AutoForum Jan-Feb 2011

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JANUARY - FEBRUARY 2011

I N F O R M E D

A N D

I N N O V A T I V E

The vehicle import threat

PAGE 27

NEWS AFRICA

NEWS AFRICA

IN PARTNERSHIP WITH AUSTRALIAN BODYSHOP NEWS

Audi A1 - The Big Small Car INNO V A T IONS

Inside VIRTUAL X-RAY VISION

Trucking - the year ahead Biodiesel hazards Copy parts questioned

RMI CONFERENCE AT AUTOMECHANIKA SA

PAGE 1

Jan / Feb 2011

CONTENTS 6

Cover Stories Audi A1 - The big small car

19

The vehicle import threat

26

Virtual X-ray vision

42

RMI Conference at Automechanika SA

64

Trade Talk Highlights of global and local industry news

14

28

4

News Forum A8 wins the Euro Car Body Award

6

Ford revs up for Puma

8

Benteler seeks new partners

10

New Merc contract good news for SA component suppliers

12

Synovate Initial Quality results good news for the industry

14

Expanded KS range planned for SA

16

Nissan LEAF voted 2011 European Car of the Year

17

Operating lean and mean

18

Thank you to Audi SA for our cover photo.

Editorial

The years seem to all start at a frantic pace, with the holidays just a memory by mid January and the pressures of work and life starting to pile up. So far 2011 appears to be bringing more good news than bad, with a strong currency protecting us from the worst of the oil prices, positive sales figure predictions and some major investments in the motor industry planned for the year. The upcoming Automechanika event in Johannesburg also promises to act not only as a successful meeting place for those in the industry, but will hopefully again set us as a major player in the global domain. So much to do and so little time...

Audi A1 - Downsize, don't downgrade

19

Mitsubishi Motors claims Guinness Worid Record

20

Auto industry critical in reducing fossil fuels dependance

21

Global automotive assembly to exceed 75 million units in 2011

22

GMSA’s PDC a big boost for PE

24

Local industry faces more threats from imports

26

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Kansai to take over Freeworld Coatings

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2010 DuPont Global Automotive Colour Popularity Report released

32

PRODUCTION:

Kaz nel

38

BodyShop News

EDITOR Clare Rutkiewicz

Assistant EDITOR Bridgette Scheelke

CONTRIBUTORS: australian bodyshop news Michel Malik Dave Scott Robert Kaiser ROY COKAYNE Warwick robinson

DESIGNERS:

Marianka els kevin bracegirdle

OPERATIONS MANAGER: SAM GRANEY Email: info@autoforum.co.za PUBLISHER: Swift Publications & Olympic Park Trading Suite 446, Postnet X033, Rivonia 2128

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AutoForum has an ABC circulation of 14 318 ABC (January 2010 to June 2010)

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Advertisers Guide

Innovations 3M Thinsulate hits Europe

38

New lighter, smarter passive dampers

40

Abro ACD/Midas Group

Augmented Reality – Virtual X-ray vision

42

Aer-O-Cure

LA Show design challenge winners

44

Alert Engine Parts Alfa International Auto Maintenance and Repair Autocosmos (Electrolog)

Automechanika

Auto Safety Ford throws doubt onto safety of copy replacement parts

50

Saving lives at the speed of sound

52

Behr Hella Bosch DHL

Ekurhuleni Business Initiative Federal-Mogul First National Battery

Commercial Vehicles Will 2011 be a trucking good year?

54

Biodiesel beware

56

A lack of flap over flaps

58

Showtime RMI Conference not to be missed - Automechanika SA 2011

62

Midas Group – unmissable at Automechanika

64

Automechanika SA update

64

Going big at AMR 2011

66

GMSA Highveld Garage Equipment Hofmann Megaplan Hurricane/Silver Falcon Integrated Marketing Ital Machinery Leaderquip Macs Automotive Midas

MISA Newclear Pressure Testers Parts Incorporated Africa/Midas Group Phoenix Exchange Probe Corporation

Sabat Safeline Brakes

New Releases Latest offerings of local products

68

Snap-on Equipment/John Bean Tuff Floors Turbo Exchange Victor Reinz Wheelquip

After-Marketplace Directory Directory listings

I N N O V A T I V E

23 11 30-31, OBC 51 7 35 42 29 13, 15 5, IBC 57 60-61 9, 49 43 33, 59 47 25 36-37 23 7, 63 39 66 41 58 25 69 19 45 65 21 63

20 16-17 53 67

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While reasonable precautions have been taken to ensure the accuracy of the advice and information given to readers, neither the editor, nor the publishers, can accept any responsibility for any damages, injury or loss which may arise there from. The opinions expressed by contributors to this magazine are not necessarily shared by the editor or the publishers.

Trade Talk

AutoForum - Jan / Feb 2011

www.AutoForum.co.za

GM hits 2 million sales in China Following record October sales last year, General Motors became the first global automaker to sell two million vehicles in China in a single year.

“This is another important milestone for General Motors in China,” said Kevin Wale, President and Managing Director of the GM China Group. “It was only three years ago that GM became the first global automaker to reach the 1 million annual sales mark in China.”

Wale added: “Over the past decade, China’s vehicle market has experienced unprecedented growth. GM has grown with it, working with our joint ventures to expand our lineup of vehicles and brands, adding to our portfolio of services, and increasing our production capacity to meet the changing needs of consumers nationwide.”

And the (Green) winner is...

The 2011 Chevrolet Volt electric car with extended-range capability was recently named Green Car Journal’s Green Car of the Year - the first electric vehicle to win the award.

“This has been a long time coming,” said Ron Cogan, Editor of Green Car Journal and GreenCar.com. “The electric vehicles that were test marketed in the 1990s tantalised us, but were without a solid business case. What a difference a decade makes.”

The Volt runs purely on electricity for 25 to 50 miles (around 40–80 km) on a single charge before a 1.4-litre petrol engine/generator seamlessly engages to create electricity to drive the wheels for an additional 300 miles (around 483 km) on a full tank of fuel. The Volt’s extended-range capability addresses the range anxiety concerns associated with battery-only electric vehicles.

Other finalists for Green Car honours were: the Ford Fiesta, Hyundai Sonata Hybrid, Lincoln MKZ Hybrid, and Nissan LEAF. The Green Car of the Year jury was comprised of six environmental and automotive experts along with Green Car Journal editors.

The Chevrolet Tahoe 2-Mode Hybrid is a previous winner of the Green Car award.

Ford shifts Focus to electric Ford Motor Company in the US has announced the first markets that will receive its first all-electric, zero CO2-emissions passenger car – the Focus Electric.

The Focus Electric will offer a similar driving experience to the petrol powered version, but will be powered by a 23 kWh lithium-ion battery. The system will also employ a liquid heating and cooling system to maximise both battery life and driving range. The Focus Electric will be available in late 2011.

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AutoForum - Jan / Feb 2011

VWSA’s contact centre ranked #1

Volkswagen Group South Africa’s Customer Interaction Centre (CIC) was awarded Gold for Call Centre Best Practice (50-249 seats) at the Contact Centre World Awards held last November.

The awards were hosted by Contact Centre World, the Global Association for best practices and networking in the contact centre industry, and were attended by industry leaders from 30 countries.

The awards were presented based on votes from the audience of around 250 of the global industry’s top performers, based on the content and relevance of a presentation that covered company history, call centre operations, strategy, staffing/HR, training, rewards and recognition, technology and future planning and strategy.

Commenting on the win, Marius Swanepoel, Call Centre Manager, Volkswagen South Africa said: “I am so pleased that the CIC has scooped the Gold award for Call Centre Best Practice (50-249 seats) at the Contact Centre World Awards held in Las Vegas on 5 November.”

This in itself is such huge recognition. This is a fantastic accolade for the Volkswagen Group South Africa CIC and its people, without whom this award would not have been possible.”

He added; “To win this category on regional, national and international level (twice - first in the UK in the Europe, Middle East & Africa region) is an exceptional achievement in its own right. It also serves as recognition for the tremendous amount of hard work, innovation and progress in the CIC since the reengineering back in 2004.”

A8 wins the Euro Car Body Award

T

he Audi brand certainly seems to have come up trumps in 2010, with two awards received in the last few months of last year.

The Audi A8 late last year scooped top honours at the 12th International Car-Body Benchmarking Conference, walking away with the Euro Car Body Award – the prized acknowledgement for innovation excellence in body manufacturing. Over 500 experts and a jury of specialists gave top scores to Audi’s top-of-the-range model.

The world’s best body-manufacturing experts convene annually in Bad Nauheim, Germany, to discuss trends as well as scrutinise numerous body shells and series-production vehicles prior to the conference highlight selecting the world’s most innovative series-built body. In late 2010, 520 specialists from 22 countries attended the event, organised by the Automotive Circle International. Along with a jury of specialists, they evaluated 14 of the latest series-production vehicles. The Audi A8 set a new record by earning 41.11 out of a possible 50 points to secure first place with ease.

This luxury-class model impresses thanks in large part to its stiffness/ weight ratio - the relationship between torsional rigidity and the body’s weight. At just 231 kg, the aluminium body is about 40% lighter than a comparable version made of steel. It also weighs nearly 30 kilogrammes less than its predecessor; at the same time, its stiffness/ weight ratio has increased by 20%. One of the particular highlights of

PAGE 6

the vehicle, however, is the use of bionic principles in the Aluminium Space Frame method. Based on the same principles as the bones of a human skeleton, all components combine optimal function with low weight – which sees the model incorporate 13 different grades of aluminium.

In addition to impressive body properties, the Euro Car Body Award recognises pioneering concepts regarding processes, production, and manufacturing as well as the automaker’s know-how concerning materials technology and joining techniques. At its Precision BodyManufacturing Shop in Neckarsulm, Audi uses various mechanical and thermal joining techniques: 1 847 punch rivets, 632 self-tapping screws, 202 spot welds, 25 MIG welds, six metres (19.69 ft) of laser welds, and 44 metres (144.36 ft) of bonded seams ensure that the body is a highly functional unit.

Of course, safety and other so called ‘first-hand customer benefits’ are also key criteria in the evaluation process. The model has achieved impressive crash-test results, and boasts excellent aerodynamic and acoustic properties.

The sought-after award was won by an earlier generation of the Audi A8 as long ago as 2003. Ingolstadt also took the trophy in 2006 and 2008 – first for the Audi TT and then for the Audi Q5. This fourth triumph makes Audi one of this field’s trailblazing manufacturers.

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NEWS FORUM

AutoForum - Jan / Feb 2011

Second-hand market slowdown According to TransUnion Auto Information Solutions’ latest Vehicle Pricing Index (VPI), used vehicle prices dropped in the last quarter of 2010, despite new car prices increasing slightly during the same period. At the same time, used car sales slowed while new car sales continued their upward trend.

Mike von Höne, CEO of TransUnion Auto Information Solutions, credited this increase in new vehicle price inflation partly to nominal annual vehicle price increases, but more significantly, to the impact of the CO2 emission tax that came into effect in the previous quarter (Q3).

“While this was the first significant upward shift in new car pricing in the past 18 months, TransUnion Auto does not expect this trend to continue into 2011,” von Höne said.

“The change in new car pricing came on the back of very high new vehicle price adjustments during 2009. This provided sufficient cushioning for manufacturers to keep new vehicle price increases to a minimum through 2010 – and there is little to suggest that this will change in the foreseeable future.”

Due to the need to maintain a price differential between new and used cars, coupled with an increase in used stock levels, TransUnion predicts that used vehicle prices will decline even further this year.

This should, however, be offset by growing consumer interest in these models, which will create a competitive environment for used car dealers to trade in.

