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CSIR OPCO Meeting
30 October 2009
Technology Assistance to Companies in the South African Foundry Industry
Willie du Preez
Manager: Metals & Metals Processes
20 May 2010
Slide 2 © CSIR 2009 www.csir.co.za
Overview
• Introduction• Knowledge Generation over past decade with DST support
• Established Competence Platforms• CSIR and its Collaborators
• Our Offerings• Lean and Clean Manufacturing• Casting Process Knowledge
• Our Approach• Collaborative
Introduction
Slide 4 © CSIR 2009 www.csir.co.za
Introduction
DST initiatives and support for knowledge generation and dissemination into industry over the past decade:
• National Product Development Centre (NPDC) (2001 - 2005)• From National Casting Technology Centre to National Foundry
Technology Network (NFTN)
• National Tooling Initiative (NTI): Institutes for Advanced Tooling, supported by DST
• Technology Stations, now the Tshumisano Programme (2000)• UJ’s Metal Casting Technology Station
• CUT’s Product Development Technology Station
• Advanced Manufacturing Technology Strategy (AMTS) (2003)• Advanced Metals Initiative (AMI)
• PRIME Lean Manufacturing lead by the AIDC
Established Competence Platforms
Slide 6 © CSIR 2009 www.csir.co.za
Competence Platforms
• Lean and Clean Manufacturing• Production Monitoring
• Advanced machine design and robotics
• Visual inspection systems for quality control
• Automation of production machinery
• Shop floor programmes by AIDC industrial engineers
• Cleaner production intervention programmes of the NCPC
• Casting Process Technologies and Know-how• Semi-Solid Metal Casting (SSM) & High Pressure Die Casting
• Investment Casting of Titanium alloys
• Metallurgical Laboratory
• Mechanical Testing Laboratory (ISO 17025 accredited)
• High Temperature Materials Laboratory (ISO 17025 accredited)
• Network of national and international collaborators
Slide 7
© CSIR 2009 www.csir.co.za
Dosing Furnace
630 Ton LK shot control die casting machine
SSM billet machine
Industrial HPDC Cell at CSIR
Slide 8
Equipment Upgrades for Ti Investment Casting
Dipping facility
• Small dip tanks for experimental slurries
• Robotic dipping facility including instrumentation for data collection
• Testing facility to characterise refractories and slurry
• Sealed dip tanks for extended life of face coat slurry
Slide 9
Equipment Upgrades for Ti Investment Casting
Melting and casting facilities
Vacuum melting and casting
Requirements for Titanium:
• Melt temperature: 1850ºC
• Mould pre-heating: 1500ºC
• Leak rate < 1 x 10-4 mbar.l/s
• Base pressure: 10-5 mbar
• Argon partial pressure: 200mbar
Slide 10
UCT
CUT
ULim
CSIR
UP
Mintek
Necsa
UJ Wits
NMMUCPUT
UKZN
SU
NLC
VUT
Aerosud
CSIR’s Collaborators
International R&D
Institutions:
NIMS(Japan)
Univ of Birmingham(UK)
Univ of Freiburg (Germany)
Slide 11 © CSIR 2009 www.csir.co.za
• Automotive Industry Development Centre (AIDC)• Extensive experience in the Automotive Industry
• Have done some work with the NFTN in foundries
• National Cleaner Production Centre (NCPC-SA)• Implementing agent of cleaner production in SA
• Pilot programmes in Automotive and Metals & Allied Processes sectors
• Leading consultants, such as• Dr Morris Murray (Member of MMP’s Research Advisory Panel)
• Mr Carl Reinhardt• Mr Dave van Niekerk
CSIR’s Collaborators (continued)
Our Offerings
Slide 13 © CSIR 2009 www.csir.co.za
Lean & Clean Manufacturing Offerings
• Production Efficiency• Production monitoring
• Machine design and robotics
• Visual inspection systems for quality control
• Automation for improved efficiency
• Process Knowledge• Permanent Mould Casting (HPDC and Gravity)
• Investment Casting
• Efficient Toolmaking• Optimisation of tooling design
• Tooling for automated fettling systems
• Die proving on CSIR machines
Slide 14 © CSIR 2009 www.csir.co.za
Lean & Clean Manufacturing Offerings (2)
• Material and Product Characterisation• Metallurgical characterisation
• Mechanical testing• Refractories testing
• Sustainable production practices• Scrap reduction
• Optimised energy consumption• Waste management
• Quality Management Systems• Implementation and maintenance of ISO 9000
• Implementation and maintenance of ISO 17025
• Environmental health and safety systems• Implementation and maintenance of EHS systems (ISO 14000 &
18000)
Our Approach
Slide 16 © CSIR 2009 www.csir.co.za
Our Approach
• Focused on individual company’s needs• Collaborating with company staff
• Jointly work towards continuous improvement
• Work closely with the NFTN• Recognised in the Foundry Industry
• Led the Benchmarking that was previously done
• Play a facilitation role
• Initial planning per individual company• Meeting of Foundry, CSIR, Mintek and NFTN
• Jointly develop improvement plan
• Sign off the agreed assistance plan
Slide 17 © CSIR 2009 www.csir.co.za
Our Approach (continued)
• Provision of technology assistance to agreed plans• Schedule intervention with the company
• Intervention will be lead by our core team
• Support will be provided by the broader expertise base as required
• Progress evaluation and monitoring• Agreed collaborative evaluation
• Evaluation immediately after intervention
• Monitoring one to two years later
Slide 18 © CSIR 2009 www.csir.co.za
Our Core Team
• Duncan Hope: Project Manager
• Pierre Rossouw: Casting Specialist
• Martin Williams: Tooling Specialist
• Sagren Govender: Research Group Leader – Advanced Casting Technologies
• Willie du Preez: Manager: Metals & Metals Processes
We are looking forward to assisting the foundry industry!