Department of Science and Technology

Unit: Manufacturing and Technology Localisation

UNIDO WORKING

GROUP MEETING

20 May 2010

PROTOCOL FOR DST ENGAGEMENT

IN LOCALISATION INITIATIVES

Supplier Development

Plan (SDP)

Existing Framework within CSDP

DST Technology Localisation Plan

Identification of Technology

Products

Supplier Networks

(vertical and horizontal)

Stage Gate

Analysis

Technology Capability Analysis

Gap Analysis

Product-Market-Technology

Combinations

Strategic Choice

(Drivers for Competitive

Advantage)

Technology Assistance

Package (TAP)

Develop Strategic

Partnerships

Cost/ benefit

Analysis

Monitor, Evaluate,

& Review TAPImplementation

3

Background on development of TAP

(cont.)

• 31 Foundries were then identified based on the technology that they currently use and linked to the appropriate technology component groups

• Of these, 28 foundries were part of the benchmarked foundries that was conducted by the NFTN

• These benchmarking results also described the Technology Gaps, as well as areas where improvement was required in these foundries

Foundries

identified

• Both the Transnet and the Eskom CSDPs contain opportunities for the Foundry Industry, mainly in the form of components linked to their infrastructure build programme (capex and opex)

• A list of possible components for localisation was generated by both Eskom and Transnet.

• These components were then grouped based on the technology used to manufacture them

CSDP Opportunity

• Key themes for assistance across the foundries were identified

• 28 Business Cases for the Technology Assistance Package’s (TAP’s) were then developed (1 for each foundry identified)

• 3 additional Business Cases for Industry Level Interventions were then developed

Assistanc

e required

by

companie

s

4

List of components for localisation for Eskom &

Transnet

Meeting with DST

Tier one Tier two Tier three

Transmission System Draw gear knuckles, couplers, yokes, draw gear

components

Transmission System Gearbox housings

Transmission System Levers handles, etc

Mechanical fluid transfer Valves

Mechanical fluid transfer Pumps housings, impellers

Mechanical fluid transfer Cylinder Engine blocks

Mechanical fluid transfer Marine equipment

Bogies Wheels

Bogies U-tube

Bogies Canonbox

Bogies Traction Motor housing, cooling fan

Bogies Sideframe

Bogies Bolsters

Bogies Centre castings

Locking Mechanism Twist Locks

Hydraulic System Hydraulic hoses couplings

Hydraulic System Hydraulic Pumps housing, impellors

Rail infrastructure Railway Crossings

Rail infrastructure Shoulders

Braking system Brake Valves

Braking system Cast iron brake blocks

General 20" Castings

Rail infrastructure Perway related Components frogs, switchblades, etc

Rail infrastructure Clips and fasteners

Substations and lines Hardware Clamps, Spacers, Dampers, insulators

Substations and lines HV Switchgear Casings

Fans Housings Gearbox housings for fans

Fans Blades Fan blades

Boiler Air heater Drive, Gearbox

Boiler Air/Gas System Fan blades

Boiler Ash System Scraper hydraulic motor

Boiler Ash System Tiles

Boiler Bag Filters Compressors

Boiler Electrical Electric motors

Boiler Fuel Cycle Gearboxes

Boiler Fuel Cycle Mills

Tier one Tier two Tier three

Mills Grinding media Balls, linings

Mills Mill Castings Grinding Tracker Carrier

Mills Mill Castings Clamping ring

Mills Mill Castings Grinding segments

Mills Mill Castings Grinding roller yoke

Mills Mill Castings Grinding tyre

Mills Mill Castings Loading arm

Mills Mill Castings Thrust plate housing

Mills Mill Castings Thrust plate frame

Mills Mill Castings Gearbox

Turbine-Generator Set Steam chests and nozzle boxes H.P. steam chests

Turbine-Generator Set Steam chests and nozzle boxes I.P. steam chests

Turbine-Generator Set Steam chests and nozzle boxes H.P. nozzle boxes

Turbine-Generator Set Steam chests and nozzle boxes I.P. nozzle boxes

Turbine-Generator Set Turbine casings H.P. inner

Turbine-Generator Set Turbine casings H.P. outer

Turbine-Generator Set Turbine casings I.P. inner

Turbine-Generator Set Turbine casings I.P. outer

Turbine-Generator Set Turbine casings L.P. Inner

Turbine-Generator Set Valve casing H.P. outer casing

Turbine-Generator Set Valve casing I.P. inner casing

Turbine-Generator Set Valve casing I.P. outer casing

Turbine-Generator Set Rotor discs L.P.