Ford revs up for Puma

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ast November saw the Ford Struandale Engine Plant play host to United States Ambassador, Donald H Gips, during a visit to Port Elizabeth, as part of his efforts to strengthen economic ties between South Africa and the US. The US Ambassador and Bill Lehmberg, Economic Officer at the US Consulate General in Cape Town, visited the engine plant to witness how the facility was gearing up for the production of the new-generation Puma diesel engine. Over R3 billion is being invested in Ford’s Struandale Engine Plant for the Puma engine, as well as in its Silverton Assembly Plant in Pretoria for the production of the new-generation Ranger compact pick-up.

The projects kick off later this year, with the majority of capacity intended for export.

“Ford has made an important investment in South Africa, and as my role is to promote more investment and trade between our two countries, I wanted to see the progress first hand,” Ambassador Gips stated.

He went on to congratulate the plant on the effort they put into winning the global Puma engine contract, which it was awarded over a number of other top-ranked plants around the world. The plant is the sole Global Puma source of machined components for the new generation Ranger, and shares the engine assembly volume for the Puma programme.

“It’s clear that it took a remarkable effort and commitment to win the Puma contract for the Struandale Engine Plant and, importantly, this has guaranteed Ford’s future in this region,” Ambassador Gips said. “It really is a win-win situation for South Africa and the US that Ford is able to produce the engine and components here and, in doing so, create jobs and become a true global player.”

en Polo

g Volkswa

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From April, the Puma engine programme will see the Struandale plant producing 220 000 component sets (engine head, block and crankshaft) annually. Seventy-five thousand of these will earmarked for the assembly of complete engines for shipping to Silverton for the new Ranger, beginning in June 2011.

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NEWS FORUM

AutoForum - Jan / Feb 2011

Benteler located in the industrial zone Rumburk

Benteler seeks new partners

M

ultinational automotive component supplier Benteler - which created about 250 jobs through a R178m investment in a new plant in Uitenhage to supply components to Volkswagen South Africa (VWSA) now has its sights on doing business with other motor manufacturers in the country.

Benteler is seeking to take advantage of the new local content requirements in the Automotive Production and Development Programme (APDP) to secure supply contracts from other manufacturers. Hubertus Benteler, Chairman of the Benteler Group, confirmed at the official opening of its plant in the Nelson Mandela Bay Logistics Park last year that 40% of the space in the plant was still available and had been “built for the future”.

He said the trend the group saw globally was that it did not make sense long-term to ship parts to plants in other countries, and it was interested in new products it could build for other manufacturers. According to Benteler, motor manufacturers in SA need to

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increase their local content by 2013 and he expressed confidence it would get new business from other original equipment manufacturers within the next two and a half to three years, to fulfil their local content requirements.

He continued that the plant in SA was its 68th in the world while its 69th and 70th plants were currently being built in China and India, and that the decision to invest here was made in April 2010 when the global economic crisis was at its deepest point and Benteler had lost 30% of its sales. VWSA Group Managing Director, David Powels, said the company had achieved a local content of 74% on the new VW Polo and 72% on the VW Vivo, which had been made possible by an investment of a total of R600m by five suppliers, including Benteler, Faurecia, Grupo Antolin, Rehau and Flex Tech in SA, creating about 700 highly skilled permanent jobs.

He said 77% of the local parts supplied to VWSA were sourced from suppliers from the Nelson Mandela Bay Metro and was creating sustainable employment there. But Powels stressed that

- By Roy Cokayne

other motor manufacturers now had to also use the capacity and competence created by Benteler and other suppliers. Powels believes SA motor manufacturers will never get to 100% local content because components such as gearboxes and crankshafts were not produced locally, but the next step is to use existing first tier suppliers to get second and third tier suppliers to reduce their imports.

He said VWSA’s next step was to increase local content in its locally produced models to 80%, but admitted this was a stretch target that would not be easy and would take between five and 10 years to achieve. “The next 10% local content is incrementally more difficult and involves much more significant investments and more marginal paybacks. It is investment intensive and also volume sensitive.”

Benteler said it did not import anything and sourced steel locally to manufacture its products, which include dashboard carrier panels and body parts, front and rear bumpers and chassis parts.

Roy Cokayne is the Transport Editor at Business Report, the Independent Newspaper Group’s daily finance and business supplement.

NEWS FORUM

AutoForum - Jan / Feb 2011

New Merc contract good news for SA component suppliers - By Roy Cokayne

A

utomotive component suppliers are set to benefit from a new contract awarded to Mercedes-Benz South Africa (MBSA) to produce the next generation C-Class. MBSA will increase local content in the C-Class to 40%, up from 35% currently, and hopes to attract new component suppliers to invest in SA. Wolfgang Bernhard, Daimler AG Board of Management Member, Manufacturing and Procurement Mercedes-Benz cars and vans, said the contract award was expected to attract more investors and new suppliers, which would strengthen the entire SA automotive value chain.

MBSA’s CE, Hansgeorg Niefer, confirmed discussions had already taken place with suppliers interested in investing in SA, and they had been handed over to the Department of Trade and Industry for discussions on supplier support. The contract award will result in an estimated R2bn investment in MBSA’s manufacturing plant in East London, which will increase its annual

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production capacity from 52 000 units on two shifts to 65 000 units on three shifts, and potentially create an additional 1 500 to 2 000 jobs.

Increased production volumes will also mean a demand for high volumes from MBSA’s suppliers.

Local content will increase to 40% and potentially 1 500 to 2 000 jobs are expected to be created by the deal MBSA’s East London plant will be one of four plants globally to produce the next generation Mercedes-Benz C-Class model, the most popular model within the Mercedes-Benz passenger car range, scheduled for launch in 2014.

Bernhard said the East London plant would join Daimler AG’s global production network with its plant in Bremen in Germany, the centre of competence for the C-Class. Its other plants that will produce the model are in Beijing in China and Tuscaloosa in the US.

He said Daimler AG had invested more than R5bn in SA over the past 10 years and the further investment provided for extensive skills development and training locally and in Germany; new equipment; and the introduction of the latest technology. “More than a dozen new technologies will come to SA in the production processes.” MBSA’s future export programme includes building both left and right-hand drive C-Class models for export to markets in Africa and the Asia Pacific region.

According to Bernhard, the decision to award the contract to MBSA was logical and based on solid facts in terms of quality and economics. He said the East London plant had been recognised repeatedly for its excellent production quality by JD Power and Associates and is one of the best manufacturing plants in the industry. MBSA had also managed to provide Daimler AG with a business and production plan that was competitive globally, he said.

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NEWS FORUM

Synovate Initial Quality results good news for the industry

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he results of the 2010 Synovate Quality Awards survey were released late last year and once again ranked automakers according to customer’s initial vehicle ownership experience.

The Synovate PP100 report measures the number of problems experienced in the first 90 days that a customer owns a new vehicle, and in this latest survey, Toyota and Mercedes-Benz emerged as frontrunners.

The study is the largest survey of its kind in SA and forms part of Synovate’s Syndicated Automotive Research – a study into the quality of sales and service transactions as well as product quality – and collects the views of an average 55 000 South African vehicle consumers annually.

The process works like this: respondents are interviewed three months after purchasing their vehicles to ascertain which, if any, problems have been encountered during the first few months of ownership.

The vehicle scores are then calculated and represented as problems per 100 vehicles. As Andries Lombaard, Client Services Director at Synovate, explains: “A lower score equates to a better result in Synovate’s PP100 study.

Mercedes-Benz’s best score (for the A-Class) is at an incredibly low 14 PP100 – meaning that out of 10 vehicles of this model, at least 8 are completely problem-free, even from the smallest squeak or rattle.”

Overall, the 2010 survey shows that the vehicle market performed very well and indicates that problems per 100 vehicles have declined from 2009 – down from 93 problems per 100 vehicles in the previous year, to 81 problems per 100 vehicles in the latest report. Lombaard continues: “The industry average has been consistently improving over the years and the manufacturers are reaching a standard that has never been seen before. This rate of improvement is going to be difficult to sustain, but based on past performance, vehicle owners are very likely to continue to benefit from fewer and fewer quality problems.”

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Synovate’s latest study only awarded those who claimed the top position in their segments. Those who made the grade were rewarded with a Gold award to celebrate and highlight the achievements of the overall winner in each segment. “It is a closely contested competition,” says Lombaard, “and there is no doubt that all of the manufacturers have, over the last few years, created an incredibly high industry standard. There are still those who stand out and excel in their segments and so should be recognised as top in their class.”

Mercedes-Benz and Toyota won six and 13 awards respectively. The best performing segments for passenger vehicles include Top Executive, Medium and Sports Coupe.

“These segments are typically highly technical segments with a lot of features. It’s really no small feat to reach such a low PP100 score for such high-spec vehicles”, Lombaard explains.

“These cars are typically made for enthusiasts who are also very discerning and quick to identify any problems.”

“Looking across the segments squeaks and rattles are by far the most common problem, followed by issues with electronically operated

items,” Lombaard points out. “This is compared to a low count of mechanical and performance problems. What this means is that vehicles are very reliable from a mechanical point of view and that other issues that do not necessarily impact on the basic reliability of vehicles are becoming more important to consumers.”

Segment Awards 2010 Passenger Vehicle Segments: Gold Awards SEGMENT

GOLD AWARD

SCORE

Entry

Toyota Yaris T1

41

Small Hatch

Toyota Yaris T3

45

Small Sedan

Toyota Corolla 140i

47

Toyota Yaris Sedan

49

Chevrolet Aveo Sedan

50

Top Hatch

Mercedes-Benz A-Class

14

Top Sedan

Toyota Corolla >140

79

Medium

Volvo S40

25

Top Executive

Mercedes-Benz E-Class

38

Sports Coupé

BMW 1-Series Coupé / Cabriolet

50

MPV / Station Wagon Mercedes-Benz B-Class

Light Commercial Vehicle Segments: Gold Awards SEGMENT

GOLD AWARD

SCORE

Three Quarter Ton

Chevrolet Corsa Utility

50

Petrol Single Cab

Toyota Hilux

48

Diesel Single Cab

Toyota Hilux

76

Petrol Double Cab

Toyota Hilux

52

Diesel Double Cab

Toyota Hilux

78

Category Awards 2010 Passenger Vehicles Best local plant manufacturing passenger vehicles

Mercedes-Benz 51

Best luxury passenger car brand overall

Mercedes-Benz 46

Best volume passenger car brand overall

Toyota

62

Peugeot

63

Petrol double cab

Toyota Hilux

52

Diesel double cab

Toyota Hilux

78

Light Commercial Vehicles 42

Recreational Vehicle Segments: Gold Awards

Best one ton single cab light commercial vehicle overall

Toyota

69

Best one ton double cab light commercial vehicle overall

Toyota

72 69

SEGMENT

GOLD AWARD

SCORE

BMW X3

37

Best local plant manufacturing light commercial vehicles

Toyota

Small RV Large RV

Mercedes-Benz M-Class

35

Best overall light commercial vehicle brand

Chevrolet 50

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NEWS FORUM

AutoForum - Jan / Feb 2011

Expanded KS range planned for SA

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AP agencies, local suppliers of MS and KS products, recently hosted a visiting delegation from MSI. Manja Hies, President of KS China, and Udo Messer, Supplier Development Manager, were on a visit to South Africa to explore the market. A wide range of KS components is already on offer, but the current local strategy is focused on their piston range, before expanding their local offering and footprint. “The additional lines, soon to be made available, are mainly aimed at completing the passenger market and keeping the brand competitive and relevant to specific local needs,” says Tammy Minnie from GAP. “The idea is that we are limiting the local range to make certain that the quality, and level of service to this market meets KS’s German head office standards,” explained Manja, adding that KS had selected Chinese production facilities based on price, flexibility and an ability to meet the German head

ALL ALL ALL

office’s high expectations. Her role as head of KS China is aimed at adding value to the lines, producing in China at high quality standards to service the world market and customer needs by including technical supervision from the head office.

