1. Plastics Chamber Regional Workshop Plastics Chamber, merSETA Version – 30 April 2011 Plastics Chamber, merSETA Version – 30 April 2011

2. Programme 8:30Introduction and background 8:45Presentation of draft value chain maps. Verify allocation of jobs to each node in the value chain - small group work 10:15Break 10:30Collection information related to the primary outputs and tasks of each job – small group work 11:30Identify skills needs in relation to each job on each value chain map and the priorities for each value chain - small group work 12:30Identify factors that impact on skills demand in each sub-sector, issues related to attraction and retention of people in each sub-sector, possible learning and career paths – small group work 13:15Break 14:00Review integrated qualifications framework against the learning and career paths, ways of attracting more people to the industry (to inform career guidance) 15:00Funding grants and incentives, including brief overview of revised new grant structure. 15:30General issues and challenges, mechanisms for improving communication between Plastics Chamber and industry. Way forward. 16:00Closure Plastics Chamber Regional Workshops – Ver. 2011-05-30 2

3. INTRODUCTION TO THE VALUE CHAINS General industry value chain Plastics Chamber Regional Workshops – Ver. 2011-05-303

4. Why do we use value chains? Identify each point in the manufacturing process where value is added Each node in the value chain generally has work attached to it – A job The job must deliver a product or a service – Requires skills – Requires training – formal and informal Identify each point in the manufacturing process where value is added Each node in the value chain generally has work attached to it – A job The job must deliver a product or a service – Requires skills – Requires training – formal and informal Plastics Chamber Regional Workshops – Ver. 2011-05-30 4

5. Purpose of the workshop Find agreement on what are the industry value chains What are the jobs? Where do the quality issues arise? Where are the skills gaps Can we address these through training? Find agreement on what are the industry value chains What are the jobs? Where do the quality issues arise? Where are the skills gaps Can we address these through training? Plastics Chamber Regional Workshops – Ver. 2011-05-30 5

6. Based on this we can then confirm and refine current information We have a common starting point We can get agreement on where the priorities lie We can link jobs to OFO codes We can make it easier to complete WSPs – Improve the quality of information The chamber can then more confidently – Develop projects, incentives, to address the skills gaps – Measure progress Also would link to the future – New industrial strategies will generally involve plastics – Allow industry to take advantage and grow as a result We have a common starting point We can get agreement on where the priorities lie We can link jobs to OFO codes We can make it easier to complete WSPs – Improve the quality of information The chamber can then more confidently – Develop projects, incentives, to address the skills gaps – Measure progress Also would link to the future – New industrial strategies will generally involve plastics – Allow industry to take advantage and grow as a result Plastics Chamber Regional Workshops – Ver. 2011-05-306

7. HIGH LEVEL VALUE CHAINS Overview of industry and where it fits in Plastics Chamber Regional Workshops – Ver. 2011-05-307

8. The full plastics life cycle FeedstockMonomerPolymer Polymer compound Plastic product Finished product Application Integration Recycling Petrochemical industry Chemical industry Compounders Converters Customers Plastics Chamber Regional Workshops – Ver. 2011-05-308

9. Polymer compound- ing Conversion FinishingAssembly Pigments Additives Fillers Reinforcing agents Processing aids Foaming agents, gases… Compounds Masterbatches Expanded beads Pre-pregs… Extrusion Film Sheet Pipe Profile Coating Laminating Cable covering Moulding Injection Blow Injection-blow Rotational Compression Thermoforming Foaming Casting Laminating… Cutting Slitting Bending Machining Decorating Printing Trimming Conditioning Adding inserts fittings, accessories Cross-linking… Fabricating Joining Welding Gluing Clipping/snappi ng together Bolting … Packing Dispatch Installing... Conversion into complete components The generalised plastics value chain Plastics Chamber Regional Workshops – Ver. 2011-05-309

10. Market-driven the value chain – the influence of the market on plastics manufacturing Polymer compound- ing Conversion Finishing Assembly End Use Graphic design Tooling design Material design Product design Origination (pre-press) Tooling mnf Material develop- ment ConsumerMarketingCustomer Plastics Chamber Regional Workshops – Ver. 2011-05-3010

11. What value does a person add to the Value Chain, what does s/he do to add value Plastics Chamber Regional Workshops – Ver. 2011-05-3011 Node:02 Production supervisor Critical skills required Alternative Titles: Process technician; shift supervisor; Product or Service Smoothly running production process Task 1 Plans, organises, staffs, schedules, co- ordinates, reports and maintains records Interpersonal skills Task 2 Supervises production activities and staffTime management Task 3 Plans, organises and implements projectsHR skills Task 4 Liaises with technical and support servicesSupervisory management qualification OR Task 5 Monitors levels and use of stock and consumables Production management qualification Task 6 Maintains levels of quality Structure and format of entries in spreadsheet

12. PROCESSES SUPPORTING THE PLASTICS VALUE CHAIN Vary greatly from company to company Plastics Chamber Regional Workshops – Ver. 2011-05-3012

