Know your competition ... 37th Census of World Casting Production--2002: as casting production across the globe grew last year, individual nations reported a mixed bag of expansions vs. contraction tales.According to according to prep. 1. As stated or indicated by; on the authority of: according to historians. 2. In keeping with: according to instructions. 3. the 26 nations responding to MODERN CASTING's 37th Annual Census census, periodic official count of the number of persons and their condition and of the resources of a country. In ancient times, among the Jews and Romans, such enumeration was mainly for taxation and conscription purposes. of World Casting Production (see table next page), 2002 offered a positive year for the global casting industry. The results from 2002 showed that total global tonnage TONNAGE, mar. law. The capacity of a ship or vessel. 2. The act of congress of March 2, 1799, s. 64, 1 Story's L. U. S. 630, directs that to ascertain the tonnage of any ship or vessel, the surveyor, &c. (represented by census participants) appeared to increase by 3%, with seven of the "Top Ten" showing increases a production in '02. Overall, 14 of the 26 responding nations' metalcasting industries experienced growth. Further, about two-thirds of the nations experienced higher casting shipments in '02 than they did six years ago in 1997. Participants Last reporting in 1998, Taiwan Taiwan (tī`wän`), Portuguese Formosa, officially Republic of China, island nation (2005 est. pop. 22,894,000), 13,885 sq mi (35,961 sq km), in the Pacific Ocean, separated from the mainland of S China by the 100-mi-wide (161-km) Taiwan re-entered with current data for '02. Failing to respond this year were Canada Canada (kăn`ədə), independent nation (2001 pop. 30,007,094), 3,851,787 sq mi (9,976,128 sq km), N North America. Canada occupies all of North America N of the United States (and E of Alaska) except for Greenland and the French islands of , Iran, Netherlands Netherlands (nĕth`ərləndz), Du. Nederland or Koninkrijk der Nederlanden, officially Kingdom of the Netherlands, constitutional monarchy (2005 est. pop. 16,407,000), 15,963 sq mi (41,344 sq km), NW Europe. , Portugal Portugal (pôr`chəgəl), officially Portuguese Republic, republic (2005 est. pop. 10,566,000), 35,553 sq mi (92,082 sq km), SW Europe, on the western side of the Iberian Peninsula and including the Madeira Islands and the Azores in the , Romania Romania (rōmān`ēə, –yə) or Rumania (r  –), republic (v), 91,699 sq mi (237,500 sq km), SE Europe. , Russia Russia, officially the Russian Federation, Rus. Rossiya, republic (2005 est. pop. 143,420,000), 6,591,100 sq mi (17,070,949 sq km). and South Africa South Africa, Afrikaans Suid-Afrika, officially Republic of South Africa, republic (2005 est. pop. 44,344,000), 471,442 sq mi (1,221,037 sq km), S Africa. . but they remain listed by
their last reporting data.
Because Russia (previously holding the number four spot in world production) did not respond, it was dropped from the "Top 10" list below. As a result, Korea Korea (kôrē`ə, kə–), Korean Hanguk or Choson, region and historic country (85,049 sq mi/220,277 sq km), E Asia. is appearing in the final spot in the list. The order of the Top 10 players remained the same as in '01. World Production Leaders Following is a summary of each nation's metric tonnage in '02 and the six-year shipment trend. 1. China--A 9% boost in shipments from '01 Lo '02 kept China as the world's leader in casting production. In '02, the nation recorded its fifth year. Casting shipments have increased 60% over the last six years. 2. U.S.--Shipments decreased slightly (70,000 tons (Transparent Optical Networking Services) A marketing term for providing dark fiber to a customer. The customer is responsible for generating the transmission signal and interpreting it at the other end. See dark fiber. ) for the third straight year in 02 to 11.8 million metric tons (13.02 short tons). Shipments remain down 9% from six years ago, when they weren't were·n't Contraction of were not. weren't were not near-peak levels. 3. Japan--Japan's casting industry a decline in casting shipments for the fourth time in five years with a 1.5% dropoff in '02 to 5.8 million tons. Japan's shipments are 19% lower than in '97. 4. Germany--Shipments dropped in '02 to 4.6 million tons (less than 1%) This figure is 13% higher than in '97. 5. India--India experienced a gain of 3.5% '02 to 3.3 million tons. Shipment totals are now 6% below 1997 totals. 6. France--After a 7% decline in '01, France's shipments grew 19% to 3.02 million tons in '02. This is nearly 24% higher than levels in '97. 7. Italy--Italy's shipments grew 2% in '02 to 2.4 million tons. Shipments remain 7% higher than six years ago. 8. Mexico--Mexico's shipments grew for the fifth consecutive year to 2.03 million tons (a 8% gain). Mexico's shipment totals are 65% higher than in '97. 9. Brazil--Brazil's shipments gained in '02 by 12% to 1.9 million tons. 10. Korea--Korea's shipments grew almost 2% in '02 (the fourth consecutive growth year) to 1.7 million tons. Over a six-year period, shipments have increased 12.5%. Shipment data typically is submitted by each nation's metalcasting trade association Comments about participation in the annual census should be directed to: Census of World Casting Production MODERN CASTING. 505 State Street, el. Des Plaines Des Plaines, city, United States Des Plaines (dĕs plānz), city (1990 pop. 53,223), Cook co., NE Ill., a suburb of Chicago on the Des Plaines River; inc. 1925. Among its manufactures are chemicals and electronic equipment. . Illinois Illinois, river, United States Illinois, river, 273 mi (439 km) long, formed by the confluence of the Des Plaines and Kankakee rivers, NE Ill., and flowing SW to the Mississippi at Grafton, Ill. It is an important commercial and recreational waterway. USA 60016-8399 or e-mail: moderncasting@afsinc.org See .org. (networking) org - The top-level domain for organisations or individuals that don't fit any other top-level domain (national, com, edu, or gov). Though many have .org domains, it was never intended to be limited to non-profit organisations. RFC 1591. .