Udo Messer added how satisfied he is with the products being supplied to the SA market: “This is as a result of the continuous support and information sharing between the German and MSC operations, from intellectual property down to servicing of the various markets. At the end of the day it comes down to a mutual

Ken Pell, Tammy Minnie, Manja Hies and Udo Messer, bringing exacting German standards to the local market

responsibility between the manufacturer and local distributor, and we are here to support our customers in South Africa.”

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HEAVY DUTY VEHICLES

Nissan LEAF voted 2011 European Car of the Year

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efore deliveries of the all-electric Nissan LEAF even began in Europe, the game-changing vehicle charged into the history books by becoming the first electric vehicles to scoop the European Car of the Year title.

As the world’s first global mass-marketed, zero-emission and affordable vehicle, the LEAF managed to beat 40 other entrants to take home one of the world’s most important motoring accolades.

“The jury acknowledged today that the Nissan LEAF is a breakthrough for electric cars. Nissan LEAF is the first EV that can match conventional cars in many respects,” said Hakan Matson, President of the Jury, Car of the Year.

Nissan Motor Co. Ltd.’s President and CEO, Carlos Ghosn commented: “This award recognises the pioneering zeroemission Nissan LEAF as competitive to conventional cars in terms of safety, performance, spaciousness and handling. It also reflects Nissan’s standing as an innovative and exciting brand with a clear vision of the future of transportation, which we call sustainable mobility.

With three other electric vehicles in the pipeline from Nissan - and with the imminent market introduction of four additional electric vehicles from our Alliance partner Renault - Nissan LEAF represents a significant first step toward a zero-emission future.”

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NEWS FORUM

AutoForum - Jan / Feb 2011

New EPA study: CO2 down, fuel economy up For the sixth consecutive year, the US Environmental Protection Agency (EPA) has reported a decrease in average carbon dioxide (CO2) emissions and a slight increase in the average fuel efficiency for new cars and light-duty trucks in that country.

The latest report from the organisation, entitled: ‘Light-Duty Automotive Technology, Carbon Dioxide Emissions, and Fuel Economy Trends: 1975 through 2010’, projects a small improvement in 2010, based on pre-model year sales estimates provided by automakers, to 395 g of CO2 per mile though there is uncertainty in these projections as they were made during the atypical automotive market in 2009. The 2010 final data will be available in the next report.

For 2009, the last year for which the EPA has final data from automakers, the average CO2 emissions from new vehicles were 397 g per mile and the average fuel economy value was 22.4 mpg.

The report confirms that average CO2 emissions have decreased and fuel economy has increased each year beginning in 2005. The positive trend beginning in that year reverses a long period of increasing CO2 emissions and decreasing fuel economy from 1987 through to 2004.

The CO2 emissions and fuel economy values reflect the EPA’s best estimates of real world CO2 emissions and fuel economy performance, and are consistent with the fuel economy estimates that the EPA provides on new vehicle window stickers and in the fuel economy guide in the US.

Operating lean and mean

P

ost-recession, most companies have adopted principles of doing more with less. A recent study in German trade journal ‘Automobil Produktion’ has shown how Audi AG has managed to further optimise its production processes, resulting in the automaker receiving top honours in the 2010 Automotive Lean Production Award.

Audi won last year’s award in the ‘Manufacturer’ category for its A3 assembly line. This time however, the automaker managed to distinguish itself further by, for the first time, winning for an entire car production facility and not just an individual production sector. The winning facility is the Audi A4, A5 and Q5 site at the Ingolstadt production plant. “We use our employees’ creative ideas when designing and realising our production system. The continuous process of improvement at Audi succeeds thanks to each and every employee’s initiative and commitment,” emphasised Peter Kössler, in charge of managing the plant at the Ingolstadt. “Winning the Automotive Lean Production Award once again provides recognition for our team.”

Audi runs staff workshops close to production lines where employees independently and promptly implement ideas that enhance ergonomics or allow the avoidance of errors. Just one such idea that has been put into practice is a bolt dispenser; by automatically supplying an employee with the precise number of bolts required to complete a given task, time is saved and errors minimised.

“Often, it is many small steps which together enable a giant leap to be made,” explains Gerhard Schneider, Head of A4/A5/Q5 Production in Ingolstadt. “The bolt dispenser is a good example of our lean philosophy: we avoid waste.”

A further example is using ‘supermarkets’, which are located near the assembly line, where a basket of necessary ‘goods’ is assembled in advance and then delivered to the line at just the right time. This considerably reduces the complexity of line operations.

Ergonomics also forms an important pillar of the Ingolstadt facility’s lean production principles. As Kössler explains: “Efficiency is boosted if employees are given ideal conditions to work in.”

One such example is the use of an ergonomic assembly seat by an employee installing head airbags. The special seat allows the employee to ‘glide’ into the vehicle’s interior. Handling devices also assist employees during physically demanding procedures, such as the installation of batteries, which can weigh up to 30 kg.

PAGE 18

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Answering the call for a downsized yet upscale subcompact, the A1 offers a range of turbocharged petrol and diesel engines that offers best-in-class standards in terms of fuel consumption, CO2 emissions and maintenance plans. In fact, four of the six A1 variants are exempt of the CO2 tax.

All models in the range feature ESP with electronic limited slip differential as standard, adding to the car’s exceptional handling abilities. Also standard across the range is a start-stop system and recuperation system that recovers energy usually lost during braking, further enhancing the A1’s efficiency credentials.

The A1 is highly customisable, allowing buyers to create a genuinely individualised vehicle. The car’s roof arches are available in a choice of contrasting colours, so expect to see some head turning combinations on our roads in the coming months.

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NEWS FORUM

AutoForum - Jan / Feb 2011

Mitsubishi Motors North America and creative agency 180 LA accept the Guinness World Record title for longest distance driven by an online-remote controlled vehicle in 24 hours

Mitsubishi Motors claims Guinness World Record

M

itsubishi Motors of North America has just earned itself a place in the Guinness Book of World Records, for the furthest distance driven by an online controlled vehicle in 24 hours – 91 miles (146 km).

The Outlander Sport Live Drive Campaign, which concluded last November, provided virtual test drives to nearly 5 000 consumers giving drivers an unprecedented interactive experience to remotely test drive a real 2011 Outlander Sport from the comfort of their own home using the keyboard on their computer and an Internet connection.

In addition to the world record, over an 11-day period that spanned from November 1 to 11, the groundbreaking project encompassed: over 40 000 registrants; nearly 5 000 drivers from

PAGE 20

all 50 US states who test drove the vehicle; 38 people who spent their entire online drive doing doughnuts; and 11 participants who chose to enjoy their entire drive in reverse. “With almost 5 000 test drives, this programme has gained wide acceptance from our dealer body, consumers, and the general public, not only improving brand awareness, but also driving consumer traffic,” noted Gregory Adams, Vice President Marketing for MMNA. The project concept was created and led by US advertising agency 180 LA and included interactive partners B-Reel, and world-renowned robotics expert and automotive engineer, Dr James Brighton (a frequent guest on Mythbusters and Top Gear). Once in the

“driver’s seat”, participants were able to steer and brake the car in real-time with only their computer keyboard, while taking in the live-streaming view out the front windshield. The whole experience was enhanced by audio of the Outlander’s revving engine or consumer-selected music tracks. To ensure that drivers didn’t steer the vehicle out of bounds, its whereabouts were constantly tracked using three laser-based GPS systems from Japanese company Topcon.

Auto industry critical in reducing fossil fuels dependance

I

n late 2010, DuPont Chair and CEO Ellen Kullman told a US audience of economic experts that addressing energy security, climate change, and increasing demand for limited natural resources will require smarter, more efficient and sustainable energy solutions. She continued that innovation and collaboration to reduce dependence on fossil fuels will also open up new possibilities for business growth, market opportunity and economic development.

“Demand for energy will continue to grow as world population increases and as more and more people in the world move into the middle class,” Kullman said. “Long before we run out of oil, simple economics, market opportunity, and innovative science - along with other unforeseen factors yet to come - are going to usher in the next energy revolution. In the short-term, a mix of

existing and emerging technologies will be needed.” Kullman noted that conservation and more efficient use of existing fossil fuels are critical factors in the short to medium-term, and then outlined how DuPont aims to advance sciencebased renewable energy solutions, in areas such as photovoltaics, biofuels, fuel-cells, renewably sourced materials, and more.

Kullman specifically pointed to the automotive industry’s critical role in reducing global dependence on fossil fuels through the adoption of sustainable products and systems, advanced drive and fuel-cell technologies, and light-weight materials. “We recognise

that no one company or country is going to solve all our energy needs. The decades ahead are going to be a time of tremendous innovation to address human needs in a sustainable way.

Reducing dependence on fossil fuels will be one of our most important global challenges. Success will involve multiple technologies, coupled with innovation and collaboration across companies, borders and sectors.”

PAGE 21

AutoForum - Jan / Feb 2011

NEWS FORUM

Keeping SA manufacturing standards high DKT Engineering, supplier of specialist jig, fixture and automated production machinery to the local catalytic converter and automotive manufacturing industries was recently awarded ISO 9001:2008 (incorporating design) accreditation.

Based in Port Elizabeth, DKT designs and manufactures complex tools that resemble mini assembly lines, complete with hydraulics, pneumatics and automation.

The company is one of a handful in the Eastern Cape to receive quality accreditation for design.

“If a tool is substandard, the product it is used to make is substandard,” explains DKT Engineering MD, Pieter Erasmus. “And good quality starts at the design phase.”

The accreditation is further proof that worldclass skills are available in the Eastern Cape, and that it is no longer necessary to import all manufacturing equipment.

T EngineerPieter Erasmus, DKDirector ing Managing

China focuses on EV market According to reports in Chinese newspapers, that country’s annual EV production capacity is expected to reach one million units in the next 10 years. With an estimated 70% of Chinese air pollution attributed to cars, the country has set increased use of public transport and moving to cleaner energy as targets to reduce the problem.

Global automotive assembly to exceed 75 million units in 2011

P

Last year, 25 cities began a joint programme backed by that country’s finance, transport and energy and development departments, which is aimed at supporting the EV industry, and which saw $1.28 billion invested over the period.

ricewaterhouseCoopers’ (PwC)s Autofacts announced this month that its 2011 global light vehicle assembly forecasts sees in excess of 75 million units being built this year - a new industry peak. And although some uncertainties persist in various regional economies, the company says the baseline global assembly estimate is reflective of a number of factors including: continued mature market recovery volume in North America, the European Union, and developed Asia-Pacific (Japan, South Korea, and Australia); new organic growth in emerging automotive markets primarily within developing Asia-Pacific (China, India, and ASEAN), South America, and Eastern Europe - which are forecasted to contribute more than 70% of global assembly volume growth from 2010-2015; and increased demand for premium brands. The latter is estimated to increase by 9.2% in 2011 versus a growth rate of 5.9% for non-premium brands.

In the middle of 2010, the Chinese government confirmed that it would assist green vehicle buyers by allowing subsidies on such vehicles in the cities involved in the pilot programme.

Anthony Pratt, Senior Automotive Analyst at Autofacts explains: “Unlike the past, vehicle assembly volumes are increasing due to natural market recovery as opposed to artificial stimulus such as automaker incentives and government intervention. Automakers who took a bitter pill by making difficult decisions to make significant cost reductions throughout their

PAGE 22

QUALITY WORKSHOP EQUIPMENT

organisation are reaping the benefits. This is evident for companies who are achieving profitable growth.”

