06-10-10-Presentation Ifc for Iindustry Eng (1)
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Transcript of 06-10-10-Presentation Ifc for Iindustry Eng (1)
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Resource efficiency benchmarking ofthe Russia Ferrous Foundry Industry:
Key findings of the studyImplemented under IFC Russia Cleaner Production Program
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GOAL: to identify the ferrous foundry sector resource efficiency potential anddevelop practical tools for foundries to implement it
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!enchmarking study time line
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#takeholder consultations at e$ery important stage: %ethodology
&uestionnaire for data collection
#elf diagnostic guide
%atri' of casting types
Ad$isory board included o$er ( representati$es fromindustry) R*+) officials and policy makers,
Consultation process -ritten comments on all key documents %eetings of Ad$isory board -orkshops in smaller teams
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-hat made our study successful :#takeholder consultations process
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/ 0ey performance indicators 10PIs2
LA!O3R
0PI /
O45RALLPRO+3C6IO75FFICI57C8
0PI
PROC5##85IL+
0PI 9
-A65R 3#5
0PI
#A7+ 3#5
0PI ;
57RG8 3#5
0PI .
CAPACI6836ILI
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Ra?material
%elting shopMelting
HoldingTreatment
%olding shopMold formingCore making
Core setting
Casting shopPouringCooling
Shake outSeparation
Finishing shopShot blasting
Grindingeburring
Thermal treatment!nspection"testing
PackagingLabeling
#torage#hipping
#and recyclingTransport# $ooling
%etal recyclingSeparation#
transport
%etal yard
Storage#charging
#and plantStorage#
preparation
9 . / "
9 / "
9 /
9 / " /
"
/"
/ "buy
#ell
%isersand
runnersScrap
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#elected 0PIs
Process 8ieldO$erall production efficiency
Capacity utili@ation
5nergy
Fresh #and
-ater
Labor
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/
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;
;
;
.
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/ 0PIs methodology tailored to foundry process
#elected 0PIs and methodology tailored tofoundry processes
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" category matri' de$eloped to co$er di$ersityof foundry production
Grey Iron Product Categories
automatic mouldingGA!B automoti$e engine blocks
and cylinder headsGAAO automoti$e otherGAAG agricultureGA%I mining
mechani@ed moulding
G%!B medium si@e engine blocksand heads 1energy generation2G%AG agricultureG%%I miningG%G5 general engineering
manual 1hand2 mouldingGB!B large si@e engine blocks
and heads 1energy generation2GB%I miningGBG5 general engineering
+uctile Iron Product Categories #teel Product Categories
automatic moulding+AA3 automoti$e other+AG5 general engineering
mechani@ed moulding
+%A3 automoti$e+%G5 general engineering
manual 1hand2 moulding+B57 energy generation
components+BCO compressor components+BG5 general engineering
automatic moulding#ARC rail?ay components 1c2#A%% mining components 1m2#AAC commercial $ehicles 1c2#AGC general engineering 1c2
mechani@ed moulding
#%RC rail?ay components 1c2#%%% mining components 1m2#%PC pumps * $al$es 1c2#%P# pumps * $al$es 1s2#%GC general engineering 1c2#%AC commercial $ehicles 1c2
manual 1hand2 moulding#B%% mining components 1m2
#BPC pumps * $al$es 1c2#B5A energy components 1a2#BGC general engineering 1c2
c: carbon steel)s: stainless steel)m: manganeseDa: high alloy steel
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9;foundries1first long listD ;E of all legally registered ferrous foundries in
Russia2
;; sets ofindependent data for foundries
#tudy based on real data from enterprises
Coverage :
Period : 3years (2007-2009)
Total # of data sets: 150
Categories covered: 27 out of 32 (8!)
"dustry: 478 kt ($%! of &ar'et)
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058 FI7+I7G# OF 6B5#63+8
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Russian foundry 5uropean foundry HJKHMNJ
Russia foundries significantly lag behind 5uropean
ussia ferrous foudry us er toe of good castig:
*ergy: 3 ti&es &ore
+ad: 3,6 ti&es &ore ,ater: 161 ti&es &ore
a.or : 3,6 ti&es &ore &a-/ours
9(
4.5&l t
C2e
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Costs:
*1 ussia ussia at *1
efficiecy level
"E
Inefficiencies eliminate Russian foundries competiti$ead$antage in lo? prices
Prices for &aor
resources i ussia are
less t/a i t/e *1:
*ergy: &'( less
a.or: )*( less
ver/eads: +,( less
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.times
verage defect rate i ussia
is 4ti&es /ig/er t/a i *1
*ffect e4ort: ussia e4orts
less t/a ,(of castig
o5 6uality t/reat for
iteral &ar'ets as custo&ers
re6uire certai 6uality (egauto&otive roducers)
Bigh le$els of defect rate
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53 Russia
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E
Cost structure ide4 for ferrous foudry (&aterials la.or eergy e6ui&et &aiteace over/eads 5ater ad sad)
Bo? much can Russia ferrous foundry industry gain $iaresource efficiency>
"," bln3#+
,9" bln3#+
" bln3#+
E
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."ELo? cost andmanagement
practices Capitalin$estment
O$er ;(E of the potential can be implemented $ia lo?cost measures and management practices
"," bln3#+
Costs
9.
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Capitalin$estment
Lo? cost andmanagement
practices
0PIs and resource efficiency potential:
9;
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%aterials 1metal2
5nergy
Labor
5=uipment related
O$erheads
.)E
.")"E
).E
.).E
)/E
"," bln3#+
9)E
/)9E
9).E
9").E
.;)E
",9E
,/E
9E
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!enchmarking of 0PIs is a tool to priorities inter$entionsto achie$e ma'imum impact
%ussia average level -evel of best practices
Cost structure
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9/
7e't steps:
Tool'it: +elf diagostic guide
Co&ediu& of P"s ;est
ractice guide ;ec/&ar'ig
study reort
Pilot rogra& 5it/ -7
co&aies 5it/ foudries
esource efficiecy fiace
directly ad via
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Information a$ailable in public domain
http:QQ???,ifc,orgQifce'tQeca,nsfQ
ContentQRussiaFoundryRussian
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http:QQ???,ifc,orgQrcpp
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IFC contacts
IFC Russia Cleaner Production 1IFC RCPP2
8ana Gorbatenko) Program manager 8GorbatenkoSifc,org
#tudy team IFC RCPP:
0ristina 6urilo$a) 6ask leader 06urilo$aSifc,org
!oris 7ekraso$) 6echnical e'pert !7ekraso$Sifc,org
%aria #igutina) PR and stakeholders %#igutinaSifc,org
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