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FOUNDRIES

B.R.I.C.S. Foundry Survey
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We are 5 months away from the BRICS Foundry Forum and planning is underway to ensure that foundries in the BRICS countries benefit from this event. This year there will be a special focus on the Iron Casting Foundries of each country. Your foundry has been selected to participate in an international survey of iron foundries in BRICS countries.

Some of the survey may require input from your finance and human resources departments. You can save the survey and continue later if you need to gather information.

The purpose of the survey is to collect information on iron foundries in South Africa, Brazil, China, India and Russia so that different aspects of foundry operations can be compared to improve the sector and make it more competitive.
Your survey responses will be strictly confidential and no individual firms will be named in the survey, and your information will be coded and remain confidential, the objective is to develop a national average picture between the five countries. If you have questions at any time about the survey or the procedures, you may contact Dominic Mitchell at +27 82 458 0760 or by email at [email protected]. You may also contact Paul Forsyth at +27832556468 or by email [email protected].

Thank you very much for your time and support. Please start with the survey now by clicking on the Continue button below.

 
 
 
1. Name:
   
 
 
 
2. Your position:
   
 
 
 
3. Country:
 
Brazil
 
Russia
 
India
 
China
 
South Africa
 
 
 
4. Province/State:
   
 
 
 
5. City:
   
 
 
 
6. Foundry name:
   
 
 
7. Type of foundry (please indicate percentage jobbing and/or production)
%
Jobbing
Production
 
 
8. Principal materials
Percentage
Grey/flake cast iron
Ductile spheroidal graphite
Ductile pipe iron
Other (specify)
 
 
 
8. Principal materials:
 
Grey/flake cast iron
 
Ductile spheroidal graphite
 
Ductile pipe iron
 
Other (specify)
 

 
 
9. Tonnage and sales value in US Dollars (R1 =$ 0.12)
Total annual tonnage shipped by foundry (Tons)
Total annual sale value of shipped product ($)
 
 
10. Market sectors served and percentage
Percentage of sales
Automotive
Manufacturing
Infrastructure
Construction
Mining
Railways
Agriculture
Other
 
 
11. Where are your markets (please indicate percentage distribution)
%
Domestic
Export
 
 
12. Annual cost of materials in US Dollars (R1 = $0.12)
Tons per annum Total cost per annum
Alloys
Scrap
Sand
Resins
 
 
13. Availability of materials
Readily available Intermediate available Scarce
Alloy
Scrap
Sand
Resins
 
 
14. What are the constraints in the supply of raw materials?
Quality Quantity Cost Delivery
Alloy
Scrap
Sand
Resins
 
 
 
15. What type of energy is used in your foundry?
 
Municipal electricity
 
National grid electricity
 
Natural gas
 
Coke/coal
 
Paraffin
 
Fuel oil/diesel
 
Other (specify)
 

 
 
 
16. What is your total energy cost per annum in US Dollars? (R1 = $0.12)
   
 
 
17. Total energy consumption per annum (either in Giga Joules, or kilowatt hours)
Giga Joules per annum
Kilowatt hours per annum
 
 
 
18. Does government provide you with any energy incentives?
 
Discounted price
 
Preferential supply
 
Other (specify)
 

 
 
19. Where do you obtain capital for new equipment?
Percentage of capital requirements
Bank loans
Subsidies from government
Own cash
 
 
 
20. Do you receive any other support from government?
 
Rates and/or tax discounts or rebates
 
Discounted raw materials and/or inputs
 
Direct financial grant or subsidy
 
Other (please specify)
 

 
 
 
21. How old is your primary furnace? (number of years)
   
 
 
 
22. Power outages: Approximately how many hours per annum do you suffer power outages?
   
 
 
 
23. How many hours a day does your primary furnace operate?
   
 
 
 
24. Number of hours per day that the foundry operates?
   
 
 
 
25. Number of days per annum that the foundry operates?
   
 
 
 
26. Total man hours per annum worked by foundry?
   
 
 
27. Number of castings
Number
Castings produced per day
Castings rejected per day
 
 
28. Personnel numbers and costs: Please list the number and estimated total cost per annum of the following categories of personnel (R1 = $0.12):
Total number of personnel Approximate cost per annum
Senior management
Middle management
Moulders
Fettlers
Other
 
 
29. Personnel training and qualifications: Please indicate the numbers of personnel per category, and the level of training they have
Tertiary academic degree Technical certificate Apprenticeship On the job training Secondary School
Senior management
Middle management
Moulders
Fettlers
 
 
Total staff complement
Number
Total number of employees in foundry section of business
Total number of employees in supporting roles
 
 
30. Total personnel costs per annum (R1 = $0.12)
Total number of personnel
Approximate personnel cost per annum
 
 
 
31. What ancillary services do you provide?
 
Pattern making
 
Machining
 
Painting
 
Heat treatment
 
Other (specify)
 

 
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