13. Overview of value chains Plastics Chamber Regional Workshops – Ver. 2011-05-3013 06-10 Conversion 01 Dispatch 01 Receiving 05 Polymer compounding 02 Tooling Mnf 04 Quality 11 Installation 12 Recycling 03 Printing Market Packaging t-plast Engineering t-plast Ind Rubber Composites T-plast fabrication

14. Value Chain Maps Map 01 - Receiving, dispatch, logistics Map 02 - Mould and tooling manufacture, repair and maintenance Map 03 - Printing, decorating, labelling Map 04 - Quality Management Map 05 - Polymer compounding Map 06 - Packaging conversion (volume production, longer runs) Map 07 - Engineering conversion (custom moulding, jobbing) Map 08 - Industrial rubber conversion Map 09 - Polymer composites (GRP, FRP, advanced composites) Map 10 - Thermoplastic Fabrication Map 11 - Installation, repair and maintenance Map 12 - Recycling Map 01 - Receiving, dispatch, logistics Map 02 - Mould and tooling manufacture, repair and maintenance Map 03 - Printing, decorating, labelling Map 04 - Quality Management Map 05 - Polymer compounding Map 06 - Packaging conversion (volume production, longer runs) Map 07 - Engineering conversion (custom moulding, jobbing) Map 08 - Industrial rubber conversion Map 09 - Polymer composites (GRP, FRP, advanced composites) Map 10 - Thermoplastic Fabrication Map 11 - Installation, repair and maintenance Map 12 - Recycling Plastics Chamber Regional Workshops – Ver. 2011-05-30 14

15. Map 01 - Receiving, dispatch, logistics Receiving Stores Conversion Stores Dispatch Material reclamation 04 Receiving clerk 03 Storeman 01 Purchasing Managing 02 Logistics Manager Plastics Chamber Regional Workshops – Ver. 2011-05-3015 08 Truck driver Truck driver’s assistant 07 Wand Scanner Scale operator 06 Crane driver Forklift operator Material handler Picker 05 In-mould label clerk

16. Map 02 Mould and tooling manufacture, repair and maintenance Tooling design CAD/CAM Tooling manufacture, repair Tooling manufacture, repair Heat treatment Installation 01 Engineering manager Tool room manager 10 Tool setter?? Disassembly cleaning 05 Draftsperson 03 Tool room supervisor/foreman 02 Engineering analyst Industrial designer Product designer Cost estimator Product design Assembly 08 Heat treatment operator Composites Post cure operator See Map 09 Composites 04 Metals Tool maker Electrician Composites Patternmaker 06 CAD/CAM programmers Plastics Chamber Regional Workshops – Ver. 2011-05- 30 16 09 Metals Toolmaker’s assistant Composites Mould cleaner /polisher see Map 09 Composites 07 Metals Milling /turning operators EDM / Sparking operators Polishers Tool maker’s assistant Composites Mould Builder Mould repairer see Map 09 Composites Composites Mould cleaner /polisher Mould Builder Mould repairer Skills similar to/embedded in production process – see Map 09 Composites Mould cleaner /polisher Mould Builder Mould repairer Skills similar to/embedded in production process – see Map 09

17. Map 03 - Printing, decorating, labelling Origination (Pre-press) Ink preparation Printing Finishing Stores 08 Printing machine minder 04 Quality controller Graphic design Product finishing 03 Printing foreman Trade printer 01 Printing manager 07 Ink mixer 09 Finishing equipment operator Flexo, litho, screen, pad printing Hot foiling Varnishing Labelling… Drying varnishing 05 Graphic designer (Generally out- sourced) Plastics Chamber Regional Workshops – Ver. 2011-05-3017 06 Screen maker Plate maker 02 Artwork Controller Stores Inks Blankets Consumables

18. Map 04 - Quality Management Stores Acceptance testing Conversion Product checking Stores 01 Quality Assurance Manager Quality Assurance Supervisor Internal Auditor Laboratory testing 02 Laboratory supervisor 04 Laboratory technician Plastics Chamber Regional Workshops – Ver. 2011-05-3018 03 Quality Inspector Quality viewer/checker 03a see Map 09 Composites, & 10 -T-plastic Fabrication Inspector - Pressure Vessels Competent Person Third Party Inspector

19. Material preparation Compounding Pelletising Packing Quality 05 Compounding operator Quality Assurance Manager 03 Compounding Supervisor Production manager 04 Material mixer 06 Packing assistant Mixing Blending Pre-heating Map 05 - Polymer compounding Formulation 02 Chemist Plastics or rubber technologist Cost estimator Product design Testing Plastics Chamber Regional Workshops – Ver. 2011-05-3019 01 Compounding manager Stores

