strategies. The results from management. the study were shared at the Ecosperity Conference organised by Temasek LHT also makes use of a compressed International in 2019. air system management toolkit with energy conservation practices to reduce Source: https://www.ecosperity.sg/en/ideas/ compressed air leaks by 20-30 per cent. environmental-impact-of-food-in-singapore. html Energy Cost Reduced With the implementation of these SIMTech provided us with One of the companies that benefited from efficiency measures, LHT has sustainable solutions these efforts is LHT Holdings Limited. LHT successfully increased their daily pallet that makes LHT more is a local company that manufactures and output and quality to boost productivity efficient and effective supplies wooden pallets to its customers with profitability, and at the same time, in overcoming current for the packing of industrial products. reduced their consumption of energy uncertainty, and makes Since 2008, SIMTech has been supporting by 20-30 per cent and increased raw our factory not only LHT to improve its processes and upgrade materials turnover by 15 per cent. better to work in, but its capabilities. also environmentally Reducing Singapore’s environmental friendly to mitigate Among these collaborations is the impact of food consumed climate change with re-engineering of its existing pallet Global food production contributes reduced carbon footprint assembly line by feeding raw materials to about 19-29 per cent of the total automatically and connecting sensors greenhouse gas (GHC) emissions. To Ms May Yap, Managing Director, LHT Holdings Ltd to create an Internet of Things-enabled assess the environmental impact of environment to obtain real-time data. The local food consumption, SIMTech and For enquiries, please contact smart pallet assembly line enhanced the Deloitte Singapore were commissioned Dr Ng Sum Huan Gary, Acting company’s productivity and relieved its by Temasek International to initiate a Deputy Director, SMC employees from intensive labour work Singapore-specific study . Email: [email protected] during the manufacturing process. Web: www.a-star.edu.sg/SIMTech-SMC Using the Life Cycle Assessment Over the past three years, LHT has been approach, SLMG quantified GHG Scan for more information able to tap on SLMG’s manufacturing emissions, energy and water on Sustainable and sustainability expertise to introduce consumption of various food items in Manufacturing Centre other energy, resource and cost efficient Singapore. The study presented existing methods to complement their daily challenges on how Singapore’s food operations. consumption contributed to these environmental impacts and provided answers to how food contributes to climate change. With this, SIMTech presented opportunities as to how sourcing fresh food from nearer countries, where air transportation is reduced, and from countries with cleaner electricity generation can potentially reduce 3MANUFACTURING MATTERS | April 2020

SUCCESS STORY GROWING IN-HOUSE TESTING CAPABILITIES X-ray ComputedTomography is used to verify non-destructive imaging of internal defects in 3D printed metal parts To assist Professional Testing Services to fabricate customised aluminium data revealed interesting insights. (PTS) Pte Ltd in pivoting towards artefacts to assist PTS with their XCT Characteristics of consequential in-house testing for metal additive experiments. These results confirmed defects were communicated during manufacturing (AM), a SIMTech PTS’ enhanced XCT expertise, paving the T-Up to PTS XCT engineer and it engineer was attached to the the way to offer XCT as a quality control was found that the company has the company under the Technology for technique to industries involved in capability to detect consequential Enterprise Capability Upgrading (T- metal AM. defects in metal AM components. Up) programme. Strong commercial Further optimisation of XCT parameters interests for metal AM in recent years This T-Up has enabled helped reduce scan time by 30 per cent have motivated PTS to build numerous us to have a better without compromising on quality of in-house testing capabilities to capture understanding of defects detection, saving machine and this rising demand. PTS is an ISO/ additive manufacturing manpower costs for PTS. IEC17025:2005 certified test laboratory, and the impact for the providing a wide range of testing Singapore industry. It services to industries in Singapore for has also allowed the several decades. company to better For the attachment, SIMTech’s years of qualify and quantify knowledge and experience in metal our X-ray CT process, AM and related metallurgical science minimising time and were shared to PTS key engineers. resources This boosted their knowledge and confidence in taking up testing services Mr Alsert