Number of Operating Foundries By Nation--2002
COUNTRY IRON STEEL NONFERROUS TOTAL
Austria *** 19 7 32 58
Belgium 20 9 10 39
Brazil * 1000 (A)
Canada * 73 38 84 195
China * 12000 (A)
Croatia 19 2 20 41
Czech Republic 108 32 59 199
Denmark 10 (C) 8 18
Finland 15 6 19 40
France 525 (A)
Germany 220 53 400 673
Great Britain 179 (C) (C) 179
Hungary 33 12 63 108
India 4700 (A)
Italy 237 27 895 1159
Japan 462 84 1178 1724
Korea 447 134 179 760
Mexico 741 27 1019 1787
Netherlands * 35 3 (C) 38
Norway 8 3 12 23
Poland * 200 (D) 40 270 (E) 510
Portugal * 49 12 67 128
Romania * 176 35 132 343
Russia ** 1900 (A)
Slovenia 16 4 33 53
South Africa *** 150 (B) (C) 40 190
Spain 153 36 117 306
Sweden 37 13 84 134
Switzerland 19 3 40 62
Taiwan 544 50 349 943
Thailand 45 5 10 60
Turkey 975 70 80 1125
Ukraine 400 233 327 960
U.S. 700 300 1700 2700
* 2001 data ** 2000 data *** 1999 data
A) all foundries
B) includes steel foundries
C) not available
D) includes about 30 foundries making both iron and steel
E) includes about 40 foundries making castings in both ferrous and
nonferrous.
37th Census of World Casting Production-2002 (Metric Tons)
Gray Ductile Malleable
Country Iron Iron Iron
Austria 52,524 17,539 (A) --
Belgium 77,954 18,593 36,979
Brazil 1,219,207 493,652 23,189
Canada * 684,000 (A,D) -- --
China 9,840,108 2,994,986 451,788
Croatia 27,583 11,799 90
Czech Republic 247,009 42,783 9,851
Denmark (L) 52,853 34,444 --
Finland 55,568 43,283 (G) --
France 2,513,000 (A,D) -- --
Germany 2,253,278 1,276,751 38,277
Great Britain (I) 545,000 326,000 15,300
Hungary 50,435 12,375 53
India 2,370,000 300,000 (J) 30,000
Iran * 280,000 95,000 (J,H) 1,500
Italy 932,855 443,840 9,650
Japan 2,351,141 1,742,123 81,064
Korea 925,100 523,400 (J) 47,900
Mexico 800,000 (A) 175,000 --
Netherlands * (I) 66,100 60,300 5,200
Norway 19,606 44,247 --
Poland 389,494 101,907 14,642
Portugal * 33,700 51,500 100
Romania * 255,473 20,736 5,840
Russia ** 4,400,000 (A,D) -- --
Slovenia 57,606 25,616 4,200
Spain 592,170 642,600 (J) 22,750
South Africa ** 221,200 88,400 1,400
Sweden 156,800 57,000 --
Switzerland 29,020 51,373 --
Taiwan 722,600 275,000 8,000
Thailand 67,080 100,800 1,350
Turkey 620,000 139,000 7,600
United States 4,463,424 3,703,190 115,214
Ukraine 626,610 40,000 10,000
TOTALS 37,998,498 14,053,237 941,937
Copper-
Country Steel Base Aluminum
Austria 14,630 4,121 102,912
Belgium 11,461 534 25,050
Brazil 87,166 13,735 122,048
Canada * 152,000 -- 76,000 (E)
China 1,692,109 156,966 979,290 (C)
Croatia 1,171 603 9,907
Czech Republic 81,911 1,766 55,839
Denmark (L) -- 1,322 --
Finland 16,678 3,898 5,287 (C)
France 114,939 390,241 (E)
Germany 181,358 89,993 660,548
Great Britain (I) -- -- --
Hungary 5,576 (K) 2,312 (K) 63,401
India 325,000 -- 242,000 (E)
Iran * 28,000 25,000 30,000
Italy 74,521 110,000 777,000
Japan 232,388 86,763 1,217,129
Korea 144,500 21,600 45,500