20. Maintenance Technology Human Resources Management Firm infrastructure Procurement Electrician Electrician Assistant Electronic/CNC/ Megatronic technician Electrician Assistant Fitters Fitter’s Assistant Riggers Plastics technologistsPlasticianEngineer Engineering technologists Engineering technician Food technologist Packaging technologist Supply chain managersBuyers HR, manager / specialist SDF HRD manager Trainer Marketing Export Public relations Sales Finance Administration ManagementSafety, Environment, Risk, Quality Consumer Protection Plastics Chamber Regional Workshops – Ver. 2011-05-3020 HRD administrator

21. PLASTICS MANUFACTURING VALUE CHAINS Plastics Chamber Regional Workshops – Ver. 2011-05-3021

22. Material preparation Conversion Printing decorating Finishing Quality 05 Production operator/packer Material reclamation 02 Production supervisor Team/cell/gap leader Machine setter Mould changer 07 Granulator operator Production manager 04 Raw Material mixer 03 Finishing supervisor 06 Finishing equipment operator Barcode labeller Palletiser Slitting trimming bag making laminating stretching, orientating assembly welding… Film blowing Cast film Moulding Injection Blow Injection/ stretch Thermo-forming… Map 06 - Packaging conversion (volume production, longer runs) Plastics Chamber Regional Workshops – Ver. 2011-05-3022 01 Operations manager Production manager Production planner Stores

23. Material preparation Conversion Assembly Finishing Quality 06 Production operator Packer Material reclamation 02 Production supervisor Machine setter 09 Granulator operator 01 Production manager 05 Raw Material Mixer 04 Finishing supervisor 08 Finishing equipment operator Mixing Blending … Map 07 - Engineering conversion (custom moulding, jobbing) 03 Assembly supervisor 07 Assembly worker Trimming Drilling Machining Grinding Marking Conditioning Annealing Post-curing … Plastics Chamber Regional Workshops – Ver. 2011-05-3023 Moulding Injection Blow Injection/ stretch Thermo-forming Roto Compression Extrusion Pipe/profile Sheet Cable / wire Pultrusion Filament winding Stores

24. Material preparation Conversion Assembly Finishing 06 Production operator/packer Material reclamation 02 Production supervisor Machine setter 09 Grinder operator 01 Production manager 05 Raw material mixer Assistant mixer 04 Finishing supervisor 08 Finishing equipment operator Fabricating Joining Welding Gluing Clipping/snappin g together Bolting… Moulding Injection Compression Extrusion Tube/ pipe/profile Sheet Cable / wire Map 08- Industrial rubber conversion 03 Assembly supervisor 07 Assembly worker Trimming Drilling Machining Grinding Marking Curing… Mixing Milling Compounding Plastics Chamber Regional Workshops – Ver. 2011-05-3024 Quality Stores

25. Map 09 - Polymer composites (GRP, FRP, advanced composites) Reinforcement preparation Lay-up Cure Assembly 04 Laminator 02 Workshop supervisor 06 Finishing worker Polisher Grinder Fairer Spray painter Room temperature cure Autoclave Hand lay up Spray up Vacuum-bagging … 07 Assembly worker Trimming Drilling Machining Grinding Marking Post-curing… Cutting Mixing Cleaning & polishing Finishing 01 Production manager Mould preparation Resin preparation Attaching Gluing Screwing / bolting Laminating Installing of components… Plastics Chamber Regional Workshops – Ver. 2011-05-3025 Site installation Quality Stores 03 See Quality Map + Inspector Pressure Vessels (Authorised Inspection Authority) Competent person Third party inspector 05 Specialisations of laminator Material /glass cutter Resin batcher Mould repairer Mould Polisher / Release applicator Gel coater

26. Map 10 - Thermoplastic Fabrication Material preparation Fabrication Assembly 06 Welders assistant 02 Workshop supervisor 07 Finishing worker Welding Bonding… 08 Assembly worker Trimming Drilling Machining Grinding… Marking Cutting Preheating… Finishing Quality Check 01 Production manager Component preparation Component preparation Joining Bolting Bonding Clipping together, … Plastics Chamber Regional Workshops – Ver. 2011-05-3026 Logistics 03 See Quality Map + Inspector Pressure Vessels (Authorised Inspection Authority) Competent person Third party inspector Installation 05 Cutter 04 Welder

27. Map 11- Installation, repair and maintenance Plastics Chamber Regional Workshops – Ver. 2011-05-3027 Erecting Testing Connecting … Site preparation Commission- ing Installation Handover Bringing on- line Stress testing… Servicing & Repair Digging Levelling Barricading Scaffolding.. 02 Generally out- sourced 01 Construction supervisor 03 Fitter Engineering Technician Laminator Welder QC Inspector 03 Fitter Engineering Technician Laminator Welder QC Inspector Training Developing SOPs …

28. Map 12 –Recycling Material preparation Compounding Pelletising Packing Quality Check 04 Equipment operator Material reclamation 03 Production supervisor 06 Packer Shredding Washing Drying Collection Post- consumer 01 Production manager 05 Extrusion operator Collection Post conversion 02 Collection agent Collector Sorter/segregator Plastics Chamber Regional Workshops – Ver. 2011-05-3028 07 Sorter/segregator Stores