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AT L A N T I S F O U N D R I E S

On course to become the best foundry Group in the world


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GAME in the

As part of the Neue Halberg-Guss Group of Foundries, Atlantis Foundries has confirmed its status as a world-class producer of cast automotive engine blocks, producing the best quality products for any industry Writer: Matthew Staff | Project Manager: Kane Weller

or the best part of 40 years, globally renowned foundry, Atlantis Foundries has overseen numerous changes across its ownership and the wider industry, but has simultaneously remained consistent across the world-class standards it has become praised for. Supplying predominantly heavyduty engine blocks for some of the world’s leading truck OEMs - including Daimler, MAN, Cummins and Perkins - the business boasts one of the largest foundry networks for engine parts the world over; and with the latest technology, the most skilled personnel, and the most refined processes in place, the Company is perfectly geared up for whatever challenges the future holds. “Our history dates back to 1979, when Atlantis Diesel Engines (ADE) was established by the South African

Government (IDC) and was licensed to produce Mercedes Benz and Perkins diesel engines for the South African commercial and agricultural markets, and for military vehicles such as the Ratel IFV, Buffel, Casspir and SAMIL Trucks,” opens Atlantis’ Commercial Director, Sally Redshaw. In the intervening years, a multitude of takeovers, acquisitions and restructurings have taken place, leading to the current day’s tone which was set in June, 2015. Redshaw continues: “As of 30

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CONTACT: Oliver Schmitz mail: oliver.schmitz@pour-tech.com web: pour-tech.com tel.: +49 172 52 44 532

WE DO AUTOMATIC POURING


THE AUTHORITY IN AUTOMATIC POURING

pour-tech AB’s staff have more then 25 years experience from more than 500 installations of automatic pouring solutions world wide. At pour-tech AB, we focus on analyzing and understanding our customers‘ needs, drawing from decades of experience from foundry and other industrial areas. This enables us to provide the best and most cost effective solution for each application, giving our clients a real competitive edge. We have succeded in building a strong relationship with our foundry partners, always exchanging new ideas, concepts and constantly improving our technologies and ourselves. This allows our users to stay well ahead of their competition. Keeping up with the latest technology advances, new generation pourTECH™ systems are currently being installed around the world, designed with the latest sensor technology and system features. pourTECH™ has become the preferred pouring system for leading foundries around the world. The pourTECH™ system is designed in Sweden and built in Germany! pourTECH™ system with 3D Line Laser for automatic pouring control of all mold line types and brands The system can be installed on new pouring furnaces and existing furnaces can be upgraded with the latest technology. TWINpour™ with two indepent laser control systems serving high speed double index mold lines

inoTECH™ for precise and dynamic instream inoculation improves the quality of castings

pourTECH™ unheated pouring system with laser control for ductile and mixed iron production

Tailor made solutions for prozess automation with full control of the pouring system and feedback for every single mold


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June, 2015, the corporate structure of Atlantis Foundries (Pty) Ltd changed to 100 percent ownership of Neue Halberg-Guss GmbH (under the ownership of HTP Investments). Halberg-Guss GmbH was founded in 1756, and is now one of the European market leaders in the development and production of cylinder blocks for cars and trucks as well as cylinder heads for trucks and other automotive components; supplying both leading car manufacturers such as Volkswagen, Daimler, Opel, and leading truck manufactures such as Daimler, Deutz, Scania and Iveco.�

Sally Redshaw, Commercial Director

This acquisition from Daimler epitomises the household names that Atlantis has been affiliated with over the years, intensified further by the foothold that the Company enjoys around the world; currently exporting 99.8 percent of its products away from its home in South Africa, mainly to the US, Germany and China. And as for the products themselves, the journey of diversification, enhancement and expansion has been equally significant: boasting a melting

