Firing on all cylinders

A business icon in the Eastern Cape community of Port Elizabeth, the Ford engine plant at Struandale has produced 3,3-million engines since 1964 – and is gearing up for increased volumes.

This month, the Struandale Engine Plant assembled its 500 000th Duratorq TDCi turbo-diesel engine since the program was launched in 2011 for the new Ford Ranger, which is built at Ford’s Silverton Assembly Plant in Pretoria and exported to 148 markets in Europe, the Middle East and Africa.

Ford has a long history in Port Elizabeth, having started its operations in the city in 1923. The Struandale Engine Plant has been a cornerstone of Ford’s South African legacy, evolving continuously over the past 53 years to become a regional centre of excellence for the Ranger engine export program.

“Reaching 500 000 Duratorq TDCi engines, and a cumulative 3,3-million engines since 1964, is a fantastic achievement for the Struandale Engine Plant which competes with some of the best Ford plants in the world,” says Ockert Berry, vice president of Operations, Ford Middle East and Africa. “It is one of the Eastern Cape’s top exporters, contributing to the success of the automotive industry and its supplier network in the region.”

Fully assembled 2,2-litre four-cylinder and 3,2-litre five-cylinder Duratorq TDCi engines are supplied to the Silverton Assembly Plant for installation in the locally-built Ford Ranger pick-up and the seven-seater Ford Everest SUV.

Engines are also exported to India and China to support their production of the Ford Everest, along with five-cylinder units being shipped to North America for the Ford Transit. A total of 34 engine derivatives are produced for the various vehicle applications.

Along with its assembly operations, the Struandale Engine Plant also machines components for the Duratorq TDCi engines, comprising the cylinder head, block and crankshaft, which are used for local engine assembly, as well as export to Ford engine plants in Argentina and Thailand. More than 1,3-million component sets have been produced since 2011.

“Due to its unprecedented global success, demand continues to grow, both locally and internationally for the Ford Ranger,” Berry states. “Accordingly, we have invested R3-billion for both product and capacity related actions to accommodate the increasing market volumes for the Ranger in South Africa and our export markets.

“The Struandale Engine Plant already achieved its highest-ever volumes for component machining and engine assembly during 2017, and we expect to set new records again in 2018,” he adds. “The R3-billion investment reaffirms Ford’s ongoing commitment to South Africa as a local manufacturer, exporter and key employer in the automotive sector, supporting a large number of direct jobs as well as indirect employment through our extensive supplier base.”

Additionally, Ford is preparing for the launch of the first-ever Ranger Raptor.

“The Ford Ranger is already one of South Africa’s best-selling vehicles, and we’re exceptionally proud to confirm that this highly anticipated performance model will be assembled in South Africa from 2019,” says Dr Casper Kruger, managing director of Ford Motor Company Sub-Saharan Africa Region.

“This is yet another fantastic achievement for our local team, and signals our ability to produce world-class products of the highest calibre.”

As an exciting new addition to the Ford Performance family, the Ford Ranger Raptor is a purpose-built, desert-racing inspired model that builds on the unrivalled heritage of Ford Performance’s legendary F-150 Raptor, the world’s most extreme production pickup.

Designed and engineered to deliver an adrenaline-pumping driving experience, the Ford Ranger Raptor sports a head-turning exterior look that exudes toughness as well as a level of capability and off-road performance never before seen in this segment.




All to play for

The 2017 South African Cross Country Series is rapidly heading towards its grand finale, with only two of the season’s six events remaining. With three crews in contention for championship glory, it is all to play for at the upcoming Sun City 400, based at the world-renowned resort in the scenic Pilanesberg.

Having scored a well-deserved debut victory last time out at the Harrismith 400, the Ford Neil Woolridge Motorsport (NWM) Puma Lubricants crew of Gareth Woolridge and Boyd Dreyer managed to slash the points deficit to current log leaders Johan and Werner Horn (Malalane Toyota).

Woolridge and Dreyer are now just seven points adrift of the Toyota crew heading into the Sun City round. With that prized first win now in the bag, the Ford NWM young guns are more determined and motivated than ever to score maximum points once again as the tail end of the 2017 campaign looms ever closer.

