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The Southern African Institute of Mining and Metallurgy
Platinum 2012
925
S. Marx
SANDVIK APPRENTICE PROGRAMME: WE MAKE IT POSSIBLE
S. Marx Sandvik
Companies that create what we call people advantage – the ability to gain competitive advantage
through people strategies – will race ahead of their competitors’. 1
Background: Skills challenge a national skills crisis?
More than twenty years ago Sasol, ISCOR, and some parastatals played a major role in ensuring
that South Africa had sufficient technical skills. When the economy became tight and business
and government were pressurized to decrease costs, the first budgets that were reduced were
the training budgets. It seemed to be too expensive and too time-consuming to train
apprentices. According to Stacey2, this is a major strategic issue facing the mining industry in
South Africa.
Two factors added to the shortage of skills challenge:
• Skills erosion and job losses
o Artisans – currently the economy produces 5 000 but the need is 12 500
o Level of mechanization in South Africa less than 10 per cent
o Average age of operators and artisans is 50
o Greater awareness of occupational health effects of hand-held drilling.
• Workplace challenges
o The impact of HIV/AIDS and other employee wellness issues
o Changes and challenges in workplace environment i.e. the mining industry.
The result of reducing training budgets and decreasing apprenticeship training is that South
Africa has now been grappling with the shortage of technical skills for over a decade. As an
example, in 2005, 1 440 apprenticeships were registered with the Mining Qualifications
Authority (MQA). This compares to 3 000 in 2000 and 33 000 in 19754.
Based on the 2008 National Scarce Skills, the latest list to be published by the Department of
Labour, Goga and van der Westhuizen estimate that there was a net scarcity of 99 500
technicians and trade workers in 2008, up 9 per cent from the previous year5. In 2008 the skills
deficit in South Africa was regarded as a national crisis6.
Solidarity, furthermore, confirms that South Africa had only 10 per cent of the artisans that it
had 20 years ago, and estimated that the country has a 40 per cent shortage of artisans.
The Southern African Institute of Mining and Metallurgy
Platinum 2012
926
1975 1982 2000 2006 2007 2008 2009 2010 2011
Number of Apprentice Required - - 5,000 10,000 12,500 25,000 37,500 50,000 50,000
Actual Number of Apprentice 33,000 13,500 3,000 3,400 5,000 10,000 15,000 20,000
-
10,000
20,000
30,000
40,000
50,000
60,000
Nu
mb
er
of
Ap
pre
nti
ce
s
Figure 1 illustrates the current shortage of technical skills in South Africa. The decline in skills is
illustrated by the fact that in 2006 there were 3 400 apprentices in training in the metals
industry, compared to the 13 000 that were in training in 1982.
Figure 1-Shortage of technical skills in South Africa (data from the Steel and Engineering Industries
Federation of South Africa3
Minister Godongwana, Deputy Economic Development Minister, confirms this shortage when
he states that the training of artisans in South Africa slipped backwards.
‘(What is) shocking is that in 1975, there were 33 000 registered apprentices, largely white, with
a few coloured and Indian (apprentices), because Africans (blacks) were not allowed to be
artisans at the time,’ he said. ‘Now if you take a picture in 2000, there were 10% of (this figure),
3 000 artisans of all races. What this means is we're not training people at all in this economy.
Clearly this is a major challenge.’
Furthermore, it is well known that there is a world shortage of skills in all technical fields,
including mining. Finding a solution to this problem will become a critical factor for ensuring
that South Africa becomes globally competitive in this area.
The question that we should ask is: what is industry doing about this?
There have been many initiatives over the years to try and revive the training in technical skills
to support the mining industry. Some of these include initiatives by original equipment
manufacturers (OEMs) and mining companies. There is a continual move towards companies
getting more involved in the process of training apprentices. Lonmin, for example, established a
trade school this year (2012). The group is planning to develop apprentices for their own needs
as well as an equivalent number of artisan tradespeople for external jobs7.
