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Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
Dst tap programme 2010 05-20 csir
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Dst tap programme 2010 05-20 csir

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  • 1. Technology Assistance to Companiesin the South African Foundry IndustryCSIR OPCO MeetingWillie du Preez30 OctoberMetals & Metals ProcessesManager: 200920 May 2010
  • 2. 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 • CollaborativeSlide 2 © CSIR 2009 www.csir.co.za
  • 3. Introduction
  • 4. 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 AIDCSlide 4 © CSIR 2009 www.csir.co.za
  • 5. Established Competence Platforms
  • 6. 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 collaboratorsSlide 6 © CSIR 2009 www.csir.co.za
  • 7. Industrial HPDC Cell at CSIR SSM billet machine Dosing Furnace 630 Ton LK shot control die casting machineSlide 7 © CSIR 2009 www.csir.co.za
  • 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 slurrySlide 8
  • 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: 200mbarSlide 9
  • 10. CSIR’s Collaborators International R&D Institutions: NIMS(Japan) Univ of Birmingham(UK) Univ of Freiburg (Germany) ULim UP Aerosud Necsa CSIR Mintek NLC UJ Wits VUT CUT UKZN UCT SU NMMU CPUTSlide 10
  • 11. CSIR’s Collaborators (continued) • 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 NiekerkSlide 11 © CSIR 2009 www.csir.co.za
  • 12. Our Offerings
  • 13. 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 machinesSlide 13 © CSIR 2009 www.csir.co.za
  • 14. 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)Slide 14 © CSIR 2009 www.csir.co.za
  • 15. Our Approach
  • 16. 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 planSlide 16 © CSIR 2009 www.csir.co.za
  • 17. 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 laterSlide 17 © CSIR 2009 www.csir.co.za
  • 18. 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 ProcessesSlide 18 © CSIR 2009 www.csir.co.za
  • 19. We are looking forward to assisting the foundry industry!

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