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As of 30 June, 2015, the corporate structure of Atlantis Foundries (Pty) Ltd changed to 100 percent ownership of Neue Halberg-Guss GmbH (under the ownership of HTP Investments)

capacity of 125,000 tonnes per annum; using cold box technology to facilitate the full spectrum of shapes and sizes across its engine blocks; operating fully automated core dipping facilities to connect to its tunnel indexing core drying oven; using green sand moulding techniques to be able to cast as many as 188,000 moulds a year; and catering for the full range of automotive component grades including GG20, GG25, GG26 Cr, GG26 CuCr, and GG30. In addition, Atlantis Foundries also has the basic infrastructure to manufacture castings in Compact Graphite Iron (CGI) and Spheroidal Graphite Iron (SGI). “After casting, Atlantis Foundries also offers a complete finishing process, enabling us to improve the product by removing excess material (fettling), powder coating, reference machining (spotting), and full or


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hen companies invest in new equipment, the goal is to add profit to the bottom line and foundries are no exception. The pourTECH™ System by pour-tech AB (www.pour-tech.com) offer improved profitability and energy savings – making the system profitable and “Green” as well. Atlantis Foundries is one of the foundries taking advantage of pourTECH’s benefits to become a leading supplier to South Africa’s automotive industry. Atlantis is enjoying both the productivity and quality increases pourTECH™ generates, as well as the energy savings. pourTECH™ is a pouring control system, using laser and stopper rod technology to control the level in the pour cup during the pour. Using real-time feedback from its laser system, pourTECH™ finds the pour cup and continuously controls the opening of the stopper rod to optimise the metal flow through the nozzle. The system offers control at very high speed, and is able to maintain the cup level during the entire pour. This keeps slag and other impurities floating, preventing them to enter the mold. By controlling the pour, short-pours and over-pours can be eliminated, increasing the casting quality – generating higher profits. By reducing the number of scrap castings and reducing the over-pours, less energy will be used by the melt shop, since this metal does not need to be melted twice –adding more to the bottom line and reducing the carbon footprint of the foundry. pourTECH™ is based on the LaserPour System, developed in the mid 1980’s by Selective Electronic Co, whose engineering staff later created pour-tech AB. Since the first system was delivered in 1985, more than

500 pouring systems have been delivered to foundries around the globe. Laser technology has proven to be extremely reliable, proven by a very large number of repeat customers, and pourTECH™ has established itself as the preferred pouring system by leading foundries around the world. pour-tech AB provides several pouring solutions, including upgrade packages for existing pouring units and complete systems ranging from unheated ladles or complete pouring furnaces. External equipment, such as in-stream inoculation units (featuring dynamic inoculation), inoTECH™ and pyrometers can be integrated in the system, allowing the user to save performance data for each pour to an internal (or external) database. inoTECH™ is a unique system developed by pour-tech AB to detect inoculant as it is injected into the iron stream. Using an external light source, it detects the inoculant cloud as it approaches the iron stream and calculates how much inoculant hits the stream (% hit rate). pour-tech AB is the head of the pourTECH group, with partners in America and Asia. In Africa, the Company works with Lauds Foundry Equipment, Johannesburg, South Africa (www.laudsfe.com) who provides local support and services.

T +49 172 52 44 532 E oliver.schmitz@pour-tech.com www.pour-tech.com


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ORTHOS PROJECTS LTD

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rthos Projects Ltd provides automated solutions for bulk solids, raw materials handling and processing. Offering design and manufacture to the highest specification with installation, commissioning and after sales support since 1977, the Company has become an established business with an in-depth knowledge of foundry sand preparation. Supplying a broad customer base of long standing clients like Atlantis Foundries, we are proud of the fact that much new business results from referrals and repeat work from satisfied customers. In 2009 Orthos Projects acquired the intellectual property rights and designs for E&F Dockside Mobile Loaders which complement our existing activities.