The Southern African Institute of Mining and Metallurgy
Platinum 2012
927
A recent assessment of skills development interventions in South Africa by the Human Sciences
Research Council8 indicates that there have been various mechanisms over the past five years
to promote both artisanal and technical skills. The HSRC believes that this process has been
facilitated largely by the Joint Initiative on Priority Skills Acquisition (JIPSA). It was found that
there is a very high rate of employment after completing apprenticeships, with over seventy
per cent of candidates finding immediate employment. However, it was also noticed that of
the candidates that completed their apprenticeship, only four per cent entered the programme
directly after school. History shows that most candidates enter an apprenticeship two, three,
or more years after leaving school. This implies that school leavers do not generally consider an
apprenticeship as a first option and prefer to try other alternatives first. The HSRC believes that
this indicates an opportunity for further efforts at targeting school leavers to encourage them
into this field of study.
An initiative currently residing within the Human Sciences Research Council, the artisan
development technical team (ADTT), has researched and is developing strategies to address the
artisan skills shortage9. The team has recommended:
• The development of a list of artisan skills that are critical for economic growth
• Increasing the capacity of industries to train artisans for other industries beyond their
own requirements
• The development of a funding model to train the unemployed to become artisans.
Despite all these initiatives, according to University of the Witwatersrand School of Mining
Head, Professor Fred Cawood, when discussing skills in the coal industry, there is still not
enough being done to meet the demand for skilled technicians and artisans. He says that there
is no clear strategy in place10
.
The National Planning Commission, as part of their National Development Plan, has set a target
of producing 10 000 artisans per year by 2014, extending this to 30 000 per year by 2030,
subject to demand. The Commission has also identified key areas that are central to improving
education and skills11
.
The Sandvik apprenticeship journey
In 1998 Sandvik South Africa realized that the lack of technical skills is not only a major
challenge for South Africa, but also a major threat to the implementation of mechanized mining
in South Africa. Johan Pieters, Sandvik’s internal technical training centre manager, stated:
’Due to the shortage of skilled labour in the industry, we have undertaken to employ and train
apprentices, specific to the needs of the Sandvik equipment and customer needs’13
.
The Southern African Institute of Mining and Metallurgy
Platinum 2012
928
We Have Only Just Begun
Sandvik conducted an internal technical skills gap analysis in 1998. Through this gap analysis
(which compared current artisan skills with required skills to maintain Sandvik equipment)
Sandvik identified a real need for mechanical, diesel, and electrical artisan skills, and the
apprenticeship programme commenced with seven millwright apprentices in 1999.
The Sandvik Apprentice Programme was implemented to ensure the availability of technical
skills to support the long term growth plans. The total intake from 2003 to 2011 was 563. By
the year 2011 Sandvik produced 417 artisans for the mining industry with specific focus on
mechanized mining, forty-one (10 per cent) of whom there females.
Since 1999 Sandvik has been continued to develop the skills and competencies required,
ensuring that the company’s products are continuously maintained and that customer needs
are addressed. Even during the tough economic times in 2008, Sandvik decided to continue
with the training of apprentices in spite of a decreasing budget. To date Sandvik has 150
apprentices in training at any one time.
Long-term planning and recruitment of apprentices
The apprentice programme of Sandvik is a large investment (the Sandvik apprenticeship budget
amounts to around R20 million per annum) and requires a great deal of planning and
forecasting of numbers.
The number of artisan skills required is reviewed every year and is also aligned with the
business strategy. It is clear that the apprenticeship programme is one of the strategic
interventions that ensure the successful implementation of mechanized mining. Sandvik strives
to match its own need for qualified artisans in specific areas of our operations on customer’s
mines throughout South Africa, and to comply with the equity policies of the company and the
country.
