Skill`s development History and Plans going forward

WELCOME
Skill’s development History
and Plans going forward
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A MODULE MANUFACTURING CAPACITY WITH THE BEST AND MOST COST EFFECTIVE TECHNOLOGIES

Location : Cnr of De Beer and Sacks Circle
Bellville South
Cape Town
South Africa
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AN INDUSTRIAL CAPACITY WITH THE BEST TECHNOLOGIES


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A photovoltaic production unit of 40 MWp
based in CAPE TOWN (Republic of South
Africa).
Production commissioning started in
January 2009, and rapidly reached the
performance expected (obtaining Final
Acceptance Test in February 2009).
A production facility exclusively dedicated
to Solairedirect (France) needs, the
parent
company
of
Solairedirect
Technologies (ownership of 100%) and to
the local SA and Africa market.
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AN INDUSTRIAL CAPACITY WITH THE BEST TECHNOLOGIES
Creation of Company and Plant construction Start –
January 2008
Line Installation completed Jan 2009
Factory Acceptance Test of Equipment – September
2008 - Japan
Start of Production – March 2009
Line assembly December 2008
First Shipment to SD – April 2009
PRODUCTION
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STORES, DISPATCH AND LABORATORY
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DESCRIPTPION OF THE MODULE MANUFACTURING PLANT C

Facility Details:
Total : 4000 sq/m
Production – 1400 sq/m
Raw Material Warehousing – 1200 sq/m
Finish Goods Warehousing – 1000 sq/m
Laboratory, Maintenance, and Office space - 400 sq/m,

Supportive Peripherals:
Generator + UPS for risk management for continual production
Climatic Controlled production unit to ensure STC.

Capacity:
Current Line installed – 40 MWp per annum
Facility Capacity –120 MWp

Production Equipment:
NPC Automated Tabbing and Stringing units
NPC Automated module Lay-up unit
Automated line for high pace manufacturing
NPC Laminator for encapsulation of Solar
MBJ Solutions GmbH automated EL tester
Berger Power measurement module Tester
VOS climatic chamber
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SDT EXPANSION POSSIBLE