A wealth of experience in casting and machining engine blocks

partial (pre) machining” Redshaw explains. “Atlantis Foundries has a wealth of experience in casting and machining engine blocks for passenger cars, medium-duty and heavyduty commercial vehicles, marine applications, and off-road applications. “Essentially, we are a global Company and do not restrict our customer base geographically. As we are centrally located to Europe, Asia and the Americas, we are able to efficiently export these products to any market in the world.”

Continuous improvement

This all-encompassing, market-leading portfolio is inevitably a far cry from the business which opened its doors in 1979, but only in terms of product development, not necessarily in terms of vision or ethos. Redshaw takes us back to the beginning following the first of many acquisitions: “In 1983, the Foundry was built on a Greenfield site by

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the Ferroform Foundry Group. The Ferroform Foundry Group was later sold to the Murray and Roberts Foundries Group and in 1985 Atlantis Foundries was sold to Atlantis Diesel Engines (ADE) where they not only cast and machined engines and engine components, but also had an assembly line.” She continues: “In 1999, ADE was liquidated, and Daimler AG (then called DaimlerChrysler), through its subsidiary, Mercedes-Benz South Africa (Pty) Ltd, purchased Atlantis Foundries and the Block Line 1 Machining facility, and incorporated Atlantis Foundries into the Daimler Trucks Powertrain business unit.” The following four years saw purchases of the Perkins Machining Line and V-Block Machining Line from the IDC, the Atlantis Foundries Business Park and Crankshaft Line from the same business, and also received approval for the Perkins Vista Capital Improvement Project which commenced in 2003.

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www.orthosprojects.com

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AMSO is one of the most important worldwide manufacturers of solid and resilient forklift, pneumatic construction and industrial tyres together with a wide range of rubber tracks for construction and leisure industry vehicles. The Solideal range displayed in the advertisement are all long life solid forklift tyres designed to meet the requirements of all forklifts in different applications that may be found across industry. Developed around the LOCS system (Lowest Operating Cost Solution), this ensures that users of these solid tyres do achieve the most effective cost per operating hour in their different operations.

www.speddick.co.za


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Orthos Projects Ltd. Fernie Road, Market Harborough LE16 7PH United Kingdom. www.orthosprojects.com T +44 (0)1858 462806 info@orthosprojects.com

Proud to have been associated with Atlantis Foundries for over 18 years.

With 40 years experience in the bulk materials handling industry, we work in partnership to design, build, install and commission the most efficient solutions.

BULK MATERIALS PROCESSING PLANT & EQUIPMENT

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§ Solid Forklift Tyres – to suit all industrial operations… § Giving you “LOCS“.. Lowest Operating Cost Solution

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GRACE STAFFING

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race Staffing aims to provide a broad range of staffing solutions to a variety of clients requiring skilled and semi-skilled employees across a wide spectrum of industrial services. This in turn will increase employment quality in the labour market, whilst also assisting and building on job related opportunities for skilled and semi-skilled individuals within our local community. We also offer a full spectrum of HR solutions, e.g. Payroll, IR, training and absenteeism related issues, which can be outsourced to us, thereby reducing your administrative burden. T +21 577 1239 E +admin@gracestaffing.co.za

www.gracestaffing.co.za

A new generation of heavy-duty engine (HDEP) blocks

“In 2008, a project for the introduction of a new generation of heavy-duty engine (HDEP) blocks was completed and commissioned for Daimler AG/Mercedes-Benz Trucks, and the ramp-up of production started; leading up to 30 June, 2015 when Neue Halberg-Guss GmbH purchased Atlantis Foundries (Pty) Ltd from Daimler/Mercedes-Benz South Africa,” Redshaw ends. This latest change of tact detracts nothing from the Company’s overall rise to prominence over the past 17 years especially, since the takeover by Daimler Group in 1999. Even prior to Neue Halberg-Guss GmbH’s purchase, Atlantis had achieved an increase, since the turn of the millennium, from 30,000 to 69,000 net tonnes a year to become one of the leading heavy-duty engine block foundries in the world, employing more than 1,000 people. “We are ISO 9001, TS16949 , and Lloyds Register certificated, demonstrating our high technical

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specifications and inherent quality management system that provides for continuous improvement, and emphasises effective prevention of and reduction of variation and waste. TS16949 is specific to the automotive industry supply chain,” Redshaw says. “Environmental compliance is also important to us,” she adds in attributing the reasons for Atlantis’ recent successes. “We are continuously looking towards more environmentally friendly methods and processes, recycling of materials and waste, energy efficiency and alternative energy sources. “To further support these initiatives, we are currently working towards implementation of ISO 14001 to ensure improved compliance and environmental awareness.”