An apprentice programme requires a high level of commitment and an understanding of the
need for continuous apprenticeship training. The challenge is to maintain this investment even
during the trying economic times such as 2008. Figure 2 shows the numbers of apprentices
that will qualify and planned intakes. This graph informs the business and advises on long term
planning with regards to the intake of apprentices. The bottom line is that if the mining industry
does not recruit and train, even in challenging financial times, it will not have the skills that it
needs skills in the long term.
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The Southern African Institute of Mining and Metallurgy
Platinum 2012
930
The quality assurance and performance management of the apprentice during this time is of
the utmost importance and ensures that high-potential candidates join the programme.
The new apprentice will take responsibility for attending all classes, completing all required
modules and logbooks, and obtaining the required theoretical subjects for the trade that
Sandvik enrolls him/her for. When the apprentice qualifies, he/she will be assigned to his/her
original site.
Another success factor of this programme is the shared ownership of an apprentice. Sandvik
appointed an apprentice programme manager with the purpose of tracking every step of the
apprentice development plan. The apprentice programme manager plays the role of
coordinator and line manager of each individual apprentice, and also tracks the performance of
the apprentices and ensures the quality of the training programme in consultation with the
Apprentice Forum.
The training programme
The training programme should be reviewed and aligned with the emerging technology within
the mechanized mining products and ensure that the skills and competencies required to
maintain Sandvik’s products are included in the training programme of the apprentices.
Diverse trades are also required to ensure that all aspects of the products are addressed. At
Sandvik we prefer the following trades:
• Millwrights - 60%
• Earthmoving equipment mechanics - 20%
• Auto electricians - 10%
• Electricians - 5%
• Fitters - 5%.
The review of the training programme is facilitated by the Apprentice Forum, which consists of
direct line managers, senior managers, and account managers, and ensures that the Apprentice
Programme is reviewed on a continuous basis
In the case of Sandvik, the Apprentice Programme also includes state-of-the-art in-house
training programmes, illustrated in Figure 3. The training outline indicates the holistic approach
of the Programme.
The Southern African Institute of Mining and Metallurgy
Platinum 2012
931
Sandvik Academy4
Apprentice Training ProgramSingle Trade
Three (3)
Months
Probation
Three (3)
Months
Training
Sandvik
Grading
Assessment
• Identify current
abilities/potential
• Theory training at
college
• Register for N2
subject
• Practical Training on
site
• Auto-Electrical
Course
• Basic Electro-
Hydraulic course
• Theory training at
college
• Register for N2
subject
• 6 Months practical
training on site
• 3 months practical
training in
workshop
• Licences: Crane,
Forklift and
Operator – Drill rig
and Loader
• EPPEC Control
system course
• Posi-Stop Brake
Training
• Flameproofing and
gas testing training
Nine (9) Months
practical
training
Continuous Improvement Plan
BRONZE SILVER GOLD
Three (3)
Months
Training
Nine (9) Months
practical
training
Four (4)
Months Trade
Test
• 4 Months
preparation
• 2 days trade
test
assessment
• Determine
current level of
Technical
knowledge
Continue with
Business Process
Training
Figure 3-Sandvik Apprentice Training Programme– example of a single trade
Apprentice Programme outcomes and continuous development of internal technical skills
The Apprentice Programme addresses the human being holistically. While Sandvik
acknowledges that technical skills and training is the focus of the programme, it is also
important to ensure that the apprentice is developed in other areas as well.
Sandvik therefore defines an artisan as competent when artisans are competent to fulfil the
following requirements:
• Artisans are able maintain mechanized equipment, mechanical, electronic and hydraulic,
according to standards and specifications
• An artisan is able to practice excellent fault-finding’ skills with machine breakdowns
quickly, in order to minimize downtime
• An artisan partners with the customer in order to consistently maximize machine drilling
performance
• An artisan develops good customer relations to ensure ongoing and new business.
The outcome of the Apprentice Programme is, therefore, not only a qualified artisan, but a
confident human being that can take their place in society and enhance the performance of
mechanized mining machines.