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SDT has the capacity to increase within its current premises with an additional 2 production
lines of 40MW each, yielding an accumulated capacity of 120MW.
There is also an option to rent a neighbouring premises that gives us an additional 3000
sq/m, yielding a further expansion possibilities.
Line 2 can be installed next to line 1 in Unit 3 without disruption of line 1 production, drawing
1 below denotes the current (line 1) in colour and the second line in grey.
Line 3 can be installed in unit 2 used currently used as the Rebate Store/raw material
warehouse. The Rebate Store will move offsite to our Freight forwarder. Drawing 2 and 3
denote line 3 layout.
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SDT EXPANSION CONT …
Drawing 1 : Line 1(current in colour) and Line 2 (expansion possible in
grey) drawing in Unit 3
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SDT EXPANSION CONT…
Drawing 2 : Line 3 positioned in Unit 2
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Drawing 3 : Line 3 close-up
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SDT PRODUCTION HISTORY
Production Actual Annually 2009- 2011
67.58
70
60
50
MW
40
32.52
30
24.69
20
10
10.37
0
2009
2010
2011
Total
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SDT PRODUCTION modules used on SD France projects
INSTALLED
CAPACITY
SURFACE
P90
PRODUCTIBLE
(kWh/kWp)
TECHNOLOGY
LEASE
STATUS
VINON
4.3 MWp
10 Ha
1,395
Real 1,511
Poly-crystalline
(100% Yingli)
40 years
Operational
(March 2009)
LES MÉES I
12.0 MWp
24 Ha
1,425
Poly-crystalline
(50% Solairedirect)
40 years
Operational
(July 2010)
LES MÉES II
11.6 MWp
27 Ha
1,425
Poly-crystalline
(50% Solairedirect)
40 years
Operational
(December 2010)
ESPARRON I
8.4 MWp
19 Ha
1,425
Poly-crystalline
(50% SDT)
40 years
Completed
(Operational March 2011)
ESPARRON II
5.2 MWp
12 Ha
1,425
Poly-crystalline
(50% SDT)
40 years
Completed
(Operational March2011)
St. HILAIRE
6.0 MWp
11 Ha
1,215
Poly-crystalline
(100% SDT)
30 years
Completed
(Operational March 2011)
OVERVIEW
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7/5/2012
SDT PRODUCTION modules used on SD France projects
INSTALLED
CAPACITY
VARAGES I
6 MWp
SURFACE
ESTIMATED
PRODUCTION
(GWh)
TECHNOLOGY
LEASE
DELIVERY DATE
12 Ha
8.1 GWh
Crystalline
(100% SDT)
40 years
September 2011
Crystalline
(100% SDT)
40 years
August 2011
VARAGES II
3 MWp
6 Ha
4.1 GWh
VENZOLASCA
4.5 MWp
10 Ha
5.6 GWh
Crystalline
(100% Jinko Solar)
40 years
September 2011
POGGIO DI NAZZA
4.5 MWp
10 Ha
5.8 GWh
Crystalline
(100% Jinko Solar)
30 years
September 2011
SARTENE
3.6 MWp
10 Ha
4.8 GWh
Crystalline
(100% Jinko Solar)
30 years
September 2011
COUTEUGES
10 MWp
21.8 Ha
11.6 GWh
Crystalline
(50% SDT / 50% Jinko)
40 years
November 2011
JUSSAC
12 MWp
26.3 Ha
13.8 GWh
Crystalline
(50% SDT / 50% Jinko)
40 years
November 2011
OVERVIEW
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SOLAIRE DIRECT TECHNOLOGIES TEAM
•
The Senior Management team of Solaire Direct Technologies (SA citizens) have years of international
experience in all fascists related to the supply chain, quality, technology and manufacturing of PV Solar
Modules.
Ajay LALLA
Sebastien FEIT
Tracey LALLA
Tony JOYCE
Muriel BOHAARDIEN
Nick CARPENTER
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7/5/2012
SOLAIRE DIRECT ORGANIZATION CHART
A.L.
Total Head Count : 90
Total SD
: 1
Total SDT