China remains the number one automotive sales market after surpassing the US in January 2009. In 2011, the forecast expects China’s vehicle assembly volume to reach more than 15 million units, an increase from 14 million units in 2010. However, the growth rate is expected to plateau as the government ends tax incentives for small cars and attempts to suppress asset price bubble concerns. Instead of China’s tremendous sales increase of 31% year-over-year recorded in 2010, Autofacts expects a 20% rise. With gross domestic product (GDP) per capita in China exceeding the $7 500 threshold, when sales tend to surge, Autofacts does not envision the possibility of single-digit growth in the short-term.

Due to booming global demand, premium automotive manufacturers are facing capacity constraints. This is a major concern given that a future China market of 40 million units would double the size of the world premium brand market.

Furthermore, premium brand assembly growth is forecasted to increase by more than 50% by 2017, while nonpremium segments are anticipated to grow by 36% during the same period. This may be counter-intuitive considering the significant growth taking place in low cost segments in emerging markets.

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AutoForum - Jan / Feb 2011

GMSA’s PDC a big boost for PE

I

n November 2010, GMSA opened its new Parts Distribution Centre (PDC) in the Coega Industrial Development Zone outside Port Elizabeth. It’s BIG. Really BIG - the roof covers an area the size of eight soccer pitches and the facility represents an investment of R250 million for the company.

But then it is also needed - according to John Astbury, Aftersales Vice President, the facility should ship around 300 tonnes of parts per month once fully operational.

According to GM, the PDC is designed to their global parts warehousing template and environmental aspects of the building have been carefully considered. Many energy and water saving technologies have been implemented, going as far as replanting of the natural scrub on the surrounding site. With all this futuristic planning one could assume that over-complex systems would run a fully automated warehouse but Neil Langner, Sales and Marketing Manager for Aftersales, stressed the important strategy of keeping the facility as simple as possible.

“The entire operation is designed to function perfectly even in a complete power failure situation,” he explained. ”The strategy was to develop a worldclass warehouse without system-based weak points.” The claimed improvement in average timeframes drops from a current period of five days down to just 24 hours and the warehouse aims to achieve 93% parts availability.

In attendance for the opening were a number of dignitaries including Dep. Minister for Trade and Industry, Ms Thabethe, who congratulated GMSA on its additional investment in education of both employees and their families. Also in attendance were Coega Dev. Corporation’s CEO Pepi Silinga, Craig Uren, COO for Isuzu Trucks South Africa, GMSA President and Managing Director Edgar Lourencon and a special visitor from Japan’s Isuzu Motors Limited Chairman and Representative Director, Mr Yoshinori Ida, officially opened the facility in a ribbon cutting ceremony with John Astbury and Pepi Silinga.

PAGE 24

From left to rig ht: Minister ThabetJohn Astbury, Deputy he, Edgar Lour enco and Pepi Silingan

We caught up with Neil Langner in January to investigate the progress on site.

1. At the opening only a portion of the parts lines were being warehoused in the PDC. What percentage is the facility up to, and when do you foresee full transfer from the old facility?

As of January 2011 we are running 100% of our 5 000 odd lines out of the PDC. The old warehouses need to be cleaned out and handed over for new uses.

2. Are you meeting your targets in terms of parts availability and delivery timelines?

Neil Langner, Sales and Marketing Manager of Aftersales

Our target of 93% availability is still a realistic target, but the migration has obviously had its challenges.

It’s the 7% that makes me lose hair!

However our call centres field problem calls and enable us to prioritise, sometimes having to fly in items from our suppliers.

I am satisfied that customer support is at the right level. In cases where we cannot meet a customer’s needs we will make every effort not to affect their mobility, in some cases going as far as providing rental cars.

3. What are the challenges from an overall viewpoint with regards parts warehousing and distribution?

As an OE we experience the dilemma of having to communicate and deal with the trade and consumer sides of the market. While the trade are the customer interface, the GM brand will still be the party identified as accountable for any part or supply issues.

I believe that negative media coverage on the subject has been biased.

With a better understanding of the value of genuine OE and aftermarket parts permeating the market, in conjunction with the CPA, this is being addressed. The reality is that these parts will naturally come at a premium directly related to higher

quality specifications and the logistical support that delivers peace of mind to the consumer. This massive investment from GMSA shows a commitment to enabling better service levels, adding value to the customer experience.

4. What does the investment mean to Coega and to the local area in general?

This investment gives Coega relevance and credibility. While not the first tenant, we are one of the anchor tenants in the zone, and GMSA would be viewed as a reference to prospective customers – the facility is practically a showcase for Coega.

This initiative is the first step towards PE’s future.

Twenty years from now people will appreciate the foresight of setting up new opportunities not only for the city but the entire region as a whole.

We now have a port that can accommodate large vessels, which allows Coega to aspire to becoming an international container depot, and opens PE as a portal into the entire sub-Saharan region. I really believe that the investment will be vindicated, and we are proud to be a part of its future success.

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NEWS FORUM

AutoForum - Jan / Feb 2011

Porsche invests $200m in development centre Porsche will soon begin extensive upgrades to its research and development centre in Weissach, Germany, and expects to spend approximately $200 million in creating a highly advanced wind tunnel, a state-ofthe-art design centre and an electronics integration centre.

Regarding the technology implemented in the new wind tunnel, Wolfgang Durheimer, Porsche AG Board of Management Member for Research and Development explains: “The new system will help us to maintain Porsche’s top position in the fields of aerodynamics and design and to further extend our lead. Outstanding design with optimal aerodynamic efficiency have always been classic Porsche strongholds.”

The system will not only be used for Porsche’s internal developments, but will also be extensively available for the automaker’s customer development. The extensions also mean that formerly scattered buildings and units will be more integrated, allowing more crossflow of information.

“This spatial proximity is a major advantage,” said Durheimer. “The close interaction of our suppliers’ various electrical system/ electronics experts and colleagues from related specialist fields during development will contribute significantly to the success of our work, particularly in the case of electronics, which now play a role in virtually every vehicle component.”

Local industry faces more threats from imports - By Roy Cokayne

T

he local motor manufacturing and automotive component manufacturing industries are facing a threat from fully built up imported vehicles. VWSA Group Managing Director, David Powels, warns that this is evident from the fact that imported Korean models manufactured by Hyundai and Kia have achieved such a high market share, while only one locally manufactured car was on the list of the finalists for the 2011 Car of the Year. “This tells you a bit about the threat to the local manufacturing industry. Volkswagen is working with its suppliers and Benteler and doesn’t want to stop where we are.”

Hyundai and Kia achieved a 20% passenger segment market share last October, as imported cars sales have been boosted by competitive pricing, facilitated by the strength of the Rand.

Powels stressed that a lot of work was required by local motor manufacturers and suppliers to deal with this threat, as well as the importance of attracting further investments by multinational automotive component suppliers in SA - in order to increase local content in locally produced vehicles.

He appealed to all tiers of Government and the Industrial Development Corporation (IDC) to work together to create a platform so companies like Benteler had the confidence to invest in the country. He said without the incentives available to automotive component manufacturers in the new Automotive Production and Development Programme (APDP), VWSA would never have been able to attract and convince these suppliers to invest here.

VWSA exceeded its own target to increase local content in the old VW Polo to 70% and to 68% in the new VW Vivo - and is now aiming at 80% local content in these locally produced models.

Naamsa forecasts that the total local car market will increase from about 326 000 unit sales in the 2010 calendar year to 362 500 units in 2011, and 400 000 in 2012.

lo agen Po VolkswResearch Porsche Centre

PAGE 26

However, it projects that total car imports will increase to 232 500 units in 2011 from 206 000 last year and increase further to 260 000 in 2012. By contrast, total domestically produced local car sales are expected to rise to 130 000 in 2011 from 120 000 last year and to 140 000 in 2012.

NEWS AFRICA

Vehicle repair insight NEWS AFRICA

In association with BodyShop News Asia and Australian BodyShop News

Contents 28

KANSAI TO TAKE OVER FREEWORLD COATINGS

2010 DUPONt GLOBAL AUTOMoTIVE COLOUR 32 POPULARITY REPORT RELEASED

NEWS AFRICA AutoForum - Jan / Feb 2011

NEWS AFRICA

Online finishing education US based GFS, which provides technically advanced equipment solutions for the finishing industry, recently launched an educational resource website, called the Finishing Academy. The ‘academy’ is a place for new painters and spray booth operators to learn the mechanics of how booths work, and the essentials needed to produce perfect paint jobs in a contaminant-free environment. It also serves as a refresher for experienced painters who are keen to brush up their knowledge of contamination control and proper usage of paint booth equipment.

The site offers users three training ‘modules’, entitled ‘Spray Booth Basics’, ‘How to Finish in the Money’, and ‘Building the Perfect Shop’. Visit http://finishingacademy.com to find out more.

Kansai to take over Freeworld Coatings

- By Roy Cokayne

A

n attempted hostile takeover of Freeworld Coatings, the listed automotive coatings and decorative paints company, has become a certainty. This follows Kansai, the Japanese paint manufacturer, announcing its firm intention to make a cash offer to acquire all the issued shares in Freeworld for R12 a share in a transaction valued at R2.4bn, which includes the value of the 27.56% shareholding Kansai has already acquired in Freeworld.

Through a JV with DuPont, Freeworld supplies automotive coatings to several major customers including Toyota, Ford and Mercedes-Benz.

Freeworld claims it and Kansai control about 80% of this market. Kansai is one of the top 10 coatings companies globally, producing coatings for automotive, industrial, marine, protective and decorative applications and employs about 8 000 people at 44 factories in 18 countries.

One bodyshop, 2 500 cars a month BASF Coating’s Glasurit division in Chile has obtained a significant order from RELSA S.A. to supply one of the world’s largest bodyshops, situated in Santiago de Chile.

RELSA S.A. is embarking on an ambitious plan to create the world’s largest bodyshop, which by 2012 will have capacity to refinish up to 2 500 vehicles a month. RELSA S.A. has already constructed a 5 574 m2 workshop that accommodates almost 100 employees and can handle 1 500 vehicles a month.

In order to handle the high volumes in the workshop, RELSA S.A. employs optimal capacity utilisation techniques that ensure vehicles can be pretreated with such accurate timing that no waiting times will accrue in front of the spraybooths.

PAGE 28

Freeworld has to date declined to comment on the offer but in November applied to the Competition Tribunal to set aside a decision by the Competition Commission refusing it permission to notify the commission of a merger separately from Kansai despite the absence then of a formal offer.

The company sought this permission because it and Kansai did not agree on the potential competition effects of the merger, particularly in the automotive paints market. The tribunal reserved judgment in the matter, which will now only be of academic interest.

Kansai said it had received irrevocable undertakings to accept or recommend the offer from certain fund managers representing 42.3% of Freeworld’s issued share capital and 58.4% of the shareholding in Freeworld it does not already own.

Commenting on the competition concerns, Kansai head of corporate strategy Nauman Malik said two-thirds of Freeworld’s portfolio was in decorative paints, in which Kansai is not involved at all, and one third in automotive coatings. Malik said Kansai’s SA presence was “only in a small manner” on the automotive side and Freeworld merely manufactured and distributed automotive coatings on behalf of DuPont, while it would become owners of the automotive technology if the Kansai transaction was approved.

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You are invited to join us in Johannesburg over the period 9 – 12 March 2011 for this important gathering of key automotive industry players. Join us for four days of unprecedented networking and learning opportunities.

Automechanika South Africa will bring together key aftermarket suppliers with thousands of service and repair providers, parts and accessories shop owners, technicians, retailers, wholesalers, distributors and sales agents.

