06-10-10-presentation ifc for iindustry eng (1)

7/25/2019 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

.

-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

9

.

/

"

;

;

;

.

9 .

/ 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

99


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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

9

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

9"


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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

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9").E

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,/E

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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

9


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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

9

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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06-10-10-presentation ifc for iindustry eng (1)

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