FUTURE MANUFACTURING FLAGSHIP

Australian Sustainable Manufacturing in 2013, and beyond

Sarah King: Leader, Sustainable Manufacturing Innovation July 2012

Agenda – Sustainable Manufacturing

CSIRO + Innovation

Global Megatrends

Resource Efficiency

Business Model Innovation

New Technology

62% of our people hold university degrees 2000 doctorates 500 masters

CSIRO undertakes $~500M of externally funded R&D each year Work with partners in over 80 countries

Top 1% of global research institutions in 14 of 22 research fields Top 0.1% in 4 research fields Highest number of citations per scientist in Australia

Darwin

Alice Springs

Bakers Hill

Atherton

Townsville 2 sites

Rockhampton

Toowoomba

Gatton

Myall Vale Narrabri

Mopra

Parkes

Griffith

Belmont

Geelong

Hobart Sandy Bay

Werribee Wodonga

Newcastle

Armidale 2 sites

Perth 3 sites

Adelaide 2 sites

Brisbane 6 sites

Sydney 5 sites

Canberra 7 sites

People 6550

Locations 57

Budget $1B+

Murchison

Cairns

Melbourne 6 sites

Snapshot

Infra $3.5bn

Patents 3000+

Partners 1300+

DIGITAL PRODUCTIVITY AND SERVICES

ENERGY TRANSFORMED BIOSECURITY

National Research Flagships

|

CLIMATE ADAPTATION

WEALTH FROM OCEANS

FOOD FUTURES

SUSTAINABLE AGRICULTURE

MINERALS DOWN UNDER FUTURE MANUFACTURING

PREVENTATIVE HEALTH

WATER FOR A HEALTHY COUNTRY

Research Themes

Flexible Electronics Low cost light-emitting and light-harvesting thin film devices - OPV & OLED Printed electronic switches & sensors (OFET)

Manufacturing technologies for transport and mining Electric drives systems and energy storage Light weighting and durability Detection systems

Titanium Technologies Powder production Metal production Powder to product Direct/Additive manufacturing

Sustainable high performance materials High performance multi- functional composites Coating technologies Lightweight ballistic resistant materials Advanced Fibre technologies

Agile Manufacturing Technologies •Intelligent manufacturing – micro-automation and assistive robotics, ICT enabled Sustainable Manufacturing – zero waste, closed loop, Advanced assembly technologies

• Over 100,000 jobs have been lost in manufacturing since 2008.

• Contribution to GDP has declined from 9.5% to 8.7% between 2005-06 and 2009-10

• Australia’s total export trade - 50% in 2006-07 to 34% in 2010-11

• Manufacturing is a vital part of the Australian economy

• Manufacturing Multiplier, 2006 – every $1 generated additional $1.25 expenditure in other sectors.

• In 2010-11, 27% of total business R&D, larger than any other sector, $4,760M, $499M inc c.f. 2009-10.

Current Manufacturing Environment Bad vs Good news

• 42% more likely to report increased profitability

• 3 x more likely to export and 18 x more likely to increase the number of export markets targeted

• 4 x more likely to increase the range of goods or services offered

• more than 2 x as likely to increase employment

• More than 3 x more likely to increase training for employees

Innovation = competitiveness

Source: Australian Innovation System Report, 2012

Barriers to innovation – 2010-11

Source: DIISRTE, Australian Small Business, Key Statistics and Analysis, Pg 64,

http://www.ge.com/au/innovation_barometer.html

Megatrends The 2012 Revision

http://www.csiro.au/Portals/Partner/Futures.aspx

Megatrends Influence on Australian Manufacturing

Source: CSIRO contribution to Prime Minister’s Manufacturing Taskforce

Resource Efficiency

New Technology

Business Model

Innovation

3 Strategic Innovation Priorities for Sustainable Manufacturing in 2013

1. Resource Efficiency

Widespread adoption of ‘zero waste’ technologies across the Australian manufacturing sector.

Zero waste coatings

Australian manufacturers are regarded as leading innovators, providing sustainable solutions for global markets.

Modelling for Process and Design Improvement

World-leading physical simulation platform that account for particles, fluid flow and free surfaces.

Case Study: Improved design of Coal Hopper Wagons

Discharge time depends on coal flowability, a complex function of:

– particle size and shapes distributions

– material properties

– cohesive forces between wet coal

Certain wagon designs showed a significant improvement in discharge time.

Corrosion Prediction, Monitoring, Prohibiting

Prediction and Material Selection

IT systems to predict life of individual components and whole systems

Sensor- based Monitoring and Prognostics

Sensor based monitoring combined with advanced prognostics

Remaining life and intelligent maintenance

Inhibitor Systems

High Throughput studies for fast selection

Electrochemical Studies for detailed Understanding

Corrosion Resistant Materials

Alloys, Conversion Coatings, Primers, Top coats

Self repair Systems

2. Business Model Innovation

The 10 types of innovation - Doblin

Source: http://www.doblin.com/tentypes/#framework

Australian Industry Example

http://www.plasback.com.au http://www.tapex.com.au

3. New Technology Additive Manufacturing Lightweight Assistive Manufacturing Solutions

Additive V’s Subtractive Manufacturing

In comparison with traditional “subtractive” manufacturing methods in which a block of finished material is machined down to make a product, additive manufacturing methods are fast, use less energy, and generate less waste material.

Additive manufacturing

Subtractive manufacturing

Source:http://news.thomasnet.com/green_clean/2012/08/29/additive-manufacturing-puts-its-clean-tech-face-forward-in-federally-funded-development-program/

EEE

Directly from Powder to Finished Product

Victorian Direct Manufacturing Centre

1. Augumentation Systems

2. Co-Worker

3. Tele-Supervised

Robotics

http://www.csiro.au/en/Portals/Media/CSIRO-launches-new-breed-of-factory-bots-focused-on-safety-and-sustainable-manufacturing.aspx

Lightweight Assistive Manufacturing Solutions | NMW 2013

Resource Efficiency

New Technology

Business Model

Innovation

3 Strategic Innovation Priorities for Sustainable Manufacturing in 2013

Thank you CSIRO Future Manufacturing Flagship Sarah King

t +61 3 5246 4747 E sarah.king@csiro.au w www.csiro.au