The availability of technical foundry support to add value and eliminate waste, solve day to day foundry problems and enhance productivity is paramount to a competitive industry.
Achieved to date
NFTN has played a key role in benchmarking the foundry industry on a number of levels. One hundred and three foundries have been technically benchmarked (46/54 permanent mould foundries and 67/105 sand foundries; ten (10) of these foundries were benchmarked for both types). The benchmarking results formed the basis for the assessment that DST conducted on the industry in preparation of their Technology Assistance Programme (TAP). NFTN completed forty one (41) profiles and conducted twenty eight (28) business benchmarks on behalf of UNIDO. Other than this NFTN also did an energy desktop benchmark of twenty three (23) foundries in terms of process, size and type of metal casted. Energy management workshops were facilitated by NFTN to present the results. In cooperation with ESKOM three (3) foundries have been identified for a pilot of their Demand Management Programme.
AIDC requested NFTN to manage short term support of three (3) automotive foundries in the North West Province. These foundries included Joerg Foundries, Hallberg Guss (Brits) and Sumba foundries. Two of the foundries now form part of the DST TAP. NFTN coordinated the introductory visits for CSIR and MINTEK once the twenty eight (28) foundries were identified for the TAP. NFTN is in the process of conducting a satisfactory survey on behalf of DST to assess the progress of the programme.
Eight (8) foundries have been indentified and contracted for Competitive Improvement Initiative (CII) from NFTN. The interventions include support such as; casting simulation, process optimisation, process monitoring, energy saving, product innovation etc. This support shall commence in 2011/12.
Planned activities for 2011/12
- Satisfactory surveys on behalf of DST completed
- Start support of eight (8) foundries that have already been contracted for CII
- An additional six (6) foundries shall be contracted and supported through the CII
- Twenty (20) additional foundries to be technically benchmarked (6 permanent mould and 14 sand casting)
- Support thirty (30) more foundries to complete the UNIDO profiles.
Possible risk identified
It should be realised that due to the fact that currently most government support is concentrated at the now 27 foundries supported through the TAP, NFTN therefore sees that it is imperative to ensure that support is extended to a larger number of foundries through the CII. This is to avoid the risk of foundries perceiving government only assisting a selected few.
10-Nov-2011
The DST TAP Programme
The programme is implemented through the CSIR, focusing on Lean and Clean Manufacturing interventions, and Mintek, focusing on casting related interventions, with the primary aim of improving efficiencies and reducing casting scrap. NFTN continues to offer support in this area.
A total of 28 foundries were selected for this first TAP intervention, under the auspices of the DST Localisation Programme. Two of these foundries have since closed down due to unforeseen circumstances, one have moved premises to the Western Cape producing only for their own capacity and need. Following consultation with the DST Localisation and Advanced Manufacturing manager, the Halberg Guss foundry located in Port Elizabeth has now been included in the TAP programme, which brings the total number of foundries being offered assistance in this programme to 26.
On 4 September the final report back by CSIR and Mintek was made to DST. NFTN has identified a number of successful projects that have been implemented through the DST TAP. Another similar project is the “Costing software for jobbing sand foundries” and NFTN believe this software would be beneficial to other jobbing foundries. For further information on this software please contact NFTN.
NFTN Competitiveness Improvement Intervention (CII) project
A contract is in the process of being signed with VUT; to facilitate the NFTN competitive improvement initiative (CII) in the Vaal region supporting at least six foundries. This will be the first of future regional initiatives under this result area. NFTN would like to leverage various support initiatives in a holistic way through the CII area. The following areas have been identified to contribute to the competitive improvement of foundries:
- Benchmarking – show current status to foundries. Foundries in the Vaal not yet benchmarked will be linked to the benchmarking (mentioned above); consultants are already working on a revised/improved questionnaire that will be benchmarked against the BRIC countries.
- Understanding the performance criteria of customers – looking at issues such as ISO accreditation, BEE, costing and identifying new opportunities for the region (the costing tool is what was developed under the DST TAP programme)
- Training and Skills development – SAIF will sign a MoU with VUT to offer the comprehensive training programme in the Vaal region
- Placement of interns – as reported in the TAP survey this could have a two-fold benefit to the student and the foundry
- Introducing innovative management practices
- Technology support and uptake of new technologies (concentrating on the 11 technology gaps identified through DST TAP)
- Promoting and assisting foundries with front-end engineering such as CAD and simulation packages
- Promoting closer cooperation between foundries, customers, suppliers and public support institutions.
This is a good opportunity to track the support and then develop a case study for reporting to industry at large and government. The same approach will be used in KZN, Ekurhuleni and Tshwane area.
