welcome [] · (july 2010) les mÉes ii 11.6 mwp 27 ha 1,425 poly- crystalline (50% solairedirect)...
TRANSCRIPT
WELCOME
Skill’s development History
and Plans going forward
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7/5/2012
A MODULE MANUFACTURING CAPACITY WITH THE BEST AND MOST COST EFFECTIVE TECHNOLOGIES
Location : Cnr of De Beer and Sacks Circle
Bellville South
Cape Town
South Africa
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A photovoltaic production unit of 40 MWp
based in CAPE TOWN (Republic of South
Africa).
Production commissioning started in
January 2009, and rapidly reached the
performance expected (obtaining Final
Acceptance Test in February 2009).
A production facility exclusively dedicated
to Solairedirect (France) needs, the
parent company of Solairedirect
Technologies (ownership of 100%) and to
the local SA and Africa market.
AN INDUSTRIAL CAPACITY WITH THE BEST TECHNOLOGIES
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AN INDUSTRIAL CAPACITY WITH THE BEST TECHNOLOGIES
Creation of Company and Plant construction Start –
January 2008
Factory Acceptance Test of Equipment – September
2008 - Japan Line assembly December 2008
Line Installation completed Jan 2009 First Shipment to SD – April 2009
Start of Production – March 2009
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7/5/2012
PRODUCTION
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7/5/2012
STORES, DISPATCH AND LABORATORY
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DESCRIPTPION OF THE MODULE MANUFACTURING PLANT C
Facility Details: Total : 4000 sq/m
Production – 1400 sq/m
Raw Material Warehousing – 1200 sq/m
Finish Goods Warehousing – 1000 sq/m
Laboratory, Maintenance, and Office space - 400 sq/m,
Supportive Peripherals: Generator + UPS for risk management for continual production
Climatic Controlled production unit to ensure STC.
Capacity: Current Line installed – 40 MWp per annum
Facility Capacity –120 MWp
Production Equipment: NPC Automated Tabbing and Stringing units
NPC Automated module Lay-up unit
Automated line for high pace manufacturing
NPC Laminator for encapsulation of Solar
MBJ Solutions GmbH automated EL tester
Berger Power measurement module Tester
VOS climatic chamber
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7/5/2012
SDT EXPANSION POSSIBLE
SDT has the capacity to increase within its current premises with an additional 2 production
lines of 40MW each, yielding an accumulated capacity of 120MW.
There is also an option to rent a neighbouring premises that gives us an additional 3000
sq/m, yielding a further expansion possibilities.
Line 2 can be installed next to line 1 in Unit 3 without disruption of line 1 production, drawing
1 below denotes the current (line 1) in colour and the second line in grey.
Line 3 can be installed in unit 2 used currently used as the Rebate Store/raw material
warehouse. The Rebate Store will move offsite to our Freight forwarder. Drawing 2 and 3
denote line 3 layout.
-
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SDT EXPANSION CONT …
Drawing 1 : Line 1(current in colour) and Line 2 (expansion possible in
grey) drawing in Unit 3
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SDT EXPANSION CONT…
Drawing 2 : Line 3 positioned in Unit 2 Drawing 3 : Line 3 close-up
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7/5/2012
SDT PRODUCTION HISTORY
10.37
24.69
32.52
67.58
0
10
20
30
40
50
60
70
2009 2010 2011 Total
Production Actual Annually 2009- 2011
MW
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7/5/2012