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AutoForum - Jan / Feb 2011

PAGE 30

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BODYSHOP NEWS

AutoForum - Jan / Feb 2011

2010 DuPont Global Automotive Colour Popularity Report released

D

uPont recently issued its 58th Global Automotive Colour Popularity Report, which outlines automotive colour popularity information and regional trends from 11 leading automotive regions of the world - including, for the first time, South Africa.

According to the global automotive coatings leader, silver and black are in tight competition for the title of ‘world’s most popular car colour’. In fact, just two percent separates silver from black as the leading vehicle colour globally (largely attributable to black’s substantial popularity in key automotive markets outside of North America). White and grey tie for third place, with grey’s popularity increasing three percent from last year’s survey. The only non-neutral colour to make it into the top five was red, which grew in popularity and clinched fifth spot globally.

The top 10 global vehicle colours are as follows: 1. Silver - 26% 2. Black/Black Effect - 24% 3. White/White Pearl and Grey - 16% each (tie) 4. Red - 6% 5. Blue - 5% 6. Brown/Beige - 3% 7. Green - 2% 8. Yellow/Gold - 1% 9. Others “Our annual global colour analysis allows DuPont to share insights into

PAGE 32

global colour trends with automakers as they’re planning future vehicle designs,” explains Nancy Lockhart, DuPont Colour Marketing Manager.

“The demand for fresh, high-quality information is more relevant today than ever before, as the industry continues to see increased consumer demand for innovative vehicle design and styling.”

For the very first time, South Africa was included in the annual survey, due to the country’s growing automotive industry.

A perennial favourite, white prevailed as the most popular vehicle colour choice, at 35%, which is the highest percentage of any region covered in the report.

Silver (24%) grabbed second spot, while 14% places black/black effect firmly in third position.

Just three years ago silver was the clear leader in all regions in colour popularity. Since then globalisation in the automotive industry has seen regional preferences increasingly influencing worldwide trends. Now silver, black and white - all neutrals are fighting it out for the top three spots in most regions, with grey also rising in popularity. (Both silver and black/black effect saw a one percent gain in global popularity in 2010, with white remaining flat. Grey, however, increased in popularity by three percent.)

While regional preferences remain for red and blue, both colours dropped three percent in 2010 over 2009. DuPont analysts are also noting a continuing trend towards brown and beige increasing in popularity.

Don’t miss next month’s BodyShop News section, where we will be highlighting DuPont’s annual colour trend show, which highlights the global collaboration of new styling trends and technologies.

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AER-O-NEWS L

shop based in a leading paint and panel udski Autobody Repairers, benchmark the of Cape Town, is one of the Athlone Industrial area ncies of cie effi designed to maximise the turn key operations jointly Ramen Sur Ludski and design team of work flow, by the owner Mr ts, MD of Aer-O-Cure. sammy and Walter Lenaer ted to the pletely upgraded and renova 2 The 2 300 m facility was com s supplied tile h luded a tiled shop floor, wit clients specification and inc se clo ir the

by Aer-O-cure and through

by Aer-O-Cure. Designed comand n ctors, the Aerocure installatio liason with the sub-contra ech hi-t rs aire d in Ludski Autobody Rep missioning process resulte repair shop.

Mr Ludski (left) show experience ing so booth duriwith the installatiome hands on ng the xma n s shutdoowf his sprayn period

er Mark VI area consists of a Car-O-Lin The designated body repair as a pair of ll we -O-Liner Bench Rack, as chassis repair bench, a Car Car-Oand s with integrated scissor lift Car-O-Liner Speed benche measuring system.

Liner Vision X3 electronic orates Prep preparation area incorp A purpose designed Aer-Osystems, ing s, Aer-O-Vac Dry Flatten under floor extraction system tes and set cas ared systems with double Aer-O-Wave overhead Infr s. temperature control system vens were combination spraybooth/o As a first in South Africa, the grated colour inte ch screens incorporating installed with the latest tou ovens and hs, oot s combination of sprayb graphics and animation. Thi high roof er” rint 9 metre Aer-O-Cure “Sp mixing room consists of one aybooth spr re plete standard Aer-O-Cu waterborne model and a com ctrum of spe the se were installed to increa oven. These types of booths rs. aire Rep aired at Ludski Autobody vehicles which can be rep their installation of igned a layout to allow for In addition, Aer-O-Cure des s modern facility Thi te ring feed with droppers. a compressor and comple , concept and tion ova it comes to the latest inn is a shining example when re is proud Cu -OAer nitely leading the market. design. Aer-O-Cure is defi ng their ievi ach in ski Autobody Repairers to partner Mr Ludski and Lud . leading repair shop status

Car-O-Liner Bench rack BR5500 body and chassis alignment bench

Aer-O-Prep area with under floor extraction, Aer-O ac and Aer-O-Wave sy-V stems

Interior of the Aer-O-Cure 9 metre “Sprinter” combination spraybooth oven with complete waterborne system

Aer-O-Cu with tanrek compressors and drye r

ination spraybooths Aer-O-Cure comb egrated and oven, with intm mixing roo

grated s en with inte Touch scnreand colour graphic animatio

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AutoForum - Jan / Feb 2011

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3M Thinsulate hits Europe

D

originally conceived without a hybrid version in mind.

As Abs Master, who heads up the group, explains: “The early-adopters buying these cars expect hybrids to provide an efficient, premium driving experience with superior refinement.

Balancing the weight and performance of the car’s acoustic package is a fine art and requires lightweight materials optimised to manage the higher range of frequencies.”

The pressure to reduce CO2 emissions is making hybrid powertrains more attractive to carmakers and customers alike and crossover from conventional engines to hybrid is becoming more commonplace. Master continues: “Buyers expect premium acoustic quality.

Adding an electric motor generates new higherfrequency noises that require changes to a vehicle’s acoustic package. Instead of adding heavy sound-deadening materials, Japan’s leading hybrid manufacturers have used specially developed grades of Thinsulate as a lightweight and cost-effective solution. We expect 3M’s approach to receive growing interest from European manufacturers.”

Specially developed versions of 3M’s Thinsulate material can absorb the higher frequency sounds produced by hybrid vehicles’ electric motors and transmissions. The material is lightweight and, because it is compact and compressible, packaging and assembly is straightforward. Its makers say that it could be particularly useful for the growing number of European model programmes based on platforms

The use of Thinsulate in cars has been rising steadily in recent years with manufacturers using the specialist material to reduce mass in door panels, headliners, wheel wells, pillars and instrument panels. The material replaces some of the cumbersome mixed-fibre shoddy mats, foams and absorbers, cutting the weight of some acoustic material parts by up to 40% and saving several kilogrammes. “Integrating the material

iversified technology company 3M will in the near future be offering European automakers its lightweight acoustic materials, which are designed to make hybrid vehicles more refined.

Having worked closely with manufacturers on some of the more well known hybrid programmes, including Toyota’s Prius and Auris and the Honda CR-Z, the company plans to apply its expertise to other vehicles via its recently-formed European Automotive Acoustics Group.

Honda worked with 3M’s acoustic experts to ensure the CR-Z hybrid is as refined as it is sporty to drive

PAGE 38

The mesh of fibres in specially developed version’s of 3M’s Thinsulate material absorb the higher frequency sounds produced by hybrid vehicles’ electric motors

into vehicles is straightforward,” says Master. “Thinsulate comes die-cut with slits so that it folds and conforms easily around the contours of the vehicle.”

3M’s Automotive Acoustics Group was created in Europe in 2010 and is a significant global supplier of noise, vibration and harshness (NVH) solutions. “3M’s Automotive Acoustics Group will give vehicle manufacturers and suppliers an opportunity to take a new approach to acoustic management,” concludes Master. “By working together, we can help them deliver a new generation of refined, light-weight vehicles.”

INNOVATIONS

AutoForum - Jan / Feb 2011

New lighter, smarter passive dampers

T

he BWI Group has announced that it has developed a new generation of lightweight smart passive dampers for B, C and D-segment vehicles.

The international braking and chassis systems specialist claims that the application-ready units improve cars’ handling without compromising passengers’ ride comfort and without the need for more expensive, heavier adaptive dampers.

BWI has reduced typical damper weights from 4 kg to 3 kg by using structural plastics instead of metal brackets and spring seats, by varying the wall thickness of the damper tube, and by using hollow piston rods

Efforts to reduce vehicle weights and CO2 emissions are encouraging vehicle dynamics experts to find new ways to maintain the appropriate ratio between sprung and unsprung mass. Reducing the sprung mass without optimising the unsprung weight can compromise a car’s handling and this, together with the international shift towards smaller premium cars, is making it even more crucial to find ways of improving ride and handling more cost-effectively.

By using structural plastics instead of metal brackets and spring seats, varying the wall thickness of the damper tube, and using hollow piston rods, BWI has been able to reduce typical damper weight from 4 kg to 3 kg. The company explains that a saving of 4 kg is possible on a typical C-segment car equipped with front and rear McPherson strut suspension. The addition of smarter valve designs also allows the dampers to deal more effectively with different road conditions, such as potholes and speedbumps and better protect the vehicle structure from large impacts.

PAGE 40

“BWI Group’s next generation of passive dampers is lighter than current units, providing reductions in unsprung mass that improve control, especially during bumps and wheel events,” says Frank Robinson, BWI Group’s Product Line Director for Suspensions. “Our work on valve design has also extended the range of passive dampers’ performance, providing more of the functions associated with adaptive dampers at lower cost and weight. As a result the compromises are fewer: the driver has more control while passengers enjoy greater comfort.”

The smarter valves in BWI’s dampers produce damping curves that allow the suspension to react differently to inputs of different amplitudes and speeds.

On harsh terrain, the valves also help reduce the shocks transmitted to rubber mounts and limit-stops that could otherwise be damaged. BWI’s combination of design expertise and process innovation is driving the company’s work to reduce mass cost-effectively.

Varying the thickness of the damper tube can save 0.25 kg per corner by removing unnecessary material. Near the suspension knuckle, a damper tube’s wall thickness needs to be up to 3 mm to carry bending loads. Higher up, 1.6-1.8 mm is sufficient for closure, spring seat attachment and welding.

Says BWI Group damper module engineering Manager Slawomir Dzierzek: “This approach can be lighter and more cost-effective than using aluminium tubes and, when the damper forms part of a suspension strut, there is further scope for mass optimisation.”

The company is targeting further reductions still – it reports that it is able to produce hollow piston rods with diameters as small 14 mm, and expects modern high strength steels to be considered for structural components in the near future.

PAGE 41

INNOVATIONS

AutoForum - Jan / Feb 2011

Augmented Reality – Virtual X-ray vision

V

olkswagen has announced that it will be placing new emphasis on innovative Augmented Reality technology - the deliberate expansion of the real world using digital projections - in the future of its service personnel training. The implementation of the technology is aimed at training VW teams worldwide to what it describes as “exceptional” standard and to inform them about the development and technical innovations of new vehicle models.

The technology works like this: a video-based positioning programme determines the correct position of an image projector and a viewer in relation to a vehicle. Computer-generated information can then be precisely imbedded into the viewer’s real-world environment via the projector image – all without data goggles.

“Three-dimensional design data is projected onto the surfaces of a production vehicle, in the correct position and in perspective even from different

viewing angles. This creates a kind of ‘virtual X-ray vision’ for the viewer, which enables them to see otherwise hidden components and structures inside the vehicle,” explains Prof.

Jürgen Leohold, Head of Volkswagen Group Research. In addition, it is also possible to superimpose individual components and component designations or to project prepared animations onto the vehicle.