Chua, Head of Chemical for metal AM component as a business Department, Professional Testing offering to industry. Services Pte Ltd X-ray computed tomography (XCT) was a key investment by PTS to support The artefact and its internal defects were industries working on metal AM characterised by PTS XCT equipment, processes. To evaluate the company’s followed by destructive characterisation XCT equipment capability for defects using optical microscope imaging of its detection in metal AM component, PTS polished cross sections. Defects data leveraged SIMTech’s research expertise from XCT and destructive testing were in detecting defects to further their processed at PTS and the processed understanding on quality issues faced in metal AM processes. SIMTech in- house metal AM facility was utilised Note: The T-UP initiative, a multi-agency effort by A*STAR, the Economic Development Board, For more enquiries, please contact SPRING Singapore (now Enterprise Singapore), IE Singapore (now Enterprise Singapore) and the Mr Lee Hock Wee, at Infocomm Development Authority (now Media Development Authority) to access the pool of R&D [email protected] talent in Research Institutes. 4 MANUFACTURING MATTERS | April 2020

PRECISION MATTERS ADVANCED MACHINING DYNAMICS: NO MORE CHATTER Large Local Enterprise shortened process time for difficult-to-machine materials During machining of components Embarking on new technology is the way to reduce with difficult-to-machine materials, waste and boost productivity. It’s never too late commonly used in the precision engineering industry, high forces Mr Tang Tuck Leong, Vice President, ST Engineering Land Systems Ltd are generated. These cause severe vibrations restraining engineers to provides quick prediction of the chatter- After validating their process time can increase material removal rate for fear free milling condition prior to real-time be shortened 15 to 20 per cent with the of insert breakage, forcing engineers to production. The scientific approach control of vibration effect, the company be conservative rather than maximise reduces trial and error, promoting first did not hesitate in fully implementing process productivity under machining part correct machining set-up. the machining dynamics technology in tolerances. The technology is beneficial for ST their manufacturing process. Engineering Land System, the land For enquiries, please contact Help is available. The machining systems and specialty vehicles arm of ST Mr Tan Chee Tat, Director, PE COI dynamics technology developed Engineering. Mr Tan Peng, manager of Email: [email protected] by SIMTech is a scientific approach the manufacturing team, decided to test Web: www.a-star.edu.sg/SIMTech-PECOI to overcome these challenges. The the technology for their manufacturing technology optimises machining process after attending SIMTech’s Scan for more information processes considering complex dynamic seminar on Machining Dynamics. Two on Precision Engineering effect arising from tooling geometries, staff were sent for the Skills Future Centre of Innovation tool holder balancing, spindle power/ WSQ course, Improve Machining torque, material composition, and other Productivity through Dynamic Analysis machining parameters. The benefits and Simulation to learn, practise and of the machining dynamic system are apply the technology to their product. numerous. The application of the quick and portable machining parameter identifier improves tooling configuration or workpiece fixtures. It 5MANUFACTURING MATTERS | April 2020

PRODUCTIVITY MATTERS BIG IMPACT WITH LEAN The SIMTech LEAN Programme transformed the Multinational Corporation, paving the way for Industry 4.0 Michelman Asia-Pacific Pte Ltd, which The LEAN Programme benefited The SIMTech LEAN provides specialty chemicals based in Michelman Asia-Pacific to build a Programme is the Singapore, is a firm believer that LEAN culture of continuous learning and foundation in our is still relevant in the Industry 4.0 era. 40 empower the individual for continuous journeys towards associates were sent for a 12-week LEAN improvement. These were evident from Operational Excellence. programme with SIMTech in 2019. This is the testimonies of Mr Lim Eng Hwa from It has empowered our more than 60 per cent of its workforce in the wastewater team and Mr Ng Chye associates not just to lean Singapore. Beng from the logistics team who have out processes, to run the attended the programme. For them, business more efficiently Underlying this is the strong conviction they learn to stay positive, embrace an but also build a culture of of Mr Phillip Choo, Vice President & attitude of continuous improvement continuous improvement, Managing Director of Michelman Asia- and transformation to perform at a breaking down silos across Pacific, that human capital