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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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Dominic mitchell march 2013

Dominic Mitchell

March 2013

BRICSIRON FOUNDRIES SURVEY


Presentation content

General overview

Materials and their costs

Power sources and usage

Cost structure

Training

Presentation content


Background

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


Survey overview

Conducted in South Africa, Brazil, India, China National Foundry Technology Network and the SA Institute of

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


Acknowledgements

  • Thanks are extended to: National Foundry Technology Network and the SA Institute of

    • The Brazilian Foundry Association

    • UNIDO Russia

    • the Indian Institute of Foundrymen

    • The China Foundry Association

    • The SA Institute of Foundrymen

Acknowledgements


Number of iron foundries
Number of iron foundries National Foundry Technology Network and the SA Institute of


Overall iron production volume in tons
OVERALL IRON PRODUCTION (VOLUME IN TONS) National Foundry Technology Network and the SA Institute of



Total number of direct and indirect employees
Total number of direct and indirect employees IRON FOUNDRIES IN THE COUNTRY



Jobbing and production ratios
Jobbing and production ratios IRON FOUNDRIES IN THE COUNTRY


Comparative ratios of iron
Comparative ratios of iron IRON FOUNDRIES IN THE COUNTRY


Average iron across countries
Average iron across countries IRON FOUNDRIES IN THE COUNTRY


Market sectors served
Market sectors served IRON FOUNDRIES IN THE COUNTRY


Average age of furnaces
Average age of furnaces IRON FOUNDRIES IN THE COUNTRY


Market sectors averaged brics
Market sectors averaged BRICS IRON FOUNDRIES IN THE COUNTRY


Domestic vs export markets
Domestic IRON FOUNDRIES IN THE COUNTRYvs Export markets


Import export ratios brics average
Import/export ratios BRICS average IRON FOUNDRIES IN THE COUNTRY


Average price of alloys ton
Average price of alloys/ton IRON FOUNDRIES IN THE COUNTRY


Scrap average cost per ton
Scrap Average cost per ton IRON FOUNDRIES IN THE COUNTRY


Resins average cost per ton
Resins: Average cost per ton IRON FOUNDRIES IN THE COUNTRY


Sand average cost per ton
Sand average cost per ton IRON FOUNDRIES IN THE COUNTRY


Average value of castings per ton
Average value of castings per ton IRON FOUNDRIES IN THE COUNTRY


Government incentives

This is a complex topic with many layers IRON FOUNDRIES IN THE COUNTRY

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


Brics iron foundries survey

COST STRUCTURE IRON FOUNDRIES IN THE COUNTRY


Material as a of production cost
Material as a % of production cost IRON FOUNDRIES IN THE COUNTRY


Energy as a of production cost
Energy as a % of production cost IRON FOUNDRIES IN THE COUNTRY


Labour as a of production costs
Labour as a % of production costs IRON FOUNDRIES IN THE COUNTRY


Equipment as a of production cost
Equipment as a % of production cost IRON FOUNDRIES IN THE COUNTRY


Overheads as a of production cost
Overheads as a % of production cost IRON FOUNDRIES IN THE COUNTRY


Combined cost structure
Combined cost structure % IRON FOUNDRIES IN THE COUNTRY


Power source in iron foundries
Power source in Iron foundries IRON FOUNDRIES IN THE COUNTRY


Power incentives govt support

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


Constraints in electricity supply
Constraints in electricity supply of the day – trough and crest pricing (peace hours)


Electricity cost per kw h
Electricity cost per of the day – trough and crest pricing (peace hours)kw/h


Kw h used per ton
Kw of the day – trough and crest pricing (peace hours)/h used per ton


Electricity cost per ton
Electricity cost per ton of the day – trough and crest pricing (peace hours)


Days per annum that foundries operate
Days per annum that foundries operate of the day – trough and crest pricing (peace hours)


Personnel costs

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


Training senior management
Training senior management foundries who felt that this was sensitive information


Training middle management
Training middle management foundries who felt that this was sensitive information


Training moulders
Training Moulders foundries who felt that this was sensitive information


Training fettlers
Training Fettlers foundries who felt that this was sensitive information


Main certification systems
Main Certification Systems foundries who felt that this was sensitive information


Brics iron foundries survey

THANK YOU foundries who felt that this was sensitive information