: 68
Total Contract
: 21
Organization Chart
Managing Director
Ajay Lalla
Senior
Production
Manager
Tony Joyce
Accounts
Manager
Muriel
Bohaardien
IT Manager
Kobus Smith
Accounts
Assistant
Joslyne Daniels
Shift Supervisor
1
Michael Gamba
Production Coordinator
Suleman Samsodien
T/S Pilot
Charlton Cupido
T/S Co-pilot
Dumani Georgias
Prep 1
Sarah Johnson
Prep 2
Edith Mdishwa
Prep 3
Prep 4
Elizabeth Tiras Bongile Mditshwa
Rework
Mario Joseph
Material Cutting
Adam Windvogel
Framer 1
Lazola Yedwa
Framer 2
Luzuko Rubushe
Operational
Manager
Sebastian Feit
Shift Supervisor
3
Ettiene Titus
Shift Supervisor 4
Murawan Masoet
T/S Pilot
Nazmie Ely
T/S Pilot
Craig Flores
T/S Pilot
Ashley Philips
Prep 2
Natalie Oliver
Prep 1
Tashwill Goliath
Prep 2
Dominique Davids
Prep 3
Soraya Noordien
Prep 4
Madeniya Ripepi
Prep 3
Chester Daniels
Prep 4
Alice Mabandla
Rework
Corlene
Solomons
Material Cutting
Shiretha Geswint
Framer 1
Alex Fulani
Framer 2
Marawaan Jacobs
Framer 1
Mzamo Tora
Framer 2
Songezo Lengisi
J/B
Wayne Bantom
J/B
Nathan Bantom
J/B
Amanda Manila
SunSim
Marlon Turner
SunSim
Roland Langeveldt
SunSim
Leeroy Jones
FQA
Ayanda Mzinzi
FQA
Morne Isaac Daniels
FQA
Porchia Paulsen
Packer
Ashley Africa
Packer
Shannon Pieterse
Packer
Alwin Pietersen
Stores Coordinator
Donovan Paulsen
Dispatch Coordinator
Keith Adbulla
Process Controller
Mustapha Jasiem
Prep 1
Elizabeth Tiras
Prep 3
Sasha-Lee Hess
Prep 4
Rozanne van
Schalkwyk
Rework
Rafiq Felix
Material Cutting
Rene Bailey
Framer 1
Elvine Bantom
J/B
Kelly Lee Williams
SunSim
Safwaan Jacobs
FQA
Veronique Conrad
Packer
Jonanthan
Abrahams
Framer 2
Lindsay Trantraal
Maintenance
Technician 1
Karl Lotter
Maintenance
Technician 3
Trevor Mathews
Receptionist
Deidre April
Prep 2
Samantha Davids
Machine
Specialist
Nick Carpenter
Maintenance
Technician 2
Menesh Daya
Sales
Carlos Rodrigues
QC 2
Shalako Mathews
T/S Co-pilot
Aaron Horswell
T/S Co-pilot
Matthew Nyaba
Prep 1
Roslyn Rhode
Quality
Manager
Saud Edries
Purchasing
Assistant
Gail Blacker
Shift Supervisor
2
Ganief Nell
Rework
Material Cutting
Masnoena Morrisi
Melanie
Goddard
Supply Chain/
Sales Manager
Tracey Lalla
SHER Manager
Deon Daries
T/S Co-pilot
Bratley Adams
DPC-HR-001
28/02/2011 Rev.7
Dispatch assistant
Malcolm
Christians
QC 2
Riyaad Dollie
QC 2
Antonio Abrahams
Dispatch assistant
Andrew Ludick
QC 2
Kashief Maclain
Stores assistant
Adolf Arandse
Job Closure Clerk
Avril Arendse
Factory Cleanner
Veronica N
Factory Cleanner
Keith Redding
Factory Cleanner
Michelle Africa
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SOLAIRE DIRECT TECHNOLOGIES’ PRODUCTS
•
•
•
•
•
•
SDT produces a module power range of from 120W to 305 Wp modules
All modules produced by SDT are IEC 61215 ed 2 and IEC 61730 class 1& 2
certified by TUV Rhienland in Germany
SDT has certified a 1500V module in its manufacturing power range capacity.
SDT has certified a BIPV module call Solrif used in roof integration, this module
has been installed in various area’s across France.
Specification sheets of all products produced by SDT accompany this presentation
Additional test have been conducted by TUV Rhienland as follows
• Max reverse current – Completed 2011
• Salt Mist testing corrosion testing (IEC 60068-2-52) - In progress
• Ammonia Resistance corrosion testing of PV Modules (IEC 62716) – In
progress
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SOLAIRE DIRECT TECHNOLOGIES’ OBJECTIVES