development much higher level. departments strengthening is key to the success of their business team culture and lays the foundation for their digital To date, the SIMTech SkillsFuture- transformation journey. approved LEAN Programme has trained Mr Phillip Choo, Vice President & Managing more than 600 participants from more Director, Michelman Asia-Pacific Arising from this LEAN Programme, 50 than 70 companies since its launch improvement initiatives were identified in 2013. The programme has helped For enquiries, please contact and implemented. Some of these companies implement initiatives for Dr Tan Puay Siew, Director, MPTC involved 6S workplace organisation, productivity improvement ranging Email: [email protected] such as eliminating wastes from current from 20-100 per cent. Some of these Web: www.a-star.edu.sg/SIMTech-MPTC processes and process re-engineering. use purely LEAN techniques. Others New initiatives using technologies like include implementation of technology Scan for more information on automated materials handling, digitised enhanced from company’s existing Manufacturing Productivity data gathering for real-time analysis technology or social media which Technology Centre and streamlining of financial processes further improve productivity. Where for better data connectivity are also needed, initiatives driving new being implemented. After the training technology adoptions were also put in programme, the associates have been place. organised into LEAN teams to continue the transformation journey. 6 MANUFACTURING MATTERS | April 2020

INDUSTRY ALLIANCE SIMTech INNOVATION FACTORY This co-working space helps Small and Medium Enterprises develop prototypes to ensure Singapore’s economy remains nimble and able to respond to changes in global trends Innovation is critical for the future of Singapore’s economy As a co-working space for local companies, it enables them where technological advancements are changing sectors to ideate and design their own unique products. Companies such as advanced manufacturing. Hence, it is necessary to based in Singapore can access equipment and software foster a spirit of innovation in Small and Medium Enterprises tools for prototyping, and get expert advice on design and (SMEs) here. technology. After successfully developing their own product designs, companies can tap on the A*STAR Model Factory For this purpose, the Singapore Institute of Manufacturing located at SIMTech and the Advanced Remanufacturing and Technology (SIMTech) Innovation Factory, an initiative by Technology Centre (ARTC), to carry out pilot production. A*STAR, in partnership with Enterprise Singapore (ESG), is spearheaded to help local companies develop quality For a start, the SIMTech Innovation Factory will provide design products for their markets. This co-working space will provide and prototyping support for applications such as inspection local companies with practical support for product innovation equipment, medtech devices, and electromechanical and development, enabling them to move up the value-chain, modules. The SIMTech Innovation Factory will be operationally and sharpen their global competitiveness. ready at CleanTech Park in Jurong Innovation District in 2021. The process from developing an idea After developing their idea into a product concept for prototyping, and turning it into a marketable companies can choose to carry out pilot manufacturing of their products at product can be complex and challenging for SMEs. The SIMTech the A*STAR Model Factory located at SIMTech (picture) and ARTC Innovation Factory will provide our local companies with hands-on support For enquiries, please contact: in their innovation and productisation Mr Rayner Ng, Deputy Director, Innovation Factory journey, by allowing them to tap Email: [email protected] on A*STAR’s design, prototyping Web: www.a-star.edu.sg/SIMTech capabilities and expertise, to create quality products, and enhance their 7MANUFACTURING MATTERS | April 2020 global market competitiveness Dr David Low, Executive Director, SIMTech, and CEO, ARTC

RESEARCH SPOTLIGHT WATER TREATMENT TECHNOLOGY FOR RECYCLING A method is developed to classify and assign unique numerical identification codes to different water and wastewater types based on their water quality The recycling and recovery of water and treatment processes based on their wastewater resources and reduces resources from wastewater is necessary specific water quality. ambiguity in the communication of to maintain sustainable use of limited To achieve this, SIMTech developed a water types. freshwater resources. In an industrial method to classify and assign unique This classification system supports park, recycling is more difficult. A factory numerical identification codes to a waste(water)-to-resource tool that may not understand