SDT PRODUCTION modules used on SD France projects
INSTALLED CAPACITY
SURFACE
P90PRODUCTIBLE
(kWh/kWp)TECHNOLOGY LEASE STATUS OVERVIEW
VINON 4.3 MWp 10 Ha1,395
Real 1,511
Poly-crystalline(100% Yingli)
40 yearsOperational
(March 2009)
LES MÉES I 12.0 MWp 24 Ha 1,425Poly-crystalline
(50% Solairedirect)40 years
Operational(July 2010)
LES MÉES II 11.6 MWp 27 Ha 1,425Poly-crystalline
(50% Solairedirect)40 years
Operational(December 2010)
ESPARRON I 8.4 MWp 19 Ha 1,425Poly-crystalline
(50% SDT)40 years
Completed(Operational March 2011)
ESPARRON II 5.2 MWp 12 Ha 1,425Poly-crystalline
(50% SDT)40 years
Completed(Operational March2011)
St. HILAIRE 6.0 MWp 11 Ha 1,215Poly-crystalline
(100% SDT)30 years
Completed
(Operational March 2011)
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SDT PRODUCTION modules used on SD France projects
INSTALLED CAPACITY
SURFACE TECHNOLOGY LEASE DELIVERY DATE OVERVIEW
VARAGES I 6 MWp 12 Ha 8.1 GWh Crystalline
(100% SDT) 40 years September 2011
VARAGES II 6 Ha 4.1 GWh 40 years August 2011
VENZOLASCA 10 Ha 5.6 GWh 40 years September 2011
POGGIO DI NAZZA 10 Ha 5.8 GWh 30 years September 2011
SARTENE 10 Ha 4.8 GWh 30 years September 2011
COUTEUGES 21.8 Ha 11.6 GWh (50% SDT / 50% Jinko)
40 years November 2011
3 MWp
4.5 MWp
4.5 MWp
3.6 MWp
10 MWp
JUSSAC 12 MWp 26.3 Ha
Crystalline
Crystalline
Crystalline
Crystalline
Crystalline
Crystalline
(100% SDT)
(100% Jinko Solar)
(100% Jinko Solar)
(100% Jinko Solar)
(50% SDT / 50% Jinko) November 2011 13.8 GWh 40 years
ESTIMATED PRODUCTION
(GWh)
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7/5/2012
SOLAIRE DIRECT TECHNOLOGIES TEAM
• The Senior Management team of Solaire Direct Technologies (SA citizens) have years of international experience in all fascists related to the supply chain, quality, technology and manufacturing of PV Solar Modules.
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Ajay LALLA Sebastien FEIT Tracey LALLA
Nick CARPENTER Muriel BOHAARDIEN Tony JOYCE
7/5/2012
SOLAIRE DIRECT ORGANIZATION CHART
Managing Director
Ajay Lalla
Senior
Production
Manager
Tony Joyce
Production Co-
ordinator
Suleman Samsodien
Shift Supervisor
1
Michael Gamba
T/S Pilot
Charlton Cupido
T/S Co-pilot
Dumani Georgias
Prep 1
Sarah Johnson
Prep 2
Edith Mdishwa
Prep 3
Elizabeth Tiras
Prep 4
Bongile Mditshwa
Rework
Mario Joseph
Material Cutting
Adam Windvogel
QC 2
Shalako Mathews
Framer 1
Lazola Yedwa
Framer 2
Luzuko Rubushe
Packer
Ashley Africa
J/B
Wayne Bantom
SunSim
Marlon Turner
FQA
Ayanda Mzinzi
Shift Supervisor
2
Ganief Nell
T/S Pilot
Nazmie Ely
T/S Co-pilot
Bratley Adams
Prep 1
Roslyn Rhode
Prep 2
Natalie Oliver
Prep 3
Soraya Noordien
Prep 4
Madeniya Ripepi
Rework
Masnoena MorrisiMaterial Cutting
Melanie
Goddard
QC 2
Riyaad Dollie
Framer 1
Mzamo Tora
Framer 2
Songezo Lengisi
Packer
Shannon Pieterse
J/B
Nathan Bantom
SunSim
Roland Langeveldt
FQA
Morne Isaac Daniels
Shift Supervisor
3
Ettiene Titus
T/S Pilot
Craig Flores
T/S Co-pilot
Matthew Nyaba
Prep 1
Tashwill Goliath
Prep 2
Dominique Davids
Prep 3
Chester Daniels
Prep 4
Alice Mabandla
Rework
Corlene
Solomons
Material Cutting
Shiretha Geswint
QC 2
Antonio Abrahams
Framer 1
Alex Fulani
Framer 2
Marawaan Jacobs
Packer
Alwin Pietersen
J/B
Amanda Manila
SunSim
Leeroy Jones
FQA
Porchia Paulsen
Quality
Manager
Saud Edries
IT Manager
Kobus Smith
Accounts
Manager
Muriel
Bohaardien
Supply Chain/
Sales Manager
Tracey Lalla
Stores Co-
ordinator
Donovan Paulsen
Dispatch Co-
ordinator
Keith Adbulla
Stores assistant
Adolf Arandse
Machine
Specialist
Nick Carpenter
Maintenance
