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Exit Survey
 
 
SECTION A: NATIONAL LEVEL INFORMATION
 
 
NAME OF NATIONAL FOUNDRY ORGANISATION
NAME
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
NAME OF RESPONDENT FROM NATIONAL ORGANISATION
NAME
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
 
COUNTRY
 
BRAZIL
 
RUSSIA
 
INDIA
 
CHINA
 
SOUTH AFRICA
 
 
TOTAL NUMBER OF IRON FOUNDRIES IN YOUR COUNTRY
NUMBER
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
OVERALL IRON PRODUCTION (VOLUME IN TONS)
TONS
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
OVERALL IRON PRODUCTION (VOLUME IN TONS) OF THE 3 LARGEST IRON FOUNDRIES IN THE COUNTRY
TONS
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
TOTAL NUMBER OF EMPLOYEES IN IRON FOUNDRIES
DIRECT INDIRECT
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
TOP 3 QUALITY CERTIFICATION SYSTEMS IN IRON FOUNDRY SECTOR
1 2 3
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
MAIN 2 SOURCES OF ENERGY TO IRON FOUNDRIES IN YOUR COUNTRY
1 2
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
WHAT ARE THE TOP 3 CONSTRAINTS OF ENERGY SUPPLY IN YOUR COUNTRY?
1 2 3
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
ARE THE MAIN PROVIDERS OF TRAINING TO THE INDUSTRY PUBLIC SECTOR OR PRIVATE SECTOR?
PUBLIC SECTOR PRIVATE SECTOR
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
WHAT IS THE NUMBER OF UNIVERSITIES OFFERING RELEVANT FOUNDRY DEGREES?
NUMBER
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
WHAT ARE THE TOP 4 CONSTRAINTS IN TERMS OF HUMAN RESOURCES? SUMMARISE.
1 2 3 4
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
 
ENVIRONMENTAL LAWS AND REGULATIONS
 
 
WHAT IS THE CLASSIFICATION OF FOUNDRY SPENT SAND?
CLASSIFICATION
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
ARE AIR EMISSIONS BY FOUNDRIES CONTROLLED?
YES NO
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
WHAT IS THE CLASSIFICATION OF SCRAP METAL?
CLASSIFICATION
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
ARE THE (SCRAP) LAWS RIGOUROUSLY ENFORCED?
YES NO
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
ARE ENVIRONMENTAL LAWS RIGOROUSLYENFORCED?
YES NO
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
WHAT ARE THE TOP 4 CONSTRAINTS IN TERMS OF ENVIRONMENTAL REGULATION FOR IRON FOUNDRIES? SUMMARISE
CONSTRAINT 1 CONSTRAINT 2 CONSTRAINT 3 CONSTRAINT 4
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
ARE THERE NATIONAL POLICIES TO SUPPORT THE MANUFACTURING INDUSTRY?
YES NO
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
IF THERE NATIONAL POLICIES TO SUPPORT THE MANUFACTURING INDUSTRY, NAME THE POLICIES
POLICY 1 POLICY 2 POLICY 3
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
ARE THERE OTHER NATIONAL LEVEL INSTITUTIONS TO SUPPORT THE MANUFACTURING INDUSTRY? NAME THEM:
1 2 3 4
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
ARE ANY FAVOURABLE RATES AND CUSTOM DUTIES AND TAXES FOR IMPORT AND EXPORT FOR THE FOUNDRY SECTOR
YES NO
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
 
COLLABORATION
 
 
DO THE LEADING FOUNDRIES COLLABORATE?
YES NO
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
IF THE LEADING FOUNDRIES COLLABORATE, HOW
1 2 3
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
DO LEADING FOUNDRIES COLLABORATE WITH UNIVERSITIES AND R&D INSTITUTIONS?
YES NO
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
 
CORPORATE STRUCTURE
 
 
WHAT IS THE TYPICAL CORPORATE STRUCTURE OF LEADING FOUNDRIES?
Listed companies with multiple shareholders Directly government owned Owned by a government parastatal Privately owned
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
ARE THE LEADING FOUNDRIES VERTICALLY INTEGRATED?
YES NO PARTIALLY
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
 
PRODUCTION
 
 
OVERALL IRON PRODUCTION (VOLUME IN TONS) OF THE 3 LARGEST IRON FOUNDRIES IN THE COUNTRY
TONS (MILLIONS)
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
 