Lean journey

Atlantis Foundries continuously strives to improve the efficiency and quality of its processes and

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BREAKTHRU TOOLING AND ENGINEERING SERVICES

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reakthru Tooling and Engineering Services operate from a well equipped and diverse manufacturing facility located in Cape Town, ideally situated and well serviced by road links, providing fast and efficient worldwide product distribution. Our mission is to give unconditional support to companies by providing manufactured parts for breakdowns or any maintenance purpose. This helps to build a sound relationship with our clients and assist with technical support and innovative ideas to improve production and durability of parts. The Company has built a solid reputation based on superior production quality, versatility and customer satisfaction. T +21 577 4090 E breakthrutes@live.co.za


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PERMANENT PLACEMENTS TEMPORARY PLACEMENTS Grace Staffing aims to provide a broad range of staffing solutions to a variety of clients requiring skilled and semi-skilled employees across a wide spectrum of industrial services.

Manufacturing of specialized tooling components:

Washers & Nuts, Collets, Locating Pins, Blades For Cutting Machines, Injection Moulds, Press Tools, Bushes, Hexagon Dowels

LABOUR HIRE / BROKING RESPONSE HANDLING PAYROLL ADMINISTRATION Please contact us on Tel: 021 577 1239 Fax: 021 577 1238 E-mail: admin@gracestaffing.co.za www.gracestaffing.co.za

BREAKTHRU TOOLING & ENGINEERING SERVICES Precision engineering of specialized parts to customers’ specifications

Automotive Parts:

Screw Plugs, Rocker Pins, Inserts and other various items.

Fabrication of:

Steel Pallets, Rocker Bins, Tables & other Engineering Structures.

Production Runs of:

Press Work for Various Sectors of Manufacturing & Engineering Parts.

email: breakthrutes@live.co.za telephone no. 021 5774090

Breaking the Barrier Thru Innovative Tooling and Engineering

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INNOVENT

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lternative funding methods such as renting the assets that you require is a viable option whether you’re cash rich or follow a conservative capex model. InnoVent Rental and Asset Management Solutions offers finance terms that are based on your preferred useful life of the asset, providing you with the latest and greatest equipment, with the flexibility to refresh when you choose to do so. For no upfront cash investment, fixed rates below prime and the sale and leaseback of existing assets, contact us today on +27 11 884 8274 to speak to a consultant.

www.innovent.co.za Striving for efficiency and quality across products and processes

products; demonstrated by the aforementioned attained certifications, and driven by the inception of its ‘lean transformation journey’ in 2008. Led by the implementation of the Daimler Truck Operating System (TOS), the Company’s commitment to lean manufacturing has filtered wholly to the products being exported, but importantly has also culminated in cost reduction, elimination of waste, enhanced problem solving capabilities, value stream mapping, process standardisation, and overall operational efficiency. “Our focus was also on layout optimisation and we moved towards the set-up of the concept of a ‘one piece flow’ with the installation of flow lines to optimise processes, improve efficiency and reduce inventory.” Further improvements have consisted of a more optimised and efficient HDEP moulding line, a more speedy and efficient production line, a reduction in manpower and