different water different water and wastewater types aims to help users find out which of qualities from another factory and the based on their water quality. This is their wastewater can be converted water recycling technologies that enable based on a commonly used set of into a potential resource or which of recycling and reuse. This is because water quality parameters for water and their resource can be derived from clean water and wastewater are typically wastewater quality monitoring. This wastewater, as well as what technology measured using different water quality includes key water quality parameters enables the waste(water)-to-resource parameters and these parameters might and additional parameters grouped into conversion. Subsequently, the tool be interpreted differently by different 2 sets, representing priority pollutants combs through the waste-to-resource industries and for different purposes. and other restricted parameters and matching database to recommend To tackle this problem, we need to developed into a 10-digit classification possible recycling technologies that distinguish and reference different water system (Fig 1). This identification code convert wastewater to usable water. and wastewater types so that water acts as a common basis for different quality is commonly understood across industries to reference water and industries, and enable suitable water The method enables Fig 1: Water classification method based on water quality parameters different water types For more information, please contact Ms to be represented Cadence Hsien, Sustainability and Lifecycle numerically. This allows Management Group at cadence_hsien@ users to identify the SIMTech.a-star.edu.sg types of (waste) water being used/discharged by their companies and make use of tools to treat or recycle them 8 MANUFACTURING MATTERS | April 2020

PAST EVENTS Events were organised to engage the industry and forge partnerships SIMTech Partnership Night, 5 February Close to 150 industry partners, representatives from trade associations and government agencies gathered at the SIMTech Partnership Night to celebrate the Lunar New Year. This annual by-invitation event is also an opportunity for the guests to network, and be updated on SIMTech’s new initiatives and upcoming events. Hosting SIMTech Partnership Night for the first time, Dr David Low, Executive Director, SIMTech, shared key highlights of SIMTech in 2019 and reiterated the institute’s commitment to collaborate with industry. In his Opening Remarks, Prof Tan Sze Wee, Assistant Chief Executive, Science and Engineering Research Council, A*STAR, emphasised on how SIMTech plays an important role in Industry 4.0 workforce training for Professionals, Managers, Engineers and Technicians to be future-ready. Dr John Yong, Director, Industry Development Office, also shared details on new SIMTech initiatives to support the manufacturing industry. One of these is the SIMTech Innovation Factory for industry to catalyse innovative design and scale- up to pilot production by Small and Medium Enterprises (see page 7 for details). 9MANUFACTURING MATTERS | April 2020

UPCOMING CIPs Collaborative Industry Projects (CIPs), initiatives, programmes and ready-to-go technologies are available to assist industry Real-time Dashboard A real-time dashboard that is customised to suit the company needs and to connect to multiple sources for congregation and analysis of real-time data. For enquiries, please contact Mr Gary Kwok at [email protected] Inventory Planning This programme aims to facilitate the decision-making and development of inventory policy to control rightsized inventory with the evolution of data & analytics techniques to maximise inventory performance. For enquiries, please contact Mr Chai Lai Sing at [email protected] Advanced Machining Dynamics Analysis Energy Efficiency Monitoring and Technology for Productivity and Quality Analysis System (E2MAS) Improvement This programme helps companies implement Energy This programme aims to improve the machining productivity Efficiency Monitoring and Analysis System (E2MAS) to assess and quality of local manufacturing industry in precision the equipment’s energy usage in real-time and identify machining of steel and non-ferrous metals through technology hotspots of excessive energy usage. These hotspots can then transfer and customisation. be analysed to derive quantifiable energy improvement. For enquiries, please contact Dr Sun Zheng at For enquiries, please contact Mr Joshua Thong at [email protected] [email protected] Collection & Delivery Management Overall Equipment Effectiveness (OEE) System (CDMS) This programme helps resource owners identify hidden This programme aims to equip companies with a real-time capacities of their machines to improve manufacturing collection and