Turbine-Generator Set Moving blades L.P. (2nd last row)

Turbine-Generator Set Moving blades L.P. (last row)

Turbine-Generator Set Fixed or diaphragm blades H.P.

Turbine-Generator Set Fixed or diaphragm blades I.P.

Turbine-Generator Set Fixed or diaphragm blades L.P.

Turbine-Generator Set Fixed or diaphragm blades L.P.

Turbine-Generator Set Sealing fins High temperature glands

Turbine-Generator Set Sealing fins Low temperature glands

Turbine-Generator Set Diaphragm glands Blade tip seals

Turbine-Generator Set Steam pipes Cross-over

5

Technology component groups

linked to Foundries

Meeting with DST

Group End User Casting Description Potential Suppliers

Group 1 Transnet Knuckles; couplers; yokes; draw gear related

components; housings; handles; U-tube;

canon box; side frame; bolster; centre

casting; twist locks

Prima Industrial

Scaw Metals

Transwerk, Koedoespoort

Thomas Foundry

Crown Foundry

Group 2 Transnet Couplings for hydraulic systems VHE Foundry

Lenreco

KEW

Wam Metals

Halberg Guss

Group 3 Transnet Gearbox and hydraulic pump housings and

impellers

Joerg Foundry

Thomas Foundry

JC Impellers

Franklin

Boschpick

KEW

Crown Foundry

Wam Metals

IPT Pefco

Group 4 Transnet Railway crossings; Perway related

components

Prima Industrial

Scaw Metals

Transwerk, Koedoespoort

Thomas Foundry

Crown Foundry

Group 5 Transnet Clips and fasteners Guestro

Transwerk, Bloemfontein

Pressure Die Casting

Halberg Guss

Group 6 Transnet Brake valves ETS Foundry

KEW

ETS

Group 7 Transnet Cast iron brake blocks Transwerk, Bloemfontein

CME

Guestro

Ukuthela

Crown Foundry

Thomas Foundry

Halberg Guss

Group End User Casting Description Potential Suppliers

Group 8 Transnet 20" castings (assume cast iron) Crown Foundry

Joerg Foundry

KEW

Group 9 Eskom Clamps; spacers; dampers; insulators;

casings

McWade Productions

Wahl Industries

Pressure Die Casting

Preformed Line Products

Franklin

Babcock

Alumacast

Lenreco

Pfisterer

Wam Metals

Group 10 Eskom Balls, linings (for coal pulverisers) Scaw Metals

M.I.S. Engineering

Thomas Foundry

Crown Foundry

Group 11 Eskom Grinding tracker carrier 24 tons Mittal

Scaw Metals

Thomas Foundry

Crown Foundry

Group 12 Eskom Clamping ring; grinding segments; grinding

roller yoke; grinding tyre; thrust plate

M.I.S. Engineering

Scaw Metals

Thomas Foundry

Crown Foundry

Group 13 Eskom Loading arm 12 tons; gearbox 12 tons Mittal

Scaw Metals

Thomas Foundry

Crown Foundry

Group 14 Eskom HP inner; HP outer; IP inner; IP outer; LP

inner; casings and other items

Steloy

Thos Begbie

IPT Pefco

Areas for Technology Assistance

L ean & C lean

Manufac turing

R &D for improving

produc tivity

R educ ing

c as ting

s c rap

Improving in-

hous e

metallurg ic al

expertis e

S kills Development

improvement

E nerg y

reduc tion

Improve fettling

s ophis tic ation

Mould/ P attern/

Tooling

improvements

R equire

Ac c reditation/

QMS

As s is tanc e

with Des ig n

P ac kag es

R educ tion in

man-hours

per ton

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26 12 9 5 26 19 22 18 10 9 19

Aircraft Engine Development

Innovation

EOS S 700-build cores and

moulds for sand casting

Thank you.