Production of a new Duratorq TDCi diesel engine at Ford Motor Company South Africa’s (FMCSA) Struandale engine plant will herald a new chapter in the facility’s role as a global hub for diesel engines.
Production of the engine in South Africa is part of a R3,4-billion (US$500-million) export investment programme that encompasses extensive upgrades to and expansion of production facilities at FMCSA’s engine plant and Silverton Assembly Plant in Pretoria.
Over the course of the last 24 months, the Struandale plant has undergone a complete overhaul. Among the new developments was the construction of an entirely new assembly hall for the Duratorq TDCi programme, which expands the total floor area to 16 514 m2. In addition, the assembly hall was fitted with the latest, most advanced equipment, systems and processes, and is complemented by a specialised clean-room, state-of-the-art cold and hot-test benches, as well as an all-new dynamometer specifically developed for the production of the high-torque Duratorq TDCi diesel engines. The upgrades to Struandale have expanded both assembly and machining capacities, allowing the plant to lift its annual production capacity to 75 000 engines and 220 000 engine-component kits.
“Employee training has been central to this project. We launched a new training centre last year, and every operator has been through extensive simulation training to ensure that we’re able to deliver engines that meet all quality, cost, and efficiency requirements. Our employees are simply the best,” commented Struandale plant manager Wallace Yearwood.
The Duratorq TDCi engines produced at Struandale will power the next-generation global Ford Ranger pick-up truck. The Ranger will then be assembled at the company’s Silverton plant that, after significant upgrades, now has an expanded annual production capacity of 110 000 vehicles.
“This new diesel engine will help drive our transformation in South Africa, and it is a key reason the all-new Ford Ranger pick-up truck is a class leader in such a globally competitive segment,” said Lewis Booth, Ford executive vice president and chief financial officer. “I am pleased to announce today that this all-new Ford Ranger will be exported from South Africa to 148 markets around the world, solidifying South Africa’s role as a key operation in Ford’s global manufacturing footprint.”
Booth joined employees and key stakeholders at a launch celebration today in South Africa, where he was FMCSA’s group managing director from 1997 to 2000.
“This programme is more than just an engine, it is confirmation that our Struandale engine plant is truly world-class in every respect” said Jeff Nemeth, FMCSA president and CEO. “The remarkable transformation that has taken place is the result of the extraordinary dedication and support of our employees, suppliers and partners.”
The Struandale engine plant is the only Ford facility that shares both component machining and engine assembly for the Duratorq TDCi diesel engine programme supporting the Ford Ranger. The machined components are used for engine kits which are exported to other Ford Ranger assembly plants, and the fully assembled engines will be used in the South African-built Ranger.