“For the first time, at the Wolfsburg Service Academy, this technology has been applied to the Touareg Hybrid in the first training sessions for importer instructors. The development and functionality of the innovative hybrid technology could be explained with a depth that would not have been possible using conventional means,” commented Michael Horn, Head of Volkswagen After Sales.

The projection-based Augmented Reality system was developed by Volkswagen Group Research together with the VW Service Academy. Not only does the system save time and money, and keep repair technicians at the cutting edge of technology, Augmented Reality will also be applied in Volkswagen’s vehicle development, from production planning right through to marketing.

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AutoForum - Jan / Feb 2011

INNOVATIONS

LA Show design challenge winners

T

he annual, themed Design Challenge - part of the Design Los Angeles Automobile Designers’ Conference that is held during the Los Angeles Auto Show - allows major automotive design studios to showcase their talents and compete against each other, while further exploring new ideas in automotive design. At the same time, it gives designers access to design industry leaders and provides the opportunity to address common industry issues.

Cadillac Aera - Described as ‘art and science’

Smart 454 WWT - Following the brand’s ‘playful and fun’ ideals

PAGE 44

Late last month, the seventh edition of the competition saw a tie for the winning design between the Cadillac Aera and the smart 454 WWT. Both of the vehicles were selected for their comfort, safety and driving performance, a feat that judges felt was pulled off

without sacrificing the styling consumers demand.

The theme for 2010 challenged automotive design studios to envision a four-passenger, 1 000 lb Car (around 453.6 kg). “Deciding this year’s Design Challenge winner was a tremendously difficult decision as the quality of entries has increased throughout the years,” agreed the judges. “This year’s winners – the Cadillac Aera and the smart 454 WWT – offer two very different visions of the 1 000 lb Car, yet are equally as amazing. They are both very expressive of their brand; GM is art and science and smart is playful and fun.”

The Cadillac Aera 2+2 touring coupe makes use of a polyhedral, 3D lattice, mono-formed frame with a flexible pressurised polymer skin to optimise weight, aerodynamics and safety. The smart 454 features a chassis “knit” by high-tech robots out of carbon fibre, optimising flexibility and strength.

Entries were judged by multi-discipline design professionals who selected the winner based upon not only meeting the weight constraint (1 500 lbs. maximum with occupants), but also for the artistic beauty, comfort, uniqueness of design, roadworthiness, sustainability, performance and user-friendliness of the vehicle. All of the entries were described as having delivered imaginative and detailed design stories.

Participating design studios included: General Motors Advanced Design California; Honda Advanced Design Studio, Pasadena, CA; Mercedes-Benz Research and Development Japan: Advanced Design Centre Japan; MAZDA Design Americas; Mercedes-Benz Research & Development North America, Inc.: Advanced Design Centre California; Nissan Design America; Mercedes-Benz Advanced Design Germany; Calty Design Research, Inc.; and Volvo Car Corporation: Monitoring and Concept Centre VMCC.

PAGE 45

ants r e ig r f e r h it w g Wor kin

w gauge, refrigerant flo en se be n condition ca ss through the sight gla

knows ody in the industry It seems that everyb that s nt ra with the refrige exactly how to deal . sis ba ily act with on a da we come into cont e case?

But is that always th

ries of how g number of horror sto There is an increasin the chargh uals are dealing wit workshops and individ case for the ke gas, which may ma ing and disposing of proach. a “back to basics” ap (when last charging refrigerant A few basic tips when ?): hnicians work, sir did you check your tec nt 1. Keep the refrigera

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posed to rigerant near fire, ex 2. Don’t keep the ref rises ure ere the temperat sun or in a space wh (such as a vehicle) ed

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PAGE 46

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PAGE 47

Bosch – Movers, shakers and deal makers

n ilian Hanse

L

B

osch recently promoted three of their automotive division onto the management team within Bosch. Gary Kaiser is now Sales Manager, Johan De Waal is the Customer Supply Chain Service Manager and last, but not least, Lilian Hansen is now Workshop Concepts Manager. We caught up with her to get an understanding of her role within the organisation and their ongoing strategy.

Now that you are heading up the workshop concepts team, what has changed in your role?

I have been responsible for Workshop Concepts for some time, I am now responsible for the overall management of Bosch Service, AutoCrew and Bosch Product Module workshops, as well as the recently launched Bosch Service maintenance policy in terms of both trade and consumer aspects.

This is a big move for you and brings new responsibilities Well, I am proud of the fact that I am one of two women on the management team, and one of the five senior management reporting directly to Ewald Faulstich. I have been within the automotive division for six and a half years, as a product manager and two years ago became senior product manager. I actually studied Mechanical Engineering and worked within the industry

while achieving my degree in Marketing Communications. The position is really multileveled and covers the legal, finance, and business development aspects of managing these brands, as well as consumer relations. The strategy is to ensure growth, set up national deals, and ultimately to deliver business into the workshops within the group.

What does the new position mean in the organisation and to the automotive sector you serve?

To all intents and purposes the position allows me to focus on this specific area of our business. Workshop Concepts are a strategic focus for the Bosch Automotive and this warranted a dedicated team, including Loretta Naidoo and a soon to be appointed extra trainee member, to concentrate on this task. One of the most important early aspects of our work this year will be based on the CPA. As workshops are often run by mechanics, who are not necessarily trained to meet the requirements of the act, we will be upskilling our members to achieve a benchmark of clear and consumer friendly communication guidelines, to protect and better serve consumers in a sector with a history of bad communication and misunderstandings.

What do you see as the biggest challenges you will face?

Locally we are aiming to spread our footprint into all the geographic areas, and maintain a position of leadership in the sector, this on its own is challenging. We will also extend into other African countries, but only after developing a better understanding of the local

challenges for each market – the vehicle parc, cultural and language issues and, of course, the logistics.

And the competitive space in which you trade?

Workshop concepts as a whole have come and gone in the past, and the OEM workshops are still our biggest competitors, with the advantage of being able to bundle their offering in the sales process.

Our maintenance product is aimed at resolving this, but we are competing against the OE’s first contact and the perceived credibility that their vehicle brands carry.

Quick fitters are also expanding their services more and more to get a greater share of the market. The independent workshop owners are both a challenge and an opportunity – their business experience and skill levels are attractive to the Bosch concepts, but their limited knowledge of more modern systems and training are problematic – this, of course, is why they want to become part of the branded concepts.

Internationally we have been keeping a keen eye on developments in their markets, the OEs are setting up their own aftermarket service concepts, those are brand specific and the local parc may not be big enough to support these yet.

Our focus is firmly set on our three concepts that we believe enable the strategic relationship across the various categories within the SA market. We will not lose sight of our flagship brand and the Bosch Service maintenance policy that will set a new benchmark in the industry.

AutoForum - Jan / Feb 2011

Auto Safety TRW launches Belt Drive EPS in Europe Safety system innovator TRW Automotive Holdings recently launched production of its Belt Drive Electrically Powered Steering (EPS) technology for the European market.

The technology will be integrated into Ford’s Focus platform in the region, which includes passenger cars and derivatives such as the Ford C-Max. The technology, which has been available in North America since 2009, is designed to increase fuel efficiency and reduce CO2 emissions, while seamlessly integrating with other electronically controlled Driver Assist Systems such as Lane Departure Warning and Lane Keeping Assist.

The Belt Drive system, also referred to as ‘rack drive’, requires negligible power, except in situations when steering assist is needed. This translates to fuel consumption benefits of 0.3 to 0.4 L/100 km, with a corresponding reduction in CO2 emissions of around 7-8 g/km when compared with hydraulic power steering.

Ford throws doubt onto safety of copy replacement parts

N

ew crash tests conducted by Ford in the US have shown that unauthorised replacement vehicle parts can negatively affect both safety and the cost of repair when an accident occurs.

The automaker’s crash tests, which were carried out at low-speed, proved that a commonly used copy bumper beam absorbs less crash energy than the vehicle’s original bumper beam or a genuine Ford replacement bumper beam. It also discovered that unintended airbag deployments were more likely during low-speed collisions when copy parts were involved due to the fact that copy parts do not transmit the crash pulse as effectively to the crash sensors to indicate when an airbag should be deployed.

Cost-wise, the results were significant; repair estimates show aftermarket copy bumper beams can more than double the repair costs after even a low-speed accident compared to a genuine Ford replacement bumper beam. The repair costs shot up even further when airbags were deployed unnecessarily.

“This should be an eye-opener for all consumers. These tests raise more questions about unintended airbag deployments r in the event of a future crash,” said Paul er superio Original parts offcra sh tests in ce an rm rfo Massie, Ford Powertrain and Collision pe Product Marketing Manager. “They also highlight the dangers of being penny-wise and pound-foolish, as lessexpensive copy parts could lead to much higher repair costs down the road. All drivers should be aware that copy parts can compromise both the safety performance and the long-term repair costs of your vehicle.”

Frank Lubischer, Vice President of Engineering, TRW Steering & Suspension, commented: “As government legislation continues to focus on establishing more stringent CO2 emissions targets, it is clear that the demand for these technologies is set to increase and at TRW we will continue to innovate in a bid to meet - and exceed - the needs of our customers.”

Visual comparisons between vehicles with the genuine part and the aftermarket part were also done after each test was carried out, showing marked differences. “The copy bumper beam had an aftermarket absorber made of polystyrene and an aftermarket isolator. The stacking up of these parts changed the crash characteristics of the entire bumper assembly,” explains Roger Chen, Ford Crash Development Engineer. Additionally, a sled test showed the aftermarket copy bumper beam failed to absorb energy like that of the genuine Ford beam, with deceleration and velocity measurements inconsistent with those of the OEM part. The copy part was crushed almost flat at each end while displaying very little energy absorption, while the original Ford part suffered only slight intrusion on the sides and absorbed more crash energy before rebounding close to its original form.

“A vehicle is required to pass a multitude of crash tests before the vehicle is sold to consumers,” concludes Massie. “In sharp contrast, aftermarket copy parts face no crash test requirements prior to distribution, and have not been proven to work effectively with the rest of the vehicle’s components. Copy parts should be subjected to the same government safety tests as the original parts so consumers can see the true costs that come with using many copy parts.”

PAGE 50

PAGE 51

AUTO SAFETY

AutoForum - Jan / Feb 2011

Telling white lines A recent report compiled by the UK’s Road Safety Markings Association has shown that eight of out ten of the UK’s most dangerous roads have centre line markings so worn that one third is almost non-existent; while half of the lines fall below the minimum specifiable standard.

The association also examined the ten roads that were found to be most improved in terms of safety and noted that seven had undergone targeted road marking treatments, with improvements resulting in cutting fatal and serious crashes by as much as 74%.

With an appalling number of South African road deaths again this past festive season, one can’t help but wonder how many could have been prevented for the price of a pot of paint.

Speed cameras do work

Saving lives at the speed of sound

C

ontinental, a global industry leader in occupant safety, has begun focusing on a new sense for its impact sensor technologies – the sense of sound. The company’s latest passive safety uses Crash Impact Sound Sensing technology that changes the way airbags deploy in frontal collisions. The system uses structure-borne noise as the determining factor, instead of more traditional impact sensors that measure changes in acceleration or air pressure.

Continental estimates that a Crash Impact Sound Sensor can transmit crash severity data to a vehicle’s restraints control module three times faster than an acceleration sensor, which translates to up to 15 milliseconds.

“Our goal is to get as much data about a crash event to a vehicle’s restraints module as quickly as possible so that the airbags and pre-tensioners can be fired with the right force at precisely the right time,” explained Dean McConnell, Head of Business Development for Continental’s North American Passive Safety Active Driver Assistance (PSAD) Business Unit.

“Every millisecond counts when it comes to optimising crash protection.”