Mexico 300,000 175,000 480,000
Netherlands * (I) 700 -- --
Norway 3,483 3,458 23,278
Poland 44,005 5,127 91,922
Portugal * 14,400 5,950 17,450
Romania * 53,798 9,984 18,100
Russia ** 1,200,000 -- 600,000 (E)
Slovenia 22,420 3,488 21,882
Spain 80,180 8,720 265,800
South Africa ** 144,496 5,000 45,600
Sweden 20,800 10,000 37,100
Switzerland -- 2,319 17,083 (C)
Taiwan 62,700 49,000 267,000
Thailand 1,300 -- 3,200
Turkey 110,000 2,120 41,350
United States 840,067 266,716 1,876,997
Ukraine 266,060 11,000 20,500
TOTALS 6,327,807 1,076,495 8,635,414
Other
Country Mag. Zinc Nonferrous TOTAL
Austria 3,917 10,661 -- 306,304
Belgium -- 1,137 50 171,758
Brazil 4,074 7,570 -- 1,970,631
Canada * -- -- -- 912,000
China -- 146,316 -- 16,261,563
Croatia -- 580 1,343 (F) 53,076
Czech Republic 2 1,935 56 441,152
Denmark (L) -- -- 88,619
Finland -- 474 8 125,196
France -- -- -- 3,018,180
Germany 24,506 66,624 4,107 4,595,442
Great Britain (I) -- -- -- 886,300
Hungary -- 2,491 116 137,759
India -- -- -- 3,267,000
Iran * -- 5,000 -- 464,500
Italy 13,100 79,600 -- 2,440,566
Japan 166 34,463 6,523 5,751,760
Korea -- -- 5,500 (B,C) 1,713,500
Mexico -- 100,000 -- 2,030,000
Netherlands * (I) -- -- -- 132,300
Norway -- -- -- 94,072
Poland 72 6,605 312 660,086
Portugal * 350 1,550 115 126,115
Romania * -- 1,560 -- 365,491
Russia ** -- -- -- 6,200,000
Slovenia 5,519 2,925 200 143,856
Spain -- 16,400 -- 1,628,620
South Africa ** -- 3,500 2,020 511,616
Sweden 1,600 4,200 -- 287,500
Switzerland -- 1,736 -- 101,531
Taiwan 5,000 50,000 1,840 1,441,140
Thailand -- -- 2,600 176,330
Turkey -- 1,530 -- 921,600
United States 78,019 297,562 170,553 (K) 11,811,742
Ukraine -- -- -- 974,170
TOTALS 136,325 844,419 195,343 70,209,475
* 2001 tonnage ** 2000 tonnage
A) includes malleable iron
B) includes zinc
C) includes magnesium
D) includes ductile iron
E) includes all nonferrous
F) lead castings
G) includes white iron
H) includes 15,000 high alloy cast iron (mostly High Cr ball mills)
I) ferrous reported only
J) includes pipe
K) includes investment castings
L) only copper reported for nonferrous
For a typical captive U.S. foundry, labor costs representing the
single largest cost driver.
Typical Captive Foundry Cost Structure $0.72/lb.
Depreciation 9.9%
Overhead 8.7%
Other Variable 8.6%
Energy 10.9%
Labor 45.0%
Material 16.9%
Captive US
This 2002 cost comparison for heavy-duty blocks and heads shows
the difference in cost structure between foundries in the U.S.,
Mexico, Brazil and China.
Heavy-Duty Blocks & Heads 2002 Cost Comparison
Other Depreci- Overhead Other
ation Variable
Captive US $1.07 $0.07 $0.07
Mexico $0.06 $0.07 $0.10 $0.07
Brazil $0.068 $0.07 $0.10 $0.07
China $0.08 $0.07 $0.10 $0.07
Energy Labor Material
Captive US $0.08 $0.31 $0.13
Mexico $0.09 $0.03 $0.14
Brazil $0.10 $0.02 $0.13
China $0.06 $0.00 $0.01
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