2015 metalcasting industry roadmap presentation
TRANSCRIPT
Introduction to metalcasting
Metalcasting is the process of pouring molten metal into a mold containing a cavity of the desired shape; The most direct and cost effective route from design of a part to its production (CTIF).
(Movies)
Present in almost every sector of the economy
• Used in 90% of all manufactured durable goods and all manufacturing machinery
• Produce complex shapes with internal cavities and hollow sections
• Very large parts can be produced in one piece
• Can utilise materials that are difficult or uneconomical to process by other means
Casting productsTypes of alloys
and availability in the Philippines
ApplicationsCasting Processes and Availability in
the PhilippinesCast Irons
Grey cast iron
White cast irons
Ductile irons
Compacted graphite irons
Malleable irons
Engine blocks
Automotive under-chassis components
Pipe fitting, municipal castings
Machine tools frame and bodies
Pumps, valves, motor bodies
Milling rolls
Sand casting
Lost foam casting
Automated molding system
Casting productsTypes of alloys
and availability in the Philippines
ApplicationsCasting Processes and Availability in
the PhilippinesSteels
Low alloy steels
High alloy steels
Industrial pumps for corrosive applications
High impact and wear applications for mining, cement
Food grade applications in food and pharmaceuticals
Components for defence such as guns and rifles
Medical and dental instruments and implants
Aerospace castings
Sand casting
Investment casting
Casting productsTypes of alloys
and availability in the Philippines
ApplicationsCasting Processes and Availability in
the PhilippinesAluminum Automotive components such as
wheels and engine components
Motorcycle components
Electronic components
Aerospace components
*majority from Japanese PEZA-located companies
HPDC
Permanent mold casting
Lost foam casting
Casting productsTypes of alloys
and availability in the Philippines
ApplicationsCasting Processes and Availability in
the PhilippinesCopper Water faucets, water meters, valves
and fittings
Automotive components
Bearings
Decorative and art works
Sand casting
Investment casting
Casting productsTypes of alloys
and availability in the Philippines
ApplicationsCasting Processes and Availability in
the PhilippinesMagnesium
Nickel alloys
Titanium alloys
Cobalt alloys
Electronics
Aerospace castings
Corrosion and high temperature applications
Special industrial and military
Biomedical applications
HPDC
Investment casting
The Philippine metal casting industry
• Approximately 80 non-PEZA located foundries and 30 PEZA-located foundries, die-casters
• Philippine Metalcasting Association, Inc. (PMAI) with 52 member foundries
• DOST-MIRDC, R&D and technical support to metalcasting industry
• UP, Mapua and MSU-IIT, offering allied foundry courses, BS Metallurgical Engg, BS Materials Engg
The Philippine metal casting industry
• Dwindling production
• ~898,644 tons in 1996
• ~40,000 tons in 2012
• Thailand has 304,100 tons in 2009
• Closing foundries
• 195 foundries in 2003
• less than 100 foundries in 2015
Characteristics of the metal casting industry
• Multi-disciplinary
• mechanical engineering, CAD, Patternmaking, machining, metallurgical engineering, materials engineering
• Wide range of plant configuration
• patterns, molds, melting, alloys, sizes, quantity
• plants are designed for a certain alloy, moulding type, size range and quantity
Characteristics of the metal casting industry
• Dynamic
• products and production processes changes with technology
• products are being phased out while new applications are constantly being introduced
• B2B
• variations (and high competition) in quality, specifications and requirements, cost and lead-time and delivery requirements
• products changes with type of businesses
• SMEs
• limitations on technology, finance, business environment (support)
Crafting of the roadmap
• Based on the horizontal concerns and measures for the manufacturing industry roadmap
Major Area Major Issues and Constraints
Infrastructure and logistics
High cost and unpredictability of powerHigh cost of domestic shipping
Governance and regulation
Smuggling, corruption, bureaucracy/red tapeLack of streamlining/automation of interrelated proceduresSME development Access to finance, technology upgrade, inability to comply with product standards and regulations
Human resource development
Lack of skilled workers, training
Innovation Industry-academe linkages, new product development, R&D facilities
Strategies for the metal casting industry competitiveness roadmap
Strategies Rationale and Functions
Establishment of the foundry institute
DOST-MIRDCUP Diliman
• Foundries are SMEs yet the industry is B2B, dynamic, multi-disciplinary, with wide variations in processes
• Market and technology trends, strategic planning and transition
• Unified technology support• New product development, technology
transfer, training and education, innovation, r&d facilities, testing facilities, consultancy, information services
• Development and localisation of sources of raw materials
Foundry institute overview
Possible Programs Development Operation and Sustainability
R & D (strategic, collaborative, contracted)
Based on professional market research findings on the amount and nature of demand; Address the day-to-day needs of the industry as well as strategic goals;
Paid services, so demand are objectively verified; Managed according to business principles and good management practices in service organization; Private sector service design and delivery; Public sector subsidies; Advisory board with representation from PMAI, DTI, SMEP and (one or two industry groups)
Technical consultancy (free, contracted) Education (Short courses, bespoke) Information services (library, publications, market and technology watch)
Technology transfer
Infrastructure (Numerical simulation, rapid tooling and product development, testing and characterization, melting and casting systems)
Strategies for the metal casting industry competitiveness roadmap
Strategies Rationale and FunctionsEstablishment of a market development program
Foundry Institute
• The industry is B2B and dynamic
• Products and market trends• Opportunities for new products and/or new
markets• Flow of information between market (prospective
clients) and foundries• Supported by the foundry institute, spearhead
market development by coordinating the required technical assistance, technology, manpower and organisation upgrading, certification and access to finance
Strategies for the metal casting industry competitiveness roadmap
Strategies Rationale and FunctionsImprovement of the foundry education system
DOST-MIRDCUP DilimanMSU-IITMapuaTESDA
• Support the technical and skills needs of the Foundry Institute and the industry
• Technical, vocational, foundry skills education and training
• Higher education engineering education enhanced for metal casting
• Advanced laboratories and graduate programs to support product and production processes technology upgrading
The Philippine IPP priority industries and activities
• Manufacturing
• automotive, ship building, aerospace, tool and die,
• Services
• Agribusiness and fishery
• Activities
• Economic and low cost housing, energy, renewable energy, public infrastructure
• Mining
Goals, KPI’s and Targets
Goals and Key Performance Indicators
Targets
Short-term (5 years)
Medium-term(10 years)
Long-term(15 years)
Increased casting production 65,000 tons 105,000 tons 172,000 tons
Increased import substitution 10,000 tons 16,000 tons 26,000 tons
Increased exports 10,000 tons 16,000 tons 26,000 tons
Concepts on SME competitiveness (OECD)
• Competitiveness is embodied in the characteristics of the firm namely:
• The current efficiency and effectiveness of the use of resources
• The willingness and the ability to relate profitability to growth of capacity
• Ability to innovate to improve the technology and organisation and thus improve efficiency and effectiveness
• (Metcalf, Ramlogan and Uyarra, 2003)