Lance Woolridge and Ward Huxtable have scored podium finishes on all but the opening round in Lichtenburg, including a win at the Battlefields 400 and second place in Harrismith. This places them third in the championship with a seven-point deficit to Gareth and Boyd – thus making it a nail-biting three-way tussle for ultimate glory.

The third Ford NWM Puma Lubricants pairing of Henk Lategan and Barry White have shown remarkable pace in their first cross country season, although two non-finishes have hampered their challenge this year. Nevertheless, they are fourth in the points log, placed well ahead of far more experienced teams, and remain serious contenders for race victories.

The Ford NWM team heads to Sun City on a high, with the victory in Harrismith followed a couple of weeks later with their second consecutive win at the arduous Rally dos Sertões in Brazil.

With the local crew supporting the X Rally Team on the punishing seven-day 3 300 km event, Cristian Baumgart and co-driver Beco Andreotti took their second win in a row in the NWM-built and prepared Ford Ranger V8. Reinaldo Varela and Gustavo Gugelmin finished second overall in another NWM-built Ford Ranger run by South Racing, with the two Fords beating some of the highly favoured factory X-Raid MINIs – a proud achievement indeed for the Pietermaritzburg-based NWM team.

“It’s been an extremely busy but very rewarding couple of weeks for the NWM team, with our boys finishing one-two in Harrismith and then heading to Brazil for the Rally dos Sertões and achieving a double win plus two of our Rangers topping the podium,” says team principal Neil Woolridge.

“Back at home, the remaining crew has been working tirelessly to prepare all three Ford NWM Puma Lubricants Rangers for Sun City, and we are aiming to score maximum points in the last two rounds.

“The Sun City race has typically been a good one for us, having finished one-two there last year. It’s a really nice event, although the terrain is hard, rough and unforgiving,” Woolridge adds. “There has been good rain in the area so we’re expecting to have to contend with long grass, and the drivers will need to keep the cars on the road to avoid punctures.”

As per last year, there’s a 30 km liaison section between the event headquarters at Sun City and the start of the race close to the village of Tweelaagte. The sprint qualifying session takes place on Friday 15 September from 13:30, with the main race being flagged off at 08:00 on Saturday.

There are two laps of the race route with a compulsory 20-minute service in between. The spectator points are located within easy reach of the Sun City complex, and public entry to these areas is free of charge.

Cross country fans can follow the action live on the RallySafe app for Apple and Android devices. The app can be downloaded free of charge from the relevant app store, and enables enthusiasts to track the cars on a detailed map, download split times and access results.

Source: Colin Mileman

Capacity upgraded

Ford Motor Company of Southern Africa (FMCSA) has invested more than R125-million to upgrade the 3 000-metre vehicle conveyor system at its Silverton Assembly Plant in Pretoria in order to increase its production capacity for the locally-built Ford Ranger and Everest.

The investment forms part of FMCSA’s manufacturing expansion plans to increase the plant’s capacity by 22% from 27 jobs/hour to 33 jobs/hour by January 2018, following the move to a two-vehicle facility last year when the Ford Everest joined the Ford Ranger on the Pretoria assembly line.

The new conveyor system, which began operating earlier this year, optimises the plant’s automated Electro Monorail System Webb conveyor between the body shop and paint shop, improving overall production efficiency by reducing stoppages.

This means fewer delays in production and an increase in the number of vehicles manufactured for the South African market, as well as for export to 148 markets in Europe, the Middle East and Africa.

Andreas Bruditz, area manager for the Body Shop, explained the new system improves the structural capability of the system by significantly reducing and, in some cases, eliminating interruptions between the two production areas.

“The new conveyor is based on similar systems employed at Ford assembly plants in Europe, using proven technology to maximise production efficiency and capacity.”

An additional benefit of the new system is the conveyor decouples the Body Shop from the Paint Shop, which allows one area to continue work should the other have a stoppage. The new conveyor has also created a buffer zone between the two areas, which allows for last minute body-panel adjustments and repairs to be made before the vehicles enter the Paint Shop.