Technician 1
Karl Lotter
Maintenance
Technician 2
Menesh Daya
Purchasing
Assistant
Gail Blacker
Dispatch assistant
Malcolm
Christians
Dispatch assistant
Andrew Ludick
Process Controller
Mustapha Jasiem
Factory Cleanner
Keith Redding
Factory Cleanner
Veronica N
Factory Cleanner
Michelle Africa
Sales
Carlos Rodrigues
Receptionist
Deidre April
SHER Manager
Deon DariesAccounts
Assistant
Joslyne Daniels
28/02/2011A.L. Rev.7
DPC-HR-001
Total Head Count : 90
Total SD : 1
Total SDT : 68
Total Contract : 21
Organization Chart
Maintenance
Technician 3
Trevor Mathews
Shift Supervisor 4
Murawan Masoet
T/S Pilot
Ashley Philips
T/S Co-pilot
Aaron Horswell
Prep 3
Sasha-Lee Hess
Prep 4
Rozanne van
Schalkwyk
SunSim
Safwaan Jacobs
Prep 1
Elizabeth Tiras
Material Cutting
Rene Bailey
FQA
Veronique Conrad
J/B
Kelly Lee Williams
Framer 1
Elvine Bantom
Prep 2
Samantha Davids
Rework
Rafiq Felix
Framer 2
Lindsay Trantraal
Packer
Jonanthan
Abrahams
Operational
Manager
Sebastian Feit
Job Closure Clerk
Avril Arendse
QC 2
Kashief Maclain
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7/5/2012
SOLAIRE DIRECT TECHNOLOGIES’ PRODUCTS
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• SDT produces a module power range of from 120W to 305 Wp modules
• All modules produced by SDT are IEC 61215 ed 2 and IEC 61730 class 1& 2
certified by TUV Rhienland in Germany
• SDT has certified a 1500V module in its manufacturing power range capacity.
• SDT has certified a BIPV module call Solrif used in roof integration, this module
has been installed in various area’s across France.
• Specification sheets of all products produced by SDT accompany this presentation
• Additional test have been conducted by TUV Rhienland as follows
• Max reverse current – Completed 2011
• Salt Mist testing corrosion testing (IEC 60068-2-52) - In progress
• Ammonia Resistance corrosion testing of PV Modules (IEC 62716) – In
progress
7/5/2012
To ensure highest quality PV module supply
PV module cost reduction : To control modules
prices, a major component of the KWh
production cost.
PV module customization:
To control modules design dedicated to
roof top installations (BIPV : Building
Integrated PV).
1500V module and system design and
certification
SOLAIRE DIRECT TECHNOLOGIES’ OBJECTIVES
Solairedirect Technologies: A team cumulating over 50 years of experience in the photovoltaic
industry.
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7/5/2012
DESCRITPION OF THE MODULE MANUFACTURING PLANT CONT…
Certifications :
IEC 61215 ed.2 by TUV Rheinland (April 2010) and TUV Intercert(January 2009)
IEC 61370 class1 and 2 by TUV Rheinland (April 2010) and TUV Intercert(January 2009)
ISO 9001:2008 certified by TUV Rheinland (June 2010)
ISO 14001:2004 audit passed successfully (June 212)
Quality Assurance :
Test Lab on premises capable of testing to all criteria of IEC 61215:2005
In house - Batch verification of Module encapsulation and Cell/Module soldering adhesion.
Onsite Climatic chamber to do all weathering test to warrantee 25 years.
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7/5/2012
SOLAIRE DIRECT TECHNOLOGIES QUALITY ASSURANCE STRENGTHS
• 100 % cell inspection for Cracks
• 100 % cell inspection for strings built for cracks, soldering coverage and conductivity
• Soldering adhesion SPC managed with 18 test conducted daily
• Gel content of EVA encapsulation check 2 weekly and verified at external laboratory
once monthly
• 100 % Electroluminescence inspection conducted after lamination for micro crack
inspection and overall quality grading .
