Foundries have partnered with government departments, research and development organisations and universities to develop foundry skills through the Gauteng Foundry Training Centre (GFTC), says National Foundry Technology Network (NFTN) project manager Adrie El Mohamadi.

The newly built GFTC is located at the Ekurhuleni East College, in KwaThema, and will train 20 school leavers and new entrants to the foundry industry each year from January 2014.

The centre will train melters, moulders and pattern makers and the development of foundry industry skills follows the tried-and-tested apprenticeship method, underpinned by a solid theoretical understanding, ensuring the employability of students in industry, she notes.

“The centre offers metal, wood and resin pattern making, bentonite and chemically bonded sand moulding and ferrous and non-ferrous melting training. The centre also has a fully equipped sample-testing laboratory for sand and metal testing to ensure that it meets international and local quality standards,” says GFTC manager Robert Bezuidenhout.

The NFTN, the South African Institute of Foundrymen (SAIF), the Manufacturing, Engineering and Related Services Sector Education and Training Authority (Merseta), the University of Johannesburg (UJ) Metal Casting Technology Station and the Ekurhuleni East College, as well as more than 20 companies in the industry, are providing the framework that will inform training courses to keep them current and relevant to the local and global foundry industry.

A demonstration was held at the centre for industry representatives last month. Ten third-year interns from ArcellorMittal South Africa’s (AMSA’s) Vanderbijl Park works participated in the demonstration to show what next year’s students will learn. These interns form part of a pilot group managed under the same constituency.

“The AMSA students performed very well in the demonstration. Our training also includes important topics relevant to industry, such as our use of recycled metals, which requires a good understanding of metals and good sample-testing practices.

“All our equipment was designed according to the latest industrial specifications and was built in South Africa using local materials. Students are taught how the machines that they operate function and how to use them effectively and efficiently,” says Bezuidenhout.

There were an estimated 184 foundries listed in the casting directory in 2011 – a 13% decline from the previous estimate in 2007, highlights El Mohamadi.

“The competitiveness of the foundry industry has a knock-on effect on the competitiveness of the whole manufacturing sector because it produces metal components related to the automotive manufacturing, general engineering, transportation and mining industries,” she says.

The specific challenges of the industry are the lack of skills and infrastructure gaps. An ageing foundry workforce and poor access to capital for technology upgrades have also reduced the competitiveness of the industry.

The applicability of the skills developed by the centre is ensured by constant engagement with and the involvement of companies operating in the industry, the NFTN and SAIF, Merseta and the UJ Metal Casting Technology Station.

“SAIF training modules focused on workers in the industry will be supplemented by the GFTC to increase the scope and impact of foundry training in Gauteng, making better-qualified artisans available to the industry. The SAIF and the NFTN are developing a skills programme and intend to apply to Merseta for accreditation, which will enable learners to obtain recognised qualifications to improve their employment prospects,” concludes SAIF CEO John Davies.