Name of the Project
Struandale engine plant expansion.

Location
Port Elizabeth, Eastern Cape, South Africa.

Client
Ford Motor Company of Southern Africa (FMCSA).

Project Description
FMCSA is expanding the capability and capacity of its operations at the Struandale engine plant as part of a wide-ranging investment in its two South African plants, announced in 2017.

The investment includes the installation of a sophisticated new assembly line for an all-new diesel engine programme that will, most notably, power the new Ford Ranger Raptor when it is launched in 2019. The new diesel engine assembly hall is located in a totally revamped 3 868 m2 section of the Struandale engine plant, and boasts Ford’s latest, state-of-the-art manufacturing processes that guarantee the highest standards of workmanship, product quality and performance.

The new assembly line will produce eight derivatives of the new engines, including the 157 kW/500 Nm bi-turbo unit.

All of the engines will be supplied to Ford’s Silverton assembly plant, in Pretoria, for installation in selected new Ranger and Everest models and the new Ranger Raptor.

The new engine assembly line incorporates a cylinder head subassembly line that will use four fully automated robots for the precise fitment of components, as well as high-pressure leak testing.

There are four more robotic stations on the main assembly line that will apply the special room-temperature vulcanising silicone gaskets, with each operation monitored by integrated camera inspection systems.

Each of the 110 assembly stations along the 312 m line will incorporate error-proofing and traceability, and every engine will be subjected to a cold test at the end of the assembly line to verify operating parameters and pressures of all systems, without physically starting the engine.

This will be followed by a hot test cell to test engine parameters when running, as well as a dynamometer that conducts a range of performance and durability tests on selected engines at predetermined intervals.

Continuing alongside the new engine programme, the existing Duratorq TDCi engine programme will increase its installed capacity from 75 000 units in 2011, to a maximum capacity of up to 130 000 units from the end of 2018.

This engine platform will continue to be offered in the range of vehicles produced at the Silverton plant, as well as in vehicles exported to global customers.

In addition, the Struandale plant’s machining capacity for the Duratorq TDCi programme has increased from the original 220 000 component sets (cylinder head, block and crankshaft), to a peak of up to 280 000 sets, in response to growing demand.

Potential Job Creation
Not stated.

Value
The projects forms part of a wide-ranging, R3-billion investment in FMCSA's two South African plants, announced in 2017.

Duration
Production ramp-up will start in early 2019.

Latest Developments
The Ford Struandale engine plant has started production of the new-generation diesel engines that are set to power the Ford Ranger Raptor and selected Ranger and Everest models that will be launched in the first half of 2019.

The new engine programme will start with low-volume production for the remainder of 2018, ramping up from early 2019. 

Key Contracts and Suppliers
None stated.

On Budget and on Time?
Not stated.

Contact Details for Project Information
FMCSA communications manager Rella Bernardes, tel +2712 842 2296 or email rgiurici@ford.com.