The Southern African Institute of Mining and Metallurgy
Platinum 2012
932
Continuous development of internal technical skills is also of utmost importance to ensure the
closing of the skills gap. Furthermore, the recertification of artisans is essential to ensure that
they stay abreast of new technology.
To ensure the continuity of lifelong learning, Sandvik has implemented an artisan grading
programme, which identifies further technical skills gaps for each and every artisan. The result
of this grading programme analysis assist with the identification of personal development plans
for each artisan. This ensures that skills development is focussed and ensures that personal
technical skills gaps are closed.
A successful apprentice programme requires partnerships
Sandvik is committed to skills development that is aligned with the economic strategies of the
country as outlined in the National Skills Development Strategy (NSDS) and is accredited with
two Sector Education and Training Authorities (SETAs), namely the Manufacturing, Engineering
and Related Services Seta (Merseta) and the Mining Qualifications Authority (MQA).
With Merseta, Sandvik has formed a partnership through the apprenticeship programme,
learnerships, as well as through being accredited by them. Sandvik also participated in various
national initiatives as may be determined by the SETA from time to time. With this partnership,
Sandvik contributes to the sector through a skills development levy (SDL) that is paid every
month towards the National Skills Fund, and this also enables the organization to apply for
mandatory and discretionary grants. The bulk of the SDL that Sandvik recovers acts as a top-up
to the Apprentice Programme budget. Sandvik strives to employ the learners that have
completed the programme, and when this is not possible, the learners are made available to
industry.
Sandvik has the interest and needs of their employees at heart. Sandvik is a member of Seifsa
(Steel and Engineering Industries Federation of South Africa), which is a bargaining council for
employers, and this enables employees and employer to set fair salary and benefit parameters
that will benefit both parties.
Sandvik also partners with various, mining houses, OEMs, and FET colleges to ensure that
training in industry is of a high standard. Not only is this training a business transection, but it is
also a way for the company to act as a responsible corporate citizen by training apprentices
from communities in mining areas that we operate in.
Through organizations such as Swedish Workplace for HIV and AID Programme (SWHAP), a
partnership is formed with some of our competitors to work together to address social issues,
specifically the HIV/AIDS pandemic. The wellbeing of employees, families, and ultimately the
community is sought after.
The Southern African Institute of Mining and Metallurgy
Platinum 2012
933
Healthy employees, which lead to healthy families, which lead to healthy communities, which
translates to a healthy economy to operate in, that leads to economic growth, is the ultimate
goal. Sandvik is committed to contributing to the scarce skills sector of the economy; hence all
training interventions and programmes are focused on the National Skills Fund. With all these
partnerships in place, we can deliver more!
Sandvik Apprentice Programme: success stories and retention rate
It is clear that Sandvik is very proud of the Apprentice Programme. Sandvik apprentices
received the Best Apprentice award in 2008 and 2009 and over 70 merit awards from the
Colliery Training Centre. Further proof of the success of the Sandvik Apprentice Programme is
the 20 ex-apprentices who have been promoted to supervisory and specialist levels14
.
Currently the retention rate of the apprentice programme is 74 per cent. This retention rate is
calculated three years after completion of the programme.
Future actions to close the skills gap
It is clear that this is not enough when considering the attrition rate and industry needs, and it
is crucial that the effort be made to continuously close the skills gap.