While our traffic police are often criticised for focusing almost solely on speed trapping, virtually ignoring moving violations, new research definitively shows that placing speed cameras on roads reduces the number of road traffic injuries and deaths.

He continued: “Just like a seismograph that measures vibrations when layers of the earth move in an earthquake, Crash Impact Sound Sensing measures sound waves. Then the collision is analysed and evaluated within just a few milliseconds using specially developed algorithms and a complex signal analysis, deciding what measures to initiate in order to mitigate the accident’s severity. That’s critical information when it comes to deploying restraint systems. Better information leads to better decisions.”

The findings were made by a team of researchers from The University of Queensland, in Brisbane, Australia, that looked for studies that had assessed the impact of speed cameras on speeding, road crashes, crashes causing injury and fatalities.

Besides giving those involved in an accident the benefit of an extra couple of milliseconds, the technology means that two acceleration sensors could be replaced by one Crash Impact Sound Sensor, reducing cost and complexity. The technology is already in production on a high-volume platform in Europe.

Using the available literature, the team identified 35 relevant studies. “While there is variation in the results, the overall finding is clear – speed cameras do reduce injuries and deaths,” says lead researcher Cecilia Wilson.

Compared with controls, the researches noted that average speed fell as did the percentage of vehicles that exceeded local speed limits. Importantly, the numbers of crashes in the areas of the cameras also fell, as did the numbers of people killed or injured.

“Even though some of the studies were not conducted as carefully as others, the consistency in the way that vehicle speeds, crashes, road traffic injuries and deaths all reduced in places where speed cameras were operating shows that these cameras do a good job,” concludes Wilson.

PAGE 52

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AutoForum - Jan / Feb 2011

Will 2011 be a trucking good year?

- By Dave Scott

US calls for heavy-duty emissions standards The EPA (Environmental Protection Agency) and the NHTSA (National Highway Traffic Safety Administration) in the US are proposing the first national standards for greenhouse gas emissions and fuel efficiency for heavy-duty trucks and buses. The proposed standards would begin in model year 2014.

For combination tractors, the standards would require up to a 20% reduction in CO2 emissions and 20% improvement in fuel efficiency by model year 2018.

For heavy-duty pick-up trucks and vans, there would be separate petrol and diesel truck standards, requiring up to a 10% reduction for petrol vehicles and a 15% reduction for diesel vehicles by MY2018 (12 and 17% accounting for air conditioning leakage). Vocational vehicles would require a 10% reduction in fuel consumption and emissions by MY2018. These standards are projected to reduce GHG emissions by 250 million tons and save 500 million barrels of oil over the lives of the vehicles produced within the first five years.

T

he National Association of Automobile Manufacturers of South Africa (Naamsa) figures illustrate that the South African truck and bus market ended on 22 022 units for 2010 – up 16.31% over 2009. We are starting to get used to the real market after it fell back to earth in 2009.

The truck and bus market actual retail segment volumes for the past five years appear as follows: YEAR

MCV

HCV

XHCV

>8.5 t GVM BUS

TOTAL

2006

14 246

6 694

10 890

1 250

33 080

2007

15 168

7 530

13 095

1 276

37 069

2008

12 130

6 957

14 056

1 516

34 659

2009

7 229

3 839

6 432

1 434

18 934

2010

7 557

4 418

8 496

1 551

22 022

Truck market segment increases for 2010 over 2009 reveal that extraheavies were the stars of the 2010 show. The bus sector flat-lining, as it always has in the past, did not show the vigour expected in a ‘World Cup Year’.

2009 vs 2010 MCV % change

HCV

XHCV

+4.5% +15.1% +32.1%

>8.5 t GVM BUS

TOTAL

+8.2%

+16.31%

In graphic form the recovery from the drama of 2009 looks sustainable with the outlook for 2011 not coming into negative territory: 40000 35000

Scania and MAN to collaborate?

30000

Scania and MAN have, for some time, been carrying out investigations into possibly cooperating on certain projects within the industrial area, mainly related to the commercial vehicles. Such collaboration would make it possible for the two companies to profit from synergies in research and development, manufacturing and sourcing.

At this stage nothing has been confirmed, but watch this space for future announcements and developments.

25000 20000 15000 10000 5000 0 2006 - 2010 truck & bus market actual volume trend 2011 truck & bus market forecast We peer at the 2011 horizon with more hope. We will not go into an extended mid-year holiday-mode for six weeks to watch football and if the truck market grew under 2010 conditions by 16% it will surely grow again.

But things are cooking out there: • The banks are still cautious – the 2009 after-shocks are still being felt in the global economy. First Greece, then Ireland in 2010 and so it goes with everyone having lived well beyond their means and rioting over having to accept fiscal discipline. British VAT is now at 20%!

PAGE 54

Dave Scott is a member of the S.A. Guild of Motoring Journalists, and is a monthly contributor to the press on transport and trucking related subjects. In 2002 and 2003 Dave Scott was the S.A. Guild of Motoring Journalists winner of the category ‘Business Motoring’. As a member of the S.A. Institute of Tribology he takes a keen interest in the application of lubricants to road transport maintenance and the cost of ownership.

His key writing focus is on fleet management including the technology of trucks and road transport.

• As this is written (8 Jan 2011) diesel fuel prices are climbing – it’s now hovering around 90 USD/barrel and one-year forecasts are around $102 US. It’s only our ‘strong’ Rand that saves the day for the present • Cost reduction mode is becoming an entrenched culture in all companies • The godfather deals have ended – the market leaders are out of stock (especially on 6 X 4 models) and do not need to indulge in distress marketing

• The used truck logjam in the 6 X 4 segment continues to grow • ESKOM’s mismanaged price-hike will continue to draw money away from cost centres such as transport.

ESKOM also continues to threaten power shortages – the recent heavy rains in the eastern part of the country are interfering with power supplies • The R400 billion infrastructural spend seems to have run out of

steam. We’ve finished the stadiums that stand as under-utilised monuments to the politicians and FIFA – what now?

Does the extra-heavy truck segment grow another 32% in 2011? Driving past yards of used 6 X 4 models does not inspire confidence for such growth.

But consumerism is on the rise and passenger vehicle sales grew in volume from 258 093 in 2009 to 337 144 units in 2010 – a rise of 30.6% - so truck sales cannot be too far behind. I must agree with industry sentiment that 23 500 will be the new market for mediums, HCV, Extra HCV and heavy buses in 2011.

That would mean growth of around 7% - that’s not too much to ask for, or even over-optimistic.

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This avoids high costs. Victor leading manufacturer of sealing systems – Reinz’s topographic head gaskets can develops and produces high-performance sealing, shielding, and valve cover systems also be used for inductively hardened for engine and drive concepts. The group cylinder heads without problems. is part of the globally positioned Dana For more information contact Intrade tel: 011 432 2667, fax: 011 432 3005 or email: intrade@iafrica.com Dana Sealing Products Group: Under the brand name «Victor Reinz», Dana Sealing Products Group – a

Holding Corporation with 29 000 employees in 26 countries, and headquarters in Toledo, Ohio. Dana acts as a global partner for all major automakers, and is a leading supplier to the automotive industry for drive units, chassis, structural and engine technologies.

PAGE 55

COMMERCIAL VEHICLES

AutoForum - Jan / Feb 2011

Biodiesel beware

A

spate of recent articles on biodiesel promotes the ease with which biodiesel can be manufactured. The problem is that the emphasis is on the ‘ease’ and not the standard to be adhered to (SANS 1935:2004) plus the additional cost of quality control. SANS 1935 does not get a mention in these articles while adherence to SANS 1935 quality standards is the most important aspect of using biodiesel. There are a number of start-up biodiesel plants in South Africa - it sounds like the environmentally friendly product to support. After all, where does all that used cooking oil go if it is not sold as a cheap mixture of carcinogens for the poor to reuse and consume? And according to estimates there are around 10 million litres of used cooking oil in circulation every year. The problem for biodiesel is adherence to standards and the consequences for modern diesel engines.

Another biodiesel problem is that variations in feedstock material for processing can have a significant effect on the processing chemistry – it’s not just a case of pouring any vegetable oil into a tube with a standard outcome while it only becomes viable to test and certify large batches.

The authoritative SAPIA book, Petrol & Diesel in South Africa, states: ‘The cost of biodiesel analysis is very high and technically complex. Analytical facilities in South Africa are limited. It is not feasible for small-scale producers to carry out the analysis due to the high costs involved and a means of overcoming this must be addressed.’ During

PAGE 56

- By Dave Scott

the development of SANS 1935:2004, it became apparent that South Africa does not have the technical and analytical capability to test biofuels.

As a countermeasure to this problem the SABS invested over R2.9 million in test equipment.

Biodiesel (fatty acid methyl esters or fatty acid ethyl ester) is rapidly gaining international acceptance as a blend component to blend levels of up to 5% for on-road use. The requirements of South African biodiesel standards are covered in SANS 1935:2004. Biodiesel quality is assessed against a SANS 1935:2004 (which entails the use of European Standard Methods and methods from the International Standard Organisation ISO) specification consisting of 26 tests. The 26 tests are designed to control the chemical and physical properties of biodiesel and to ensure that it is produced to a uniform standard, performs well in an engine, does not damage it, and does not produce harmful emissions.

Petrol and Diesel in SA goes on to say that: ‘Care needs to be taken to ensure acceptable quality of the manufactured biodiesel (SANS 1935), so that when blended with conventional diesel at up to 5% by volume, the resultant product complies with the national automotive diesel specification (SANS 342) and is therefore fit for use as an on-road

transport fuel.’ How many of these small biodiesel processing plants are not making use of the SABS test equipment or alternatively could afford the R2.9 million and trained staff it needs to operate the test machinery?

Every batch of biodiesel needs to be certified to the relevant SANS specification at the point of manufacture/ blending and whether additives are included or excluded needs to be noted. But this practice should not be confined to biodiesel alone. It applies equally to the supply of standard SANS 342 hydrocarbon diesel. Petrol & Diesel in SA points out: ‘In certain quarters, there is a growing resistance to the use of biodiesel because it tends to have blending and performance characteristics that are not consistent, especially with new ultra-high pressure common rail injection systems and associated emission control devices.’

The point of all this is that if you are operating a modern common-rail diesel powered truck you dare not tank up with diesel of unknown quality. The tendency to offer power-train warranties that include unlimited distances over two years and more does not extend to diesel fuel that cannot match consistent laid down standards. Insist on a batching certificate or fill up at reputable sites. And even then audit your suppliers on a regular basis.

References:

SAPIA – Petrol & Diesel in South Africa.

REPORT ON SABS PETROLEUM LABORATORY CAPABILITY TO TEST BIODIESEL Compiled by Aleesha Sewpersad MARCH 2008.

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AutoForum - Jan / Feb 2011

COMMERCIAL VEHICLES

A lack of flap over flaps

S

ANS 1496 covers the requirements for wheel flaps fitted to motor vehicles and to articulated tractor units of gross vehicle mass or gross combination mass, respectively, exceeding 7.5 t, and to trailers of gross vehicle mass exceeding 3.5 t, for the purpose of providing other road users with some protection against stones, mud or other debris thrown up by the vehicle tyres.

Wheel flap beyond

300 mm

What happens on the ground, however, is vastly different. Fleet audits reveal that wheel flaps are incorrectly mounted, well beyond the maximum specified distance – 300 mm – from the wheel.

To add to the perceived ‘non-role’ for wheel flaps, many are missing or torn and badly maintained. Regulation 217 (1) (a) only requires wheel flaps to be ‘properly maintained’, so not even law enforcers are interested.

