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Resource efficiency benchmarking of the Russia Ferrous Foundry Industry:
Key findings of the studyImplemented under IFC Russia Cleaner Production Program
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GOAL: to identify the ferrous foundry sector’ resource efficiency potential and develop practical tools for foundries to implement it
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Benchmarking study time line
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Stakeholder consultations at every important stage:
Methodology Questionnaire for data collection Self diagnostic guide Matrix of casting types
Advisory board included over 20 representatives from industry, R&D, officials and policy makers.
Consultation process Written comments on all key documents Meetings of Advisory board Workshops in smaller teams
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What made our study successful : Stakeholder consultations process
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7 Key performance indicators (KPIs)
LABOUR
KPI 7
OVERALL PRODUCTION EFFICIENCY
KPI 2
PROCESS YEILD
KPI 1
WATER USE
KPI 6
SAND USE
KPI 5
ENRGY USE
KPI 4
CAPACITY UTILIZATION
KPI 3
Depends on technology and
processes
Depends on type of final product and technology
Depend on management practices and
equipment
What is being benchmarked?
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Raw material
Melting shopMeltingHolding
Treatment
Molding shopMold formingCore makingCore setting
Casting shopPouringCooling
Shake outSeparation
Finishing shopShot blasting
Grinding Deburring
Thermal treatmentInspection/testing
PackagingLabeling
StorageShipping
Sand recyclingTransport,
сooling
Metal recyclingSeparation,
transport
Metal yardStorage, charging
Sand plantStorage,
preparation
1 2 4 7 3
1 2 7 3
1 2 7
1 2 7 3 7
2 3
2 73
2 7 3buy
Sell
Risersand
runnersScrap
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Selected KPIsProcess YieldOverall production efficiencyCapacity utilizationEnergyFresh SandWaterLabor
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4
7
3
56
5
6
5
66 4
1 42
7 KPIs methodology tailored to foundry process
Selected KPIs and methodology tailored to foundry processes
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32 category’ matrix developed to cover diversity of foundry’ production
Grey Iron Product Categories
automatic mouldingGABH = automotive engine
blocks and cylinder heads
GAAO = automotive otherGAAG = agricultureGAMI = mining
mechanized mouldingGMBH = medium size engine
blocks and heads (energy generation)
GMAG = agricultureGMMI = miningGMGE = general engineering
manual (hand) mouldingGHBH = large size engine blocks
and heads (energy generation)
GHMI = miningGHGE = general engineering
Ductile Iron Product Categories
Steel Product Categories
automatic mouldingDAAU = automotive otherDAGE = general engineering
mechanized mouldingDMAU = automotiveDMGE = general engineering
manual (hand) mouldingDHEN = energy generation
componentsDHCO = compressor
componentsDHGE = general engineering
automatic mouldingSARC = railway components (c)SAMM = mining components
(m)SAAC = commercial vehicles (c)SAGC = general engineering
(c)
mechanized mouldingSMRC = railway components
(c) SMMM = mining components
(m)SMPC = pumps & valves (c)SMPS = pumps & valves (s)SMGC = general engineering
(c) SMAC = commercial vehicles
(c)
manual (hand) mouldingSHMM = mining components
(m) SHPC = pumps & valves (c)SHEA = energy components (a)SHGC = general engineering
(c)
c: carbon steel, s: stainless steel, m: manganese; a: high alloy steel
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215 foundries(first long list; 25% of all legally registered ferrous
foundries in Russia)
55 sets of independent data for foundries
Study based on real data from enterprises
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Coverage :•Period : 3 years (2007-2009)•Total # of data sets: 150•Categories covered: 27 out of 32 (85%) • Industry: 478 kt (14% of market)
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KEY FINDINGS OF THE STUDY
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Russian foundry European foundry предприятие
Russia foundries significantly lag behind European
Russian ferrous foundry us per tone of good casting:•Energy: 3 times more•Sand: 3,6 times more•Water: 161 times more•Labor : 3,6 times more man-hours
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4.5 mln t CO2e
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Costs:
EU Russia Russia at EU efficiency level
-36%
Inefficiencies eliminate Russian foundries’ competitive advantage in low prices
Prices for major resources in Russia are less than in the EU:
• Energy: 54% less
• Labor: 92% less
• Overheads: 71% less
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4 times
• Average defect rate in Russia is 4 times higher than in EU• Effect export: Russia exports less than 1% of casting
• Low quality – threat for internal markets as customers require certain quality (eg. automotive producers)
High levels of defect rate
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EU Russia
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- 26%
Cost structure index for ferrous foundry (materials, labor, energy, equipment maintenance, overheads, water and sand)
How much can Russia ferrous foundry industry gain via resource efficiency?
$ 3.3 bln USD
$2.13 bln USD
$ 3 bln USD -
29%
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- 43% Low cost and management
practices Capital investment
Over 50% of the potential can be implemented via low-cost measures and management
practices
$3.3 bln USD
Costs
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Capital investment
Low cost and
management
practices
KPIs and resource efficiency potential:
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Materials (metal)
Energy
Labor
Equipment related
Overheads
4,2%
43,3%
9,4%4,4%9,7%
$ 3.3 bln USD
12,8%
7,1%
21,4%
13,4%
45,2%
-3.1%-2.7%
-12%
-9.2%
-1.9%
Benchmarking of KPIs is a tool to priorities interventions to achieve maximum impact
Russia average level
Level of best practices
Cost structure
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Next steps:
• Toolkit: Self diagnostic guide, Compendium of KPIs, Best practice guide, Benchmarking study report
• Pilot program with 5-7 companies with foundries
• Resource efficiency finance directly and via FIs
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Information available in public domain
http://www.ifc.org/ifcext/eca.nsf/Content/
Russia_Foundry_Russian
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http://www.ifc.org/rcpp
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IFC contacts
IFC Russia Cleaner Production (IFC RCPP)• Yana Gorbatenko, Program [email protected]
Study team IFC RCPP:• Kristina Turilova, Task leader [email protected]• Boris Nekrasov, Technical expert [email protected]• Maria Sigutina, PR and [email protected]
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