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BRICS IRON FOUNDRIES SURVEY

Dominic Mitchell March 2013. BRICS IRON FOUNDRIES SURVEY. General overview Materials and their costs Power sources and usage Cost structure Training. Presentation content.

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BRICS IRON FOUNDRIES SURVEY

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  1. Dominic Mitchell March 2013 BRICSIRON FOUNDRIES SURVEY

  2. General overview Materials and their costs Power sources and usage Cost structure Training Presentation content

  3. The survey was commissioned at the end of 2012 by the National Foundry Technology Network and the SA Institute of Foundrymen At last BRICS conference delegates expressed the need to create stronger focus areas for discussion As iron foundries are significant by output volume, it was agreed to focus on them. Background

  4. Conducted in South Africa, Brazil, India, China Russia recently had an extensive benchmarking exercise with UNIDO Main purpose was to pick out trends and set a context for comparison Challenges related to language, short time frames for cleaning and checking of data, and countries responded with differing degrees of accuracy. Foundries too. Survey overview

  5. Thanks are extended to: • The Brazilian Foundry Association • UNIDO Russia • the Indian Institute of Foundrymen • The China Foundry Association • The SA Institute of Foundrymen Acknowledgements

  6. Number of iron foundries

  7. OVERALL IRON PRODUCTION (VOLUME IN TONS)

  8. OVERALL IRON PRODUCTION (VOLUME IN TONS) OF THE 3 LARGEST IRON FOUNDRIES IN THE COUNTRY

  9. Total number of direct and indirect employees

  10. No. of universities offering foundry related degrees

  11. Jobbing and production ratios

  12. Comparative ratios of iron

  13. Average iron across countries

  14. Market sectors served

  15. Average age of furnaces

  16. Market sectors averaged BRICS

  17. Domestic vs Export markets

  18. Import/export ratios BRICS average

  19. Average price of alloys/ton

  20. Scrap Average cost per ton

  21. Resins: Average cost per ton

  22. Sand average cost per ton

  23. Average value of castings per ton

  24. This is a complex topic with many layers Incentives range from export incentives (SA) State/province/local government investment incentives (Brazil) Sub-sector and equipment development plans(China) Manufacturing and skills development policy (India) Government incentives

  25. COST STRUCTURE

  26. Material as a % of production cost

  27. Energy as a % of production cost

  28. Labour as a % of production costs

  29. Equipment as a % of production cost

  30. Overheads as a % of production cost

  31. Combined cost structure %

  32. Power source in Iron foundries

  33. Brazil and India have differing tariffs for different times of the day – trough and crest pricing (peace hours) Brazil has a national cost reduction project SA has a green energy efficiency fund with a rebate for energy efficient equipment, also differing pricing structure Power incentives/GOVT SUPPORT

  34. Constraints in electricity supply

  35. Electricity cost per kw/h

  36. Kw/h used per ton

  37. Electricity cost per ton

  38. Days per annum that foundries operate

  39. This section of the survey was not completed by many foundries who felt that this was sensitive information A consequence is also that labour productivity was not possible to calculate. Personnel costs

  40. Training senior management

  41. Training middle management

  42. Training Moulders

  43. Training Fettlers

  44. Main Certification Systems

  45. THANK YOU

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