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Since the divesture from Mercedes-Benz SA/ Daimler AG, Atlantis Foundries has continued on its ‘lean journey’ and has since embarked on the implementation of 20 Keys

maintenance costs, and a decrease in material costs. Redshaw continues: “Since the divesture from Mercedes-Benz SA/ Daimler AG, Atlantis Foundries has continued on its ‘lean journey’ and has since embarked on the implementation of 20 Keys for continuous business improvement. At Atlantis Foundries, we believe that ’20 Keys’ is the roadmap to maintaining the status of a world-class foundry. “Our modern machining facility is the last step in this process, and we are equipped with two machining lines and flexible machining centres for the full, or partial (pre) machining of engine blocks, parts or components.” As a result of a more refined internal operation, the consequent product range has also been given license to expand across both engine block production and the production of complementary automotive components; and being located close to a large container harbour with


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Rental & Asset Management Solutions Transforming asset finance as you know it

www.innovent.co.za info@innovent.co.za 011 884 8274

Freeing up capital through subsidized asset finance is what we do best. Whether it is computers, vehicles, plant or machinery, our clients are assured of a personal, cost effective, lifecycle management solution.

Atlantis Foundries: ICT Hardware, proudly financed by InnoVent.

+27 (0) 12 657 2800 www.nortonabrasives.com

As a brand of Saint-Gobain, a world leader in the habitat and construction markets, Norton offers the widest portfolio of cutting, grinding, blending, finishing and polishing solutions for all markets, materials and applications with the most advanced and affordable technology.

At Norton, we care about delivering right choices that matter to you.

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international scope - as well as 5,000 square metres of warehousing space - the business is better geared up than ever before to leverage its own process efficiencies and proficiencies.

Proven track record

To complement the lean nature of the business, Atlantis has simultaneously looked to upgrade the equipment and machinery available to the Company in-line with this ethos. An increased reliance on automation as opposed to manual labour has subsequently made the works carried out, not just more efficient, but much safer for its employees as well. “Foundry technology is an old and established, complicated process, and technological advancements are not as fast developing as in other industries. We therefore focus on standardisation and layout optimisation, maintenance, and efficiencies to ensure we stay ahead of the industry curve,” Redshaw states. “Our focus is on quality, and we have a proven track record of producing outstanding quality products attributable to a world-class foundry. “Investment in our future is critical to survival. The foundry business is extremely competitive with only a handful of major foundries across the globe able to produce high quality heavy duty truck engine block castings for the OEMs. We have to keep up-todate with technological advancements and efficiency improvements to remain ahead of the game.” Such technological improvements include the use of water-based paint as a more cost-effective method of coating the core packages, while also noticing an improvement in the casting surface that has improved the overall quality of its products and in helping to reduce finishing costs. Redshaw adds: “We are also active in benchmarking; not only in our own industry, but other industries, and are keen to share the knowledge and

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International scope facilitated by 5,000 square metres of warehousing space

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Investment in our future is critical to survival... We have to keep upto-date with technological advancements and efficiency improvements to remain ahead of the game

experiences of our lean transformation to other companies just starting out on their journey. We frequently visit other companies and look for new ideas and, in return, host many benchmarking visits to our foundry to share our successes and knowledge.”

Effective leadership

Since the sale of Atlantis Foundries to Neue Halberg-Guss GmbH in June, 2016, the Company has continued to invest in the South African operation’s future in terms of technology, efficiency and environmental impact; and as a result, the Western Capebased foundry has undergone some significant changes in terms of technological advancements. As part of the Neue Halberg-Guss Group, Atlantis Foundries now has access to R&D facilities at its parent foundry based in Saarbruecken,


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Be more efficient across the board. N E X T G E N E R AT I O N R - S E R I E S A I R C O M P R E S S O R S N O W AVA I L A B L E I N 1 0 & 1 4 B A R A N D VA R I A B L E S P E E D

Interpon A1250 Powder coatings for engine blocks; • Strong combination of mechanical properties • Withstands high speed machining • Excellent performance and penetration into recessed areas • Good edge coverage and faster cure times Proud Partner to Atlantis Foundries

