Feedback on international trips

The past two and a half weeks have been filled with rather hectic schedules while we visited five states in the United States of America (a trip organised through the DST TAP) and attended GIFA, the International Foundry Trade Fair, organised by Messe Dusseldorf in Germany. The feedback is not to give an account of our day-to-day activities, but rather to share with you those lessons learnt that truly stood out during these trips.

At an American family foundry called Bremen Castings Inc. based in Indiana we were told that they do not practice lean and clean manufacturing principles, but that they do have a motto: SQS meaning “Status Quo Sucks” This motto is seen everywhere in the foundry and known and practiced by all with the clear knowledge that tomorrow’s operations should be better than today. The same foundry has a policy to reinvest 10% of their annual profit into new technology.

In Germany a representative of the very impressive Georg Fischer Piping Systems, through words and action clearly showed us that it is imperative to “manage the process not the product” Here, every effort is made to ensure that front end engineering is practiced to reduce handling the casting at the end. Nearly no fettling was needed. At Maynard Steel Casting Co in Milwaukee (US) banners placed strategically throughout the foundry communicates to the workers “Rework costs money” and “Safety is first priority”.

At Neenah Foundry in Wisconsin, the foundry manager said it is equally important for them that the foundries around them continuously grow and develop. They take cognizance of the fact that they cannot operate in isolation. If they were the only foundry in that area, there will be no foundry industry at all.

I believe this should be the attitude of our foundry community in South Africa. Unless we increase the competitiveness of our foundry industry as a whole, there will be no industry in the future in South Africa. Our competitors are not the foundries around the corner from us, but the foundries in the international arena.

A technical feedback session on the trips will soon be arranged by SAIF at one of their Technical Meetings. We hope to see you there. For further details regarding this feedback session please contact:

South African Institute of Foundrymen
Marina De Goede Biljon
Executive Secretary
Tel: +27 (11) 559 6455
Fax: +27 (11) 559 6526
Fax to email: 086 509 7045
email: saif@icon.co.za / mbiljon@uj.ac.za
www.foundries.org.za

DST TAP SATISFACTION SURVEY

The Technology Assistance Programme (TAP) aims to address the numerous technology gaps that the foundry industry must overcome for them to be well-positioned as competitive bidders for the State Owned Enterprises (SOE) expansion contracts. Eskom and Transnet are the two SEO’s, for now, targeted by the South African Government-sanctioned Competitive Supplier Development Programme (CSDP). They will be embarking on extensive multi-billion dollar expansion programmes in the next decade. In order to meet this challenge the myriad of technology gaps were identified through a number of surveys done in the foundry industry. The DST managed to isolate 11 prime technology areas that were deemed to be worthy of immediate attention. CSIR and Mintek was contracted to execute the two most imperative technology areas; CSIR is supporting the industry on “Lean and Clean manufacturing”, and Mintek on “Scrap Reduction”.

After a year of implementing the support to industry, DST requested an independent survey to be conducted in order to obtain evidence of the impact and the current state of the programme. NFTN and SAIF conducted this survey. For the shortened report, click here

Global Castings magazine

Welcome to the premier issue of Global Casting Magazine, an electronic magazine launched by MODERN CASTING, FOUNDRY-PLANET.COM and the CHINA FOUNDRY ASSOCIATION. This quarterly web-based publication will provide the global perspective on metalcasting, including news, features and technology from all regions of the world.

Global Casting Magazine represents a breakthrough in metalcasting communication, as it truly is a global partnership, drawing on the perspectives of North America, Asia and Europe. Through the partnering of MODERN CASTING, FOUNDRY-PLANET.COM and the CHINA FOUNDRY ASSOCIATION, this resource will reach 70,000 metalcasters, including the leadership of the world’s largest communities in North America, Europe and Asia, via the internet.
To receive the electronic copy of this magazine please click: http://www.globalcastingmagazine.com/

CALL FOR APPLICATIONS: UJ-FREIBERG HCD ADVERTISEMENT

In the interest of strengthening advanced knowledge and technology in the Foundry Industry in South Africa, the Metal Casting Technology Station at the University of Johannesburg in conjunction with the Department of Science and Technology (DST) presents an incredible opportunity for five diligent post-graduate candidates to study a Masters Degree in Advanced Foundry Technology in Germany.

The Human Capital Development (HCD) programme in advanced Foundry Technology is an initiative by the Department of Science and Technology; and offered by the University of Johannesburg in partnership with Freiberg University in Germany. The purpose of the programme is to invest in South Africa by developing research skills and practical knowledge in advanced foundry technology. The research Masters programme will be offered over two years in Germany and South Africa.

Please submit the following documentation by 30 July 2011 to Amy Driessel at amyd@uj.ac.za.

For further information please contact Hannelie Nel on (011) 559 6134 or Farouk Varachia on (011) 559 6304.

• Updated curriculum vitae.
• Certified copies of academic records, indicating pass rates of relevant theoretical knowledge.
• A certified copy of your ID.

For further details please click here

PANEL OF EXPERTS: Introducing John Lyons

The Panel of Experts featured on the website, will be profiled in the coming newsletters. These profiles will feature the most important projects that they are currently working on. Our first expert profile is on Mr John Lyons of England.
“I am currently working as a consultant with a large OEM that supplies complete systems to the auto industry. Some of these systems contain magnesium die castings which they die cast around the world themselves. As you know the automotive and aerospace industries are seeking weight reductions in components in order to reduce fuel consumption. The demand for magnesium over the coming years will continue to increase.

• Magnesium versus Aluminium:
• Quicker cycle times
• Superior die life (comparable to zinc)
• Superior flow characteristics
• Equal or superior mechanical properties depending on the alloy.

One of the disadvantages with Magnesium is that all the waste material must be sent back for recycling unless you make a very substantial capital investment yourself. It can cost in the order of one Euro per kilogram to recycle magnesium (handling/transport/recycle costs/etc.). I will be working on several projects one of which is to reduce consumption of material i.e. increase the percentage yield of castings per kilogram of magnesium purchased. This will involve minimising gate/runner area, reducing quantity of over flows and volume of same, reduction in scrap produced, possible reduction in plunger diameter, etc”.

To view the complete profile, click here

UPCOMING EVENTS

AFRIMOLD WELL SET TO PROVIDE A TRULY COSMOPOLITAN TOOLING, DIE & MOULD EXHIBITION
The second AfriMold tooling, die & mould making exhibition at the Sandton Convention Centre from 27-29 September is poised to generate a truly cosmopolitan atmosphere with local participants being joined by overseas exhibitors from the UK, Germany, France, Switzerland, Korea and India, among others. For more information please click here

RAPDASA 2011
This event will focus on the impact of AM on the complete product development process/value chain. Therefore, participants are invited to submit papers that address AM’s impact on new product development for the peer review process. Suggested topics include design, simulation, modeling, virtual prototyping and digital sculpting, direct manufacturing of consumer, artistic and industrial products, tooling, medical applications, business models, business cases and educational development.
For further information please click here