• 100 % Hipot testing
• Sample wet leakage testing
• 100% module flashing of modules to determine power, sunsimulator calibrated at TUV +
0%.
• Modules tested for IEC Damp Heat, Thermal Cycling and Humidity freeze test at three
times IEC specification
• Module manufacturing plant has be audit by Munich RE and has successfully passed
• IEC 61215 edition 2, IEC 61730 (class 1& 2) certified, extra testing done by TUV for max
reverse current and Salt mist Testing successfully passing these test.
• 1500 V module certification to the IEC 61215 ed.2 and IEC 61730 (class 1 and 2) via
TUV.
• Claim and non-conformities managed through 8D reports and root cause analysis
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SOLAIRE DIRECT TECHNOLOGIES CERTIFICATIONS
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IEC 61215 IEC 61370 class1 and 2
7/5/2012
SOLAIRE DIRECT TECHNOLOGIES CERTIFICATIONS
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ISO 9001:2008 ISO 14001:2004
7/5/2012
SOLAIRE DIRECT TECHNOLOGIES CERTIFICATIONS
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ISO 14001:2004 (June 2012) => 0 non-conformity
ISO 9001:2008 (March 2012) => 0 non-conformity
7/5/2012
SDT FINANCIAL INFORMATION
Due to experience, R&D and continuous productivity improvement employing principles of lean
manufacturing SDT is able to reduce its cost to produce as illustrated below on the expected cost with the
added expansion.
Annual Capacity (MW) 40 MW 80MW 120MW
Year 2012 2012 2012
Organisation
# Tabber stringers 2 4 6
# Laminators 1 2 3
Overhead analysis Permanent People 0.029 0.022 0.02
euro/w Temporary People 0.004 0.008 0.009
Spares parts 0.002 0.002 0.002
Elec/water 0.003 0.003 0.003
Building 0.005 0.003 0.002
Depreciation 0.022 0.011 0.013
Other 0.017 0.013 0.013
Consumables (flux,…) 0.003 0.002 0.001
Logistic Externalization 0 0 0.003
Transfer Pricing Mark-up 5.5% of O/H 0.005 0.004 0.003
Overhead recovery (€/W) € 0.090 € 0.068 € 0.066
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SKILLS GAP ANALYSIS
2008 - 12 Employees
2009 - 45 Employees
2010 - 76 Employees (25 Temps)
2011 - 81 Employees (25 Temps)
2012 - 63 Employees (No Temps)
0
10
20
30
40
50
60
70
80
90
2008 2009 2010 2011 2012 2013
Qty
Em
plo
yee
s
Year
SDT Employee Growth Structure
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CURRENT AND PLANNED SKILLS DEVELOPMENT
PV Induction – All Staff (PV Exposure)
Manufacturing Process Training – Work Station, Work Instruction (Process,
Quality, Safety, Environmental Management System)
Process Optimization – Formula 1 Response, Cell Breakage, Cost Reduction,
Quality Reaction, Waste Avoidance, Best Practice, IPX IT system.
External Skills – Health & Safety, First Aid, Fire Fighting, SDF, Internal
Auditing, Quality 9001, EMS 14001 - TUV Rheinland
Additional Internal Training – FMEA, Problem Solving, Supervisors & Team
Leaders, Basic ISO & EMS.
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QUALIFICATION PROCESS
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WORK INSTRUCTION
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COMMUNITY PROJECTS AND SKILLS
INTRODUCTION
High School Introduction to Photovoltaic Manufacturing in partnership with
UCT
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EMASITHANDANE (EMASI) CHILDREN’S HOME
Emasi Children’s home is a 1 bedroom house that is situated in the Nyanga
township of Cape Town that houses more than 20 children.
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NELSON MANDELA METROPOLITAN UNIVERSITY
AND UNIVERSITY OF JOHANNESBURG SOLAR CAR PROJECT SPONSOR
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THANK YOU
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