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Germany, which also enables its role as a development partner for the customer as well as enhancing its own commitment to innovation in South Africa. Subsequent forays into improved engineering support, rapid prototyping, in-house machining, photo digitisation, casting simulations, prototype tooling and design optimisation represent just a select few of these research and development tools; but are all underpinned by the Companies primary focus on health & safety. “The health & safety of our employees is always at the forefront of our minds. With the switch to waterbased coatings, our employees are no longer exposed to the inhalation of vapours given off from alcohol-based paint. In addition, the risk of fire is significantly reduced as the waterbased coatings are non-flammable, versus the high flammability of alcoholbased coatings previously used,”

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The health & safety of our employees is always at the forefront of our minds. With the switch to water-based coatings, our employees are no longer exposed to the inhalation of vapours given off from alcohol-based paint

Redshaw offers as an example. Such dedication to employee comfort and satisfaction makes Atlantis a clear employer of choice in the Atlantis area, with 85 percent of the workforce emanating from the local region, while also achieving very high retention rates as a result of its internal development programmes. “We firmly believe that we must respect, support and understand the culture of Atlantis Foundries. There is a lot of history within the Company and the workforce, alongside a lot of knowledge and experience. Our Employees have dedicated a large portion of their lifetime to contributing towards the success that Atlantis Foundries is today, and we appreciate that,” Redshaw emphasises. “We also support the learning needs and development paths of our employees and, as such, have seen production operators move to administrative positions within finance and human resources for example.


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Onsite Couriers Onsite Couriers Neil Hare Road, Atlantis Industria Atlantis, 7349, South Africa

T: +27 21 577 1134 F: +27 21 577 1132 E: onsitecc@iafrica.com

We provide export packaging International & national courier

“We provide education subsidies for those employees wanting to develop their knowledge and careers further, we provide NQF training for all levels of supervision to give them the tools they need for effective leadership, and we also support their families by offering bursaries to the children of our employees.”

People are our future. Without people, we cannot operate, and as such the community of Atlantis and the surrounding areas are important to us. Not only because the majority of our workforce live in these areas, but also because our employees of the future will most likely come from the same area.” Supporting initiatives such as HOPE @ ATLANTIS is a strong example of The opportunity for change this approach, with the initiation of Atlantis Foundries’ enrichment of local the Atlantis Industrial Initiative where artisans and consistent preference it has joined forces with other local of internal promotion fits within a Companies to support education in wider corporate social responsibility the community, and by providing free philosophy which is committed to of charge additional tuition in maths allocating a minimum of one percent of and science; helping young learners its net profits to local uplifting projects. gain entry into Stellenbosch University, With the belief that ‘charity begins at in addition to providing bursaries for home’, schools and charities in Atlantis children of Atlantis employees. and surrounding areas have benefitted Education is exactly what the hugely from the Company’s works Company is giving to the wider market outside of the foundry. as well, leading across the production Redshaw says: “Atlantis Foundries of cast iron blocks in excess of 400 strongly believes in investing in people. kilograms, while also casting some of

the largest, heavy and most complex castings in the business; all from a platform of continuous improvement and cost competitiveness in a highly specialised market. “The message is clear – Atlantis Foundries is back in the game,” Redshaw enthuses. “We are not just an automotive foundry. We now have the opportunity for change. We want to grow our customer base, and develop a diverse product portfolio for a sustainable future. “We hope to have put our name back out into the marketplace as not only a world-class producer of cast automotive engine blocks, but as a world-class foundry that can produce the best quality products for any industry.” She concludes: “As part of the Neue Halberg-Guss Group of Foundries, together we are stronger, and we believe that we have what it takes to become the best foundry Group in the world.”

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ATLANTIS FOUNDRIES (PTY) LTD William Gourlay Street Atlantis Industria Atlantis 7349 South Africa T: +27 21 573 7200 E: af-info@atlantisfoundries.com www.atlantisfoundries.com

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Atlantis Foundries Business Brochure - Africa Outlook Issue 45