1. Department of Science and Technology
Unit: Manufacturing and Technology Localisation
UNIDO WORKING
GROUP MEETING
20 May 2010
2. PROTOCOL FOR DST ENGAGEMENT
IN LOCALISATION INITIATIVES
Identification of Technology Supplier Development Existing Framework within CSDP
Products Plan (SDP) DST Technology Localisation Plan
Supplier Networks
(vertical and horizontal)
Stage Gate Technology Capability Analysis
Analysis Gap Analysis
Product-Market-Technology
Combinations
Strategic Choice
(Drivers for Competitive Monitor, Evaluate, Implementation
Advantage) & Review TAP
Technology Assistance
Package (TAP)
Cost/ benefit Develop Strategic
Analysis Partnerships
3. Background on development of TAP
(cont.)
• Both the Transnet and the Eskom CSDPs contain opportunities for the
Foundry Industry, mainly in the form of components linked to their
CSDP infrastructure build programme (capex and opex)
Opportunity • 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
• 31 Foundries were then identified based on the technology that they
currently use and linked to the appropriate technology component groups
Foundries • Of these, 28 foundries were part of the benchmarked foundries that was
identified conducted by the NFTN
• These benchmarking results also described the Technology Gaps, as well as
areas where improvement was required in these foundries
Assistanc • Key themes for assistance across the foundries were identified
e required • 28 Business Cases for the Technology Assistance Package’s (TAP’s) were
by then developed (1 for each foundry identified)
companie • 3 additional Business Cases for Industry Level Interventions were then
s developed
3
4. List of components for localisation for Eskom &
Transnet
Tier one Tier two Tier three Tier one Tier two Tier three
Transmission System Draw gear knuckles, couplers, yokes, draw gear Mills Grinding media Balls, linings
components Mills Mill Castings Grinding Tracker Carrier
Transmission System Gearbox housings Mills Mill Castings Clamping ring
Transmission System Levers handles, etc Mills Mill Castings Grinding segments
Mechanical fluid transfer Valves Mills Mill Castings Grinding roller yoke
Mechanical fluid transfer Pumps housings, impellers Mills Mill Castings Grinding tyre
Mechanical fluid transfer Cylinder Engine blocks Mills Mill Castings Loading arm
Mechanical fluid transfer Marine equipment Mills Mill Castings Thrust plate housing
Bogies Wheels Mills Mill Castings Thrust plate frame
Bogies U-tube Mills Mill Castings Gearbox
Bogies Canonbox Turbine-Generator Set Steam chests and nozzle boxes H.P. steam chests
Bogies Traction Motor housing, cooling fan Turbine-Generator Set Steam chests and nozzle boxes I.P. steam chests
Bogies Sideframe Turbine-Generator Set Steam chests and nozzle boxes H.P. nozzle boxes
Bogies Bolsters Turbine-Generator Set Steam chests and nozzle boxes I.P. nozzle boxes
Bogies Centre castings Turbine-Generator Set Turbine casings H.P. inner
Locking Mechanism Twist Locks Turbine-Generator Set Turbine casings H.P. outer
Hydraulic System Hydraulic hoses couplings Turbine-Generator Set Turbine casings I.P. inner
Hydraulic System Hydraulic Pumps housing, impellors Turbine-Generator Set Turbine casings I.P. outer
Rail infrastructure Railway Crossings Turbine-Generator Set Turbine casings L.P. Inner
Rail infrastructure Shoulders Turbine-Generator Set Valve casing H.P. outer casing
Braking system Brake Valves Turbine-Generator Set Valve casing I.P. inner casing
Braking system Cast iron brake blocks Turbine-Generator Set Valve casing I.P. outer casing
General 20" Castings Turbine-Generator Set Rotor discs L.P.
Rail infrastructure Perway related Components frogs, switchblades, etc Turbine-Generator Set Moving blades L.P. (2nd last row)
Turbine-Generator Set Moving blades L.P. (last row)
Rail infrastructure Clips and fasteners Turbine-Generator Set Fixed or diaphragm blades H.P.