SECTION B: NATIONAL IRON FOUNDRY SURVEY RESULTS
 
 
Survey sample average breakdown between jobbing and production foundries
JOBBING PRODUCTION
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample breakdown of principal materials: (Please indicate percentage)
1. Grey/flake cast iron 2. Ductile spheroidal graphite 3. Ductile pipe iron 4. Other (specify) Steel
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average tonnage and sales value
Total annual tonnage shipped by foundry What is the total annual sale value of shipped product?
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average breakdown of Market sectors served and percentage
1. Automotive 2. Manufacturing 3. Infrastructure 4. Construction 5. Mining 6. Railways 7. Agriculture 8. Other (specify)
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average market (please indicate percentage distribution)
DOMESTIC EXPORT
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample annual cost of materials in US Dollars (use currency exchange rate at 31 October)
ALLOYS (TONS P/A) ALLOYS (COST P/A) SCRAP (TONS P/A) SCRAP (COST PA) SAND (TONS P/A) SAND (COST P/A) RESINS (KG P/A) RESINS (COST P/A)
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average availability of materials
ALLOY SCRAP SAND RESINS
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average constraints in the supply of ALLOYS?
ALLOY QUALITY ALLOY QUANTITY ALLOY COST ALLOY DELIVERY
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average constraints in the supply of SCRAP
SCRAP QUALITY SCRAP QUANTITY SCRAP COST SCRAP DELIVERY
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average constraints in the supply of SAND
SAND QUALITY SAND QUANTITY SAND COST SAND DELIVER
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average constraints in the supply of RESINS
RESIN QUALITY RESIN QUANTITY RESIN COST RESIN DELIVERY
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
What type of energy is used in your foundry? Indicate percentage of sample size.
1. Municipal electricity 2. National grid electricity 3. Natural gas 4. Coke/coal 5. Paraffin 6. fuel oil/diesel own generation DG set / windmill 7. Other (specify)
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average, lowest and highest energy cost per annum in US Dollars?
AVERAGE LOWEST HIGHEST
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Total average energy consumption and energy cost per ton of iron cast
Giga Joules per ton Cost of energy per ton $
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Percentage of foundries who receive government energy incentives?
1. Discounted price 2. Preferential supply 3. Other (specify)
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Percentage of foundries who receive other support from government?
1. Rates and/or tax discounts or rebates 2. Discounted raw materials and/or inputs 3. Direct financial grant or subsidy 4. Other (please specify)
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average age of primary furnace? (# years)
AGE OF FURNACE (YEARS)
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average power outages: How many hours per annum do you suffer power outages?
HOURS PER ANNUM OF POWER OUTAGES
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average hours a day that the foundry operates?
8 hours 12 hours 18 hours 24 hours
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
22. Survey sample average hours a day that the furnace operates?
8 hours 12 hours 18 hours 24 hours
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average number of days per annum that the foundry operates?
NUMBER OF DAYS FOUNDRY OPERATES P/A
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample average total man hours per annum worked by foundry? (number of foundry staff x hours worked per person per day x days worked per person per annum)
TOTAL MAN HOURS P/A
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey sample percentage of rejects
Survey sample percentage of rejects per day
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey average personnel numbers and costs: Please list the average number and estimated total cost per annum of the following categories of personnel
Average Total number of personnel Average Total cost per annum ($)
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey average SENIOR MANAGEMENT personnel training and qualifications: Please indicate the percentage of personnel (across whole survey sample) with the qualifications listed in the table
Tertiary academic degree % Tertiary Technical certificate % Apprenticeship % On the job training % Secondary school %
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Average total personnel costs per annum
Average total number of personnel Average total personnel cost per annum
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey average % of ancillary services provided by foundries?
1. Pattern making 2. Machining 3. Painting 4. Heat treatment 5. Other (specify)
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Where do foundries obtain capital for new equipment (survey average percentage)?
1. Bank loans 2. Subsidies from government 3. Own cash
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey average MIDDLE MANAGEMENT personnel training and qualifications: Please indicate the percentage of personnel (across whole survey sample) with the qualifications listed in the table
Tertiary academic degree % Tertiary Technical certificate % Apprenticeship % On the job training % Secondary school %
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
Survey average MOULDERS personnel training and qualifications: Please indicate the percentage of personnel (across whole survey sample) with the qualifications listed in the table
Tertiary academic degree % Tertiary Technical certificate % Apprenticeship % On the job training % Secondary school %
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA
 
 
28. Survey average FETTLERS personnel training and qualifications: Please indicate the percentage of personnel (across whole survey sample) with the qualifications listed in the table
Tertiary academic degree % Tertiary Technical certificate % Apprenticeship % On the job training % Secondary school %
BRAZIL
RUSSIA
INDIA
CHINA
SOUTH AFRICA