SOUTH AFRICAN INTITUTE OF FOUNDRYMEN

ANNUAL GENERAL MEETING

24 May 2016 PRESIDENT’S REPORT

T Madzivhandila

South African Foundry Industry

Foundries are resource intense businesses, (material, energy and labour) and are subject to the ever increasing pressures to improve performance to maintain their competitiveness The foundry industry is predominantly still an SMME industry, with limited resources and financial means for skills development and training.

Total of 13,000 employees

43% Reduction in Output from 2007:

374,700 tons VS from 660, 400 tons

SAIF Vision and Strategy

The vision of the SAIF is “to be the voice of the South African Foundry Industry, creating growth and job opportunities through training, skills development and education”.

Develop and Coordinate a Sustainable National Workforce Development Programme,

promoting lifelong learning in the foundry industry

To rise to the challenge of the global manufacturing marketplace driven by productivity, flexibility and the need to develop workers able to lead in such an environment, our strategy is to:

South African Institute of Foundrymen (SAIF) Introduction

1937 • The South African Institute of Foundrymen (SAIF) was established in 1937 as a branch

of the Institute of British Foundrymen.

1964 •  SAIF was registered as an independent body

2015

• In 2010 SAIF was registered as a Non Profit Organisation, as per the Companies Act of 2008

• Today SAIF is the official industry body of a very diverse foundry industry. It has a 186 member base of which 89 are companies;

• Member of the BRICS Foundry Association

Governance and Organisation

u  New Memorandum of Incorporation was registered in 2015 with EXCO and Council changing to Board of Directors and Management Committee

u  CEO agreed to another term in office

u  Restructuring of the focus areas

u  Appointment of Alan Wood as SAIF representative early 2016

u  BBBEE Accreditation from Level 4 to Level 3 in 2015

u  Pieter Dielwart from Q Pumps, Glen Tillett from Mattcast and Robert Bezuidenhout passed away

 

Key Partnerships

§  The National Foundry Technology Network (NFTN)

§  The Aluminium Federation of South Africa (AFSA)

§  Copper Development Agency (CDA)

§  The Metal Casting Technology Station (MCTS) hosted and the University of Johannesburg

§  The Department of Science and Technology (DST) Through the agencies of the CSIR and Mintek to assist industry and conduct research

§  The University of Johannesburg, Vaal University of Technology, Cape Peninsula University of Technology and the Tshwane University of Technology

§  The BRICS Foundry Association

SAIF Focus 2015

u  1. Training

u  2. Representing the Foundry Industry at National and Local Government Levels as well as various National Initiatives

u  3. Promoting the South African Foundry Industry at home and abroad

u  4. Fund Raising

u  5. Enlarging Membership Base

1. SAIF Skills and Training Programme History

1990’s • SAIF Western Cape Branch Implemented 8 module training course

2003

• SAIF initiated the revision of the artisan skills curriculum for Moulders, Patternmakers and introduced a new trade – Melter

2004 - 2009

• Ad-hoc Training in the foundry

2010 - 2015

•  SAIF partnered with the NFTN (National Foundry Technology Network) to develop a national co-ordinated approach to foundry skills development, ensuring sustainability of the existing interventions and enhancing the roll-out of new training courses deemed relevant to the industry.

• The Career Path Framework project focussed on the development of curricula for the training of apprentices in the following trades: Patternmakers, Moulders and Melters

• Learnership Pilot Project was launched with 18 learners

Financial  Year   Facilitated  

2010/11   190  workers  

2011/12   200  workers  

2012/13   443  workers  

2013/14   484  workers  

2014/15   454  workers  

2015/16    258  new  workers   479  total  workers  

 

1. Training – GFTC (Gauteng Foundry Training Centre)

u  The SAIF continued to support the GFTC with materials and additional plant and equipment necessary for the training and accreditation of the centre.

u  In March 2016, the GFTC was accredited for both training and as a decentralised trade test centre for patternmakers and moulders (old curricula) whilst the melter trade test is almost complete.

u  Obtaining MerSeta funding for apprentices at GFTC

u  Twenty one learners (9 melters, 5 moulders and 7 patternmakers) have remained on the course, with the drop-out rate dramatically reducing with the MerSeta support.

u  Confirmed all 14 Career Path Framework Learners in employment

1. Training – Module Courses

u  349 workers were trained on the various foundry diploma modules during this financial year, representing 63 Companies

u  NFTN Target was 300

u  Another 7 learners completed the Diploma Program

u  The course material of the melting and metallurgy modules have been revised, updated with latest practices and reviewed by industry

66%

18%

4% 12%

Module Courses Presented per Province

Gauteng KZN Northern Cape Western Cape

1. Training - On Site on Demand Courses

u  130 workers were trained on the various In House on Demand training courses during this financial year, representing 22 companies

u  NFTN target was 50.