Substations and lines Hardware Clamps, Spacers, Dampers, insulators Turbine-Generator Set Fixed or diaphragm blades I.P.
Turbine-Generator Set Fixed or diaphragm blades L.P.
Substations and lines HV Switchgear Casings
Turbine-Generator Set Fixed or diaphragm blades L.P.
Fans Housings Gearbox housings for fans
Turbine-Generator Set Sealing fins High temperature glands
Fans Blades Fan blades
Turbine-Generator Set Sealing fins Low temperature glands
Boiler Air heater Drive, Gearbox
Turbine-Generator Set Diaphragm glands Blade tip seals
Boiler Air/Gas System Fan blades
Turbine-Generator Set Steam pipes Cross-over
Boiler Ash System Scraper hydraulic motor
Boiler Ash System Tiles
Boiler Bag Filters Compressors
Meeting
Boiler with DST Electrical Electric motors 4
Boiler Fuel Cycle Gearboxes
5. Technology component groups
linked to Foundries
Group End User Casting Description Potential Suppliers
Group 1 Transnet Knuckles; couplers; yokes; draw gear related Prima Industrial Group End User Casting Description Potential Suppliers
components; housings; handles; U-tube; Scaw Metals Group 8 Transnet 20" castings (assume cast iron) Crown Foundry
canon box; side frame; bolster; centre Transwerk, Koedoespoort Joerg Foundry
casting; twist locks Thomas Foundry KEW
Crown Foundry
Group 2 Transnet Couplings for hydraulic systems VHE Foundry Group 9 Eskom Clamps; spacers; dampers; insulators; McWade Productions
Lenreco casings Wahl Industries
KEW Pressure Die Casting
Wam Metals Preformed Line Products
Halberg Guss Franklin
Group 3 Transnet Gearbox and hydraulic pump housings and Joerg Foundry Babcock
impellers Thomas Foundry Alumacast
JC Impellers Lenreco
Franklin Pfisterer
Boschpick Wam Metals
KEW
Crown Foundry Group 10 Eskom Balls, linings (for coal pulverisers) Scaw Metals
Wam Metals M.I.S. Engineering
IPT Pefco Thomas Foundry
Group 4 Transnet Railway crossings; Perway related Prima Industrial Crown Foundry
components Scaw Metals Group 11 Eskom Grinding tracker carrier 24 tons Mittal
Transwerk, Koedoespoort Scaw Metals
Thomas Foundry Thomas Foundry
Crown Foundry Crown Foundry
Group 5 Transnet Clips and fasteners Guestro
Transwerk, Bloemfontein Group 12 Eskom Clamping ring; grinding segments; grinding M.I.S. Engineering
Pressure Die Casting roller yoke; grinding tyre; thrust plate Scaw Metals
Halberg Guss Thomas Foundry
Group 6 Transnet Brake valves ETS Foundry Crown Foundry
KEW Group 13 Eskom Loading arm 12 tons; gearbox 12 tons Mittal
ETS Scaw Metals
Group 7 Transnet Cast iron brake blocks Transwerk, Bloemfontein Thomas Foundry
CME Crown Foundry
Guestro
Ukuthela Group 14 Eskom HP inner; HP outer; IP inner; IP outer; LP Steloy
inner; casings and other items Thos Begbie
Meeting with DST Crown Foundry 5
Thomas Foundry IPT Pefco
6. Areas for Technology Assistance
Improving in-
R educ ing hous e Mould/ P attern/ R equire As s is tanc e R educ tion in
L ean & C lean R &D for improving c as ting metallurg ic al S kills Development E nerg y Improve fettling T ooling Ac c reditation/ with Des ig n man-hours
Manufac turing produc tivity s c rap expertis e improvement reduc tion s ophis tic ation improvements QMS P ac kag es per ton
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