Some key recommendations regarding the Apprentice Programme can be summarized in the
following few points:
• Ownership: Ownership of the programme should be with the business and not with
central services. Although the programme is managed and co-ordinated by the human
resources function, the business owns it and must take responsibility and accountability
for the programme
• Teamwork: Industry should train for the industry, and organizations or sectors should
not rob critical skills from one-another. An industry critical skill action plan should be
created where all stakeholders of the industry work together as a team. We now have
to build on this in partnership with the government, industry, and our customers,
through a consolidated needs analysis
• Purpose-driven: The industry should form a partnership with the main purpose of
developing the critical skills needed in South Africa to ensure the successful
implementation of mechanized mining
• Continuous improvement and planning: Benchmarking against global companies is critical
to ensure that the programme is continuously improved and aligned with the latest
technology. Once of the critical areas that the National Planning Commission has
highlighted in order to improve education and training within South Africa emphasizes the
need for a national skills planning system11
. Australia has developed a scheme to monitor
and forecast specific skills shortages in the mining industry, with the aim of developing a
five-year national plan to forecast skills demand and supply for the industry12
. Figure 4
demonstrates a continuous process for improvement of a learning programme. It also
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s
The Southern African Institute of Mining and Metallurgy
Platinum 2012
935
• Chantelle Gouws – Communication: Case Study Interviews.
References
1. Boston Consulting Group. WFPMA Report. http://www.bcg.com
2. Stacey, T.R, Hadjigeorgiou, J., and Potvin Y. Technical skills – a major strategic issue.
Journal of the Southern African Institute of Mining and Metallurgy, vol. 108, 2008. pp.
775-782.
3. Finance 24. SA’s artisan shortage of skills.
http://www.fin24.com/Economy/SAs-artisan-shortage-laid-bare-20110216
4. Miningmx. World swooping on SA miners. 17 Nov. 2005.
http://www.miningmx.com/news/archive/550204.htm
5. Mining Weekly. Skills deficit ‘National Crisis’ 2008.
http://www.miningweekly.co.za/article.php?a_id=131094
6. Goga, S. and Van Der Westhuizen, C. Scarce skills information dissemination: A study of
the SETAs in South Africa. HSRC, commissioned by the Department of Labour, Pretoria,
South Africa, Jan. 2012.
7. Mining Weekly. Lonmin to boost artisanal skills. 19 Apr. 2012.
http://www.miningweekly.com/article/company-announcement-lonmin-to-boost-
artisanal-skills-2012-04-19
8. Haupt, G. An assessment of skills development interventions in South Africa: skills
development through structured qualifications: learnerships and apprenticeships:
apprentices remain undervalued. HSRC Review, vol. 10, no. 1, 2012. pp. 22-23.
9. Chamber of Mines of South Africa. South African Annual Report – Skills Development. The
Chamber, Johannesburg, 2011. pp. 70-75.
10. Mining Weekly. Coal industry still plagued by skills shortage. Mining Weekly, 16 March
2012. http://www.miningweekly.com/article/coal-industry-still-plagued-by-skills-
shortage-2012-03-30
11. National Planning Commission. National Development Plan. Chapter 9. Improving
Education, Training and Innovation. Department of The Presidency. Republic of South
Africa, Pretoria, 2012. pp. 260-294.
The Southern African Institute of Mining and Metallurgy
Platinum 2012
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12. Queensland Government Mining Journal. Heartbeat Project: taking the pulse of the
resources industry 2009. P. 47.
13. Pieters, J. Teamtalk Employee Magazine, 2002 –
14. Sandvik Mining. Market Area EMEA Project: Retention Of Critical Skills. Doorsamy, J., Prinsloo, J.,
Salifu, N., Mubita, R., and Rweikza, D. (eds). Aug. 2012
15. D’Amigo, K. http://comerecommended.com/blog/2011/11/17/employers-6-ways-to-
close-the-skills-gap/ Nov. 17, 2011
The Author
Sunet Marx, BA Mining: Global Talent and Performance Manager, Sandvik
2002 – Current
Various Positions within Sandvik HR
• Global Talent and Performance Manager for Business Area Mining
• Sandvik Academy Manager Region Africa
o Apprentice Programme Project
o Strategic Management for Competence Development
• General Human Resource Management
1988 - 2002
FET Colleges
Senior Lecturer in Mathematics and Science and Supervisory Development