To ensure highest quality PV module supply

PV module cost reduction : To control modules
prices, a major component of the KWh
production cost.

PV module customization:
 To control modules design dedicated to
roof top installations (BIPV : Building
Integrated PV).
 1500V module and system design and
certification
Solairedirect Technologies: A team cumulating over 50 years of experience in the photovoltaic
industry.
DESCRITPION OF THE MODULE MANUFACTURING PLANT CONT…
Certifications :

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
IEC 61215 ed.2 by TUV Rheinland (April 2010) and TUV Intercert(January 2009)
IEC 61370 class1 and 2 by TUV Rheinland (April 2010) and TUV Intercert(January 2009)
ISO 9001:2008 certified by TUV Rheinland (June 2010)
ISO 14001:2004 audit passed successfully (June 212)
Quality Assurance :
Test Lab on premises capable of testing to all criteria of IEC 61215:2005
In house - Batch verification of Module encapsulation and Cell/Module soldering adhesion.
Onsite Climatic chamber to do all weathering test to warrantee 25 years.
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SOLAIRE DIRECT TECHNOLOGIES QUALITY ASSURANCE STRENGTHS
•
•
•
•
•
•
•
•
•
•
•
•
•
100 % cell inspection for Cracks
100 % cell inspection for strings built for cracks, soldering coverage and conductivity
Soldering adhesion SPC managed with 18 test conducted daily
Gel content of EVA encapsulation check 2 weekly and verified at external laboratory
once monthly
100 % Electroluminescence inspection conducted after lamination for micro crack
inspection and overall quality grading .
100 % Hipot testing
Sample wet leakage testing
100% module flashing of modules to determine power, sunsimulator calibrated at TUV +
0%.
Modules tested for IEC Damp Heat, Thermal Cycling and Humidity freeze test at three
times IEC specification
Module manufacturing plant has be audit by Munich RE and has successfully passed
IEC 61215 edition 2, IEC 61730 (class 1& 2) certified, extra testing done by TUV for max
reverse current and Salt mist Testing successfully passing these test.
1500 V module certification to the IEC 61215 ed.2 and IEC 61730 (class 1 and 2) via
TUV.
Claim and non-conformities managed through 8D reports and root cause analysis
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SOLAIRE DIRECT TECHNOLOGIES CERTIFICATIONS
IEC 61215
IEC 61370 class1 and 2
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SOLAIRE DIRECT TECHNOLOGIES CERTIFICATIONS
ISO 9001:2008
ISO 14001:2004
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SOLAIRE DIRECT TECHNOLOGIES CERTIFICATIONS
ISO 9001:2008 (March 2012) => 0 non-conformity
ISO 14001:2004 (June 2012) => 0 non-conformity
SDT FINANCIAL INFORMATION

Due to experience, R&D and continuous productivity improvement employing principles of lean
manufacturing SDT is able to reduce its cost to produce as illustrated below on the expected cost with the
added expansion.
Annual Capacity (MW)
40 MW
Year
80MW
120MW
2012
2012
2012
# Tabber stringers
2
4
6
# Laminators
1
2
3
Overhead analysis
Permanent People
0.029
0.022
0.02
euro/w
Temporary People
0.004
0.008
0.009
Spares parts
0.002
0.002
0.002
Elec/water
Building
Depreciation
Other
0.003
0.005
0.022
0.017
0.003
0.003
0.011
0.013
0.003
0.002
0.013
0.013
Consumables (flux,…)
0.003
0.002
0.001
Logistic Externalization
0
0
0.003
5.5% of O/H
0.005
0.004
0.003
€ 0.090
€ 0.068
€ 0.066
Organisation
Transfer Pricing Mark-up
Overhead recovery (€/W)
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SKILLS GAP ANALYSIS

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2008
2009
2010
2011
2012
-
12
45
76
81
63
Employees
Employees
Employees (25 Temps)
Employees (25 Temps)
Employees (No Temps)
SDT Employee Growth Structure
90
80
70
Qty Employees

60
50
40
30
20
10
0
2008
2009
2010
2011
2012
2013
Year
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CURRENT AND PLANNED SKILLS DEVELOPMENT
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PV Induction – All Staff (PV Exposure)
Manufacturing Process Training – Work Station, Work Instruction (Process,
Quality, Safety, Environmental Management System)
Process Optimization – Formula 1 Response, Cell Breakage, Cost Reduction,
Quality Reaction, Waste Avoidance, Best Practice, IPX IT system.
External Skills – Health & Safety, First Aid, Fire Fighting, SDF, Internal
Auditing, Quality 9001, EMS 14001 - TUV Rheinland
Additional Internal Training – FMEA, Problem Solving, Supervisors & Team
Leaders, Basic ISO & EMS.
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QUALIFICATION PROCESS
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WORK INSTRUCTION
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COMMUNITY PROJECTS AND SKILLS
INTRODUCTION
High School Introduction to Photovoltaic Manufacturing in partnership with
UCT
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EMASITHANDANE (EMASI) CHILDREN’S HOME
Emasi Children’s home is a 1 bedroom house that is situated in the Nyanga
township of Cape Town that houses more than 20 children.
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NELSON MANDELA METROPOLITAN UNIVERSITY
AND UNIVERSITY OF JOHANNESBURG
SOLAR CAR PROJECT SPONSOR
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THANK YOU
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