delivery management solution with Cloud-based productivity. By analysing the OEE losses such as machine Mobile Apps to support courier/logistics industries in service breakdown, machine slow-down and scrap parts, a improvement at reduced cost and time to achieve information manufacturing company can optimise the OEE of their accuracy, process efficiency and resource optimisation. existing equipment. For enquiries, please contact Mr Chai Lai Sing at For enquiries, please contact Dr Zhou Junhong at [email protected] [email protected] Manpower Scheduling System (MSS) Last Mile Logistics This programme aims to equip companies with a manpower scheduling solution that enables users to create schedules A planning and tracking solution to improve the management with one click, reassign tasks effortlessly and share of drivers/vehicles to effectively meet customer-imposed scheduling changes with employees instantly. pickup and delivery requirements amidst resource contraints. For enquiries, please contact Mr Chua Tay Jin at For enquiries, please contact Mr Gary Kwok at [email protected] [email protected] 10 MANUFACTURING MATTERS | April 2020

UPCOMING ACTIVITIES EVENTS wfMOBILE Webinar 18 May 2020 | 2.00pm – 3.00pm | Webinar Been wanting to convert manual paper-workflows to mobile workflows? Local SMEs and LLEs can find out more about how they can benefit from digitalisation and improve on productivity through this webinar. For enquiries, please contact Dr Justin Lim at [email protected] KAIZEN and DIGITAL approaches to help companies strengthen BUSINESS RESILIENCE CONTINUITY 27 May 2020 |10.00am – 11.00am | Webinar Senior management and managers from manufacturing and service SMEs will be able to benefit from this online seminar where knowledge on Operations Management Innovation (OMNI) Programme and Digital Transformation & Innovation (DTI) Programme will be shared. Targeted at the chemicals, electronics, logistics, engineering and environment services, precision engineering sectors, this webinar aims to help companies improve operations and accelerate their digitalisation transformation efforts. For enquiries, please contact Mr Ma Bin at [email protected] Watch this space for more exciting upcoming events for 2020! Scan for more events COURSES PE WSQ Graduate Diploma in Advanced Welding I-LEAN Technologies 12 May 2020 | 9.00am - 1.00pm | On-Line Training Module 4: Review Welding Operation & Quality Control Masterclass in Mastering Sales and Operations 5 May 2020 | 6.30pm - 9.30pm | On-Line Training Planning (S&OP) Process To Align Strategies To PE WSQ Graduate Diploma in Additive Manufacturing Operational Excellence Module 3: High Speed Additive Manufacturing Processes 18 - 19 May 2020 | 8.30am - 5.30pm | On-Line Training for Metallic Components PE WSQ Plan and Manage Project for Implementation 5 May 2020 | 6.30pm - 9.30pm | On-Line Training PE WSQ Graduate Diploma in Mechatronics 1 July 2020 | 6.30pm - 9.30pm | Fusionopolis 2 Module 2: Enhance Control Performance of Precision PE WSQ Graduate Diploma in Additive Manufacturing Machines Module 4: Polymer-based Additive Manufacturing 5 May 2020 | 6.30pm - 9.30pm | On-Line Training Processes for Flexible Mass Customisation 2 July 2020 | 6.30pm - 9.30pm | Fusionopolis 2 PE WSQ Graduate Diploma in Industrial Automation Module 1: Apply Robotics for Manufacturing Automation For course details and registration, please visit https://www.a-star.edu.sg/SIMTech/KTO 11 May 2020 | 6.30pm - 9.30pm | On-Line Training For general enquiries, please contact Scan for Tel: 6590 3193 or more courses email: [email protected] Editorial Committee About SIMTech Dr John Yong Advisor The vision of the Singapore Institute of Manufacturing Technology (SIMTech) is a world-class innovation partner in Ms Yap Yi Jin Editor advanced manufacturing technologies, systems and capabilities. It develops targeted high-value manufacturing Dr Goh Kiah Mok Member technologies and human capital to enhance the competitiveness of Singapore’s manufacturing industry. It collaborates Mr Joshua Thong Member with multinational and local companies in the precision engineering, medtech, aerospace, automotive, marine, oil & Ms Charlotte Lim Member gas, electronics, semiconductor, logistics, and other sectors. Ms Connie Ng Member Ms Nurul Ain Designer SIMTech is a research institute of the Agency for Science, Technology and Research (A*STAR). We are committed to serving the manufacturing industry to develop the human, intellectual, and industrial capital in Singapore. All rights reserved. Copyright © SIMTech | Singapore Institute of Manufacturing Technology, 2 FusionopoMlisANWUaFyA, C#T0U8R-0IN4G, InMnAoTvTiEsR, SSin| gAappriol r2e021038634 04/2020 11For enquiries, please contact us at Tel: 6501 1800 | Fax: 6250 3659 | Email: [email protected] | Web: www.SIMTech.a-star.edu.sg