62%

38%

Inhouse On Demand Courses per Province

Gauteng KZN

1. Training Workshops

SAIF are hosting various technical workshops to disseminate information to the foundry industry

u  Monthly Technical Presentations u  Modern Ferrous & Non Ferrous Melting, Smelting & Process Treatment Plants

u  Innovative Financing Solutions for Capital Plant Funding

u  GIFA 2016 Feedback Session

u  Casting Design Methods

u  Mobile Extraction Systems to meet Emission Monitoring Requirements

u  Using Solar Power as Alternative Energy in Foundries

u  Advances in CAE & Manufacturing Technology

u  Co-Hosted MCTS Colloquium in Sept 2015

u  Co-hosted EFFSAFOUND 2 (materials) workshops in Gauteng, KZN and Western Cape in March 2016.

u  Co-hosted VDMA Workshop in Gauteng in March 2016

2. SAIF Government Interactions

SAIF is interacting with various government bodies and represent the foundry industry at various interventions to address foundry challenges and to identify additional volumes for foundries:

u  Energy : Interaction with authorities to discuss solutions for Energy Efficiency as well as tariff considerations

u  Scrap Metal : Engaging with the Department of economic Development, looking at lower input cost solutions for ferrous and ferrous metals

u  Dept Labour : Overarching safe working practices for the iron and steel industry

u  Environmental : HAZCOM - , DEA (Dept of Environmental Affairs) - Representation on the waste material subcommittee, engagement with NCPC via the NFTN to assist foundries with emission licences

u  Higher Education : Merseta, QCTO, development of new curriculum, engagement with Numsa training representative

u  Localisation : TLIU, Vamcosa, Pump cluster

3. Promoting the Foundry Industry

u  Exhibited at GIFA / METEC / THERMPROCESS World of Metals South African Pavilion in June 2015 in Germany

u  Co-hosted the Technology Localisation Imperative Colloquium in September 2015

u  6th BRICS FOUNDRY FORUM, 16th May – 20th May

4. Fundraising

u  SAIF depends on membership fees as well as the income generated from the golf day and annual dinner to fund the operational cost of the organisation

u  In 2011 SAIF partnered with the NFTN to roll out the training programme on a large scale. The agreement ended March 2016, and SAIF is engaging with the NFTN to ensure the renewal of the contract.

u  The management of SAIF is actively exploring additional funding mechanisms for the training programme.

4. Golf Day 2015

u  144 Players participated in the 2015 Golf day at Reading Golf Course

u  17 Sponsored holes, & 10 Special prizes sponsored

4. SAIF Annual Awards Dinner 2015

u  ·Excellent support from industry – 296 people attended the function at Emperors Palace

u  9 Learners received their Diplomas for completing 6 modules of the foundry course

u  2 SAIF Members receiving AH Guy Awards(Clive Jones & Bruce Crawford)

u  Kobus Krog from Autocast (Autocast being a member) received award for best technical paper

u  Best university student awards were from UJ (MCTS – UJ being a member) and VUT

u  Acknowledgement to sponsors, committee members and venue management and attendees

        

5. Membership Drive

u  SAIF is actively promoting the Institute to industry, individuals as well as students to increase the membership.

u  The membership increased from 174 to 186 in the 2015 period

u  SAIF is in the process of developing an interactive website with specific information only available to members.

2016 - 2017

•  The South African Foundry Industry is facing strong headwinds, but working together and focusing on key issues with the relevant role players, we can realise the following opportunities:

o  Improvement of Skills and Technical Knowledge

o  Increased Localisation and Import Replacement

o  Environmentally Compliant Foundries

o  Increased use of new Technologies

The SAIF will continue to leverage both increased demand and new technology to grow the industry, improve competitiveness and build human capacity.

I would like to thank the Directors, Management Committee, Staff, as well as members for their efforts and continuous

support in building and growing the SAIF to a relevant foundry organisation.