Now let’s revert to the position of the THE INTELLIGENT average motoristALTERNATIVE who is in the most

- By Dave Scott

danger of poor visibility that badly placed and maintained wheel flaps can cause. Summer rainfall is currently what motorists and truck drivers across the country have to contend with, and control over wheel spray on a wet road is critical to other road users. We have all faced that situation where we questioned whether we should really attempt to pass a truck that is speeding over the 80 km/h speed limit, especially when the road spray from the drive axle(s) makes forward passing visibility treacherously poor. Not that such fears seem to be a problem for the majority of minibus taxis on our roads - they definitely never hang back and will risk penetrating heavy truck road spray.

But that is the problem with the word ‘wheel flap’ – it does not deal with spray suppression, an issue far more dangerous than the odd stone or mud.

Reference in overseas legislation states that ‘suitable spray suppression equipment should be fitted on each axle.’ That’s the real point of it all – first dampen road spray, with control over mud and road detritus being a side-beneficiary.

Spray suppression requires thought in terms of wheel flap design – it’s much more that a flat piece of heavy-duty rubber. And then everything should work together. Those expensive strips of retro-reflective material referred to in Regulation 192A only work if they can be seen through the spray. A truck passing another can have its rear end totally obscured by spray and invites a rear end shunt from daring motorists.

The truckers’ attitude to spray suppression is that it’s someone else’s problem.

Not so! A collision occurring alongside a 22 m rig bowling along at 100 km/h is bound to involve the truck as well – by default it becomes the trucker’s problem. It’s clear that two things must happen: Road traffic authorities must enforce Regulation 217 (1) (a) & (b) – it’s too simple to ignore. At the same time SABS must revisit SANS 1496 and change terminology to read ‘spray suppression’ and the specifications to give effect to this. The cost of one

road fatality to the economy is over R1 million – surely fixing this issue is not too much to ask?

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PAGE 60

PAGE 61

AutoForum - Jan / Feb 2011

Show Time Tyrexpo Africa 2012 organiser bullish Tyre trade and garage equipment show, Tyrexpo Africa will again be taking place in Johannesburg in March 2012 and the show’s organiser - ECI International - is feeling confident of its success.

“We know that millions of dollars of business was transacted among the record number of exhibitors and visitors who attended the last show in March 2010,” says Paul Farrant, Managing Director of ECI. ECI also predicts that with a stronger global economy forecast for 2012 these impressive figures will be surpassed.

“The aftermarket for tyre equipment and service is increasingly global and extremely mobile,” adds Paul Farrant. “That means that suppliers looking to increase their export penetration will travel the world to assess new markets and establish business relationships. Exhibitions like Tyrexpo Africa are perfect for them as it provides a ready-made opportunity to get under the skin of a market and meet the people who can deliver results for them.”

In addition to the trading attractions of the exhibition hall, ECI will again be staging its popular one-day tyre industry conference during the show. In 2010 this attracted speakers of the calibre of Sir Tom Farmer and Georg Schramm from Dunlop/Apollo, South Africa.

RMI Conference not to be missed - Automechanika SA 2011

T

his year’s Automechanika show is set to be a crucial meeting place for those within our industry yet again, and this year one of the key events will be the RMI Conference on 10 March. With the theme “The Motor Industry; A Global Perspective”, attendees are promised a platform for strategic debate, key new trends in business and critical information on how to survive the market today.

Constantly shifting business imperatives in the automotive industry across the globe mean that the way SA business is conducted must align with what is happening internationally. And with the lag time between what happens elsewhere in the world and its impact on the SA Motor Industry reduced to almost nothing, there is simply no excuse for SA businesses to ignore new trends and developments.

The RMI Conference 2011 promises to keep the organisation’s members up to date on the latest issues confronting the local industry, as well as how to deal with new challenges and at the same time highlight significant business opportunities.

Some highlights of the conference include the following topics: • The inside track on the new Companies Act: Dr Johan Erasmus of well known auditing firm Deloitte will share real inside track information and guidance.

Scenario Planner Clem Sunter briefing the media at the RMI Conference at Automechanika SA 2009

PAGE 62

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SHOW TIME

AutoForum - Jan / Feb 2011

Midas Group – unmissable at Automechanika

T

he Midas Group has announced that it will be making its presence felt at next month’s Automechanika SA. This will mark the first time that the country’s largest independent retailer of automotive replacement parts and accessories will be taking part in the bi-annual trade show, and it intends on making quite an appearance.

The Group’s Auto Care and Diagnostics (ACD) workshop concept will take centre stage, promoting the franchise network to both fleets and other potential workshop customers.

“We see Automechanika SA as the biggest automotive aftermarket event of its kind on the African continent and believe it will provide an ideal opportunity to showcase the Midas products and services to current and potential customers,” explained Marketing and Franchise Director Stefan le Roux.

He continued: “Our sales teams will be able to give advice and information

on the full range of our offerings to the public and the trade. The Midas focus will not be on procurement, but rather on our customers and their wellbeing.”

Le Roux confirmed that besides having a stand to showcase its training opportunities, the Midas Group would also be launching new training concepts to the market at Automechanika.

He added that the company had moved forward its annual regional meeting with franchisees to coincide with the trade fair – meetings will be held on site at the Nasrec Expo Centre during the exhibition. Le Roux said that the Group is expecting all its Midas, Motolek, Adco, CBS, Battery Hub and ACD franchisees from Limpopo, North West, Mpumalanga, Free State and Gauteng to attend. While there, franchisees

will be encouraged to attend the RMI Conference, among others, to expand their knowledge of the industry and the challenges it faces.

The Midas Group bringing its clout to Automechanika SA shows a significant vote of confidence in the fair, which is being held in South Africa for only the second time this year. It’s also an important strategy lesson for other industry players on how to leverage such an event to create opportunities to strengthen relationships internally as well as externally.

Automechanika SA update

L

ate in 2010 we had a meeting with Michael Johannes and Stephan Kurzanski from Messe Frankfurt.

Stephan has been the man at the helm of the brand for the past few years and Michael is the incoming head as reported in our coverage of the 2010 Frankfurt show. “This is my first official trip in the position and is intended to show my commitment to the South African market.”

The local show has been met with some criticism regarding the amount of Chinese companies exhibiting at the show, but both Michael and Stephan were realistic about this misperception. The Chinese have become a dominant force in production of virtually every product range – obviously including Automotive, and while many in the auto sector are concerned about price competitiveness

PAGE 64

and especially quality, the reality is that they are not going anywhere.

“If the Chinese are being viewed as a Tsunami, producers have to decide whether to stay on the beach or stand on a hill.” Stephan believes that strong brands will still hold their market share.

Price is not the only determining factor and the trade appreciate the delivery of quality products. Together with the introduction of the CPA in South Africa, Michael explained: “The Automechanika brand is also firmly behind Messe Frankfurt’s no counterfeit policy, and these products are not tolerated at the shows as witnessed in Frankfurt last year where customs police confiscated items off any stands.”

We caught up with Philip Otto in the final stretch to Automechanika SA

in March. “So far we have over 360 companies from over 25 countries committed and we are still filling spaces every day.” He continued: “It’s looking to be a great show and we are very happy with the support the local market has shown, to what is broadly considered the premium show brand in this sector.” As well as the exhibitor stands there are also a number of events and forums, as well as break away meetings to be held at the show, that will take participation and interaction to the next level. AutoForum will publish a detailed itinerary for the show, but remember to diarise these highlights: • • • • • • •

MIWA/ERA/SADFIA 9/3 MPEA Conference 9/3 Midas Regional Meetings 9-10/3 SAMBRA Conference 9-10/3 RMI Conference 10/3 TDAFA Conference 11/3 MISA Event 11/3

PAGE 65

AutoForum - Jan / Feb 2011

Going big at AMR 2011

L

ast year’s Auto Maintenance & Repair Show (AMR), held in Beijing, China, recorded no less than 789 exhibitors exhibiting on 56 000 m2 of fairgrounds. Not only was visitor and exhibitor response overwhelmingly positive, but 97% of AMR 2010 exhibitors booked space for AMR 2011, with over half requesting more exhibiting space, saying that the show is worth the investment. Cathy Peng, President of the show’s organisers, Beijing Traders-Link, commented: “We’re happy to see the show’s rapid growth year by year, and have full confidence for the success of the upcoming AMR 2011.”

PAGE 66

AMR 2011 takes place this year at New China International Exhibition Centre (NCIEC), Beijing, from March 16 to 19 and will play host to over 1 000 exhibitors and 70 000 m2 of exhibition space.

Pre-registered international buyers to AMR 2011 will be able to take advantage of either free accommodation or free sightseeing, so if you are travelling to next month’s show it’s well-worth filling out the online pre-registration form at show website of www.automaintenance.com.

Ca BeijingthTy Peng of raders-L ink

PAGE 67

New Releases

AutoForum AutoForum - Jan / -Feb Jan2011 / Feb 2011

www.AutoForum.co.za

Welcome Ferodo Premier

A seed net could save your engine

Federal-Mogul recently took the opportunity to announce that it had re-branded its Ferodo brake pads as the Ferodo Premier range at the its annual roadshow, which took place late last year.

According to SecureTech, if you often travel in grassy sections of veldt it could have a long-term detrimental effect on your vehicle’s performance and may even result in a critical failure.

What makes the Ferodo Premier brake pads so special is that they are able to stop an average 7 m before their closest competitor – a distance that can make the difference between life and death. The product is compatible with most vehicles and are produced to Original Equipment (OE) quality specifications.

The company recommends that off-roaders fit a seed net across the front of their grille to prevent grass seeds and husks from entering the radiator core. Initially these may simply cause overheating but over time it could lead to engine failure as the particles melt and fuse within the core, thereby restricting airflow.

The brake pads consist of a combination of over 50 friction materials, together with a specially designed thermal under-layer that enables outstanding heat dissipation, and also offer excellent fade resistance and water recovery, minimised noise, reduced disk wear and full ABS compatibility. In addition, all OE-matched accessories are included as a standard. Of course to make sure there is optimal friction, it is vital that brake pads are paired with the correct brake discs, and Ferodo discs are not only matched to OE requirements, they also boast a unique surface finish that aids the bedding-in process, excellent metallurgy and design extend durability.

The nets are competitively priced and available in three sizes to suit a wide variety of vehicles (500 mm X 800 mm, 800 mm x 1 000 mm and 1 000 x 1 200 mm). SecureTech can also custom make nets to any size or design.

For more information www.liftlash.co.za.

The company strongly advises that all elements of a braking system be thoroughly checked for leaks, blockages and brake fluid quality whenever brake pads or discs are replaced – made all the easier thanks to its comprehensive range of brake fluids, including the DOT 4, DOT 5.1, ESP DOT 4, LHM mineral and SSF (for C5 suspensions) fluid types for standard road cars.

For more information please contact the customer care line on 0800 555 832.

MACS launches new generation Robinair machines MACS Automotive has announced the launch of the new generation Robinair RRR (Recovery, Recycle and Recharge) machines.

The Robinair machines’ benefits include the automatic control of every phase of maintenance including oil and coolant recovery, recycling and refilling without direct intervention from a technician. The units have multi-lingual software and are equipped with a database to provide the necessary oil and coolant quantities for the specific vehicle’s air-conditioning.

The new range includes the cost-efficient Baby Cool ACM3000, the 595PRO as well as the 695PRO for larger fitment centres. The sales staff at MACS is able to assist in selecting the correct model for your specific operation.

Contact MACS on 0114980700; marketing@macsauto.co.za or www.macsauto.co.za for more information.

PAGE 68

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PAGE 69

AUTOFORUM

DIRECTORY LISTING

After-Marketplace Directory

To advertise your listing in AutoForum After-Marketplace Directory Contact us on 011 706 0277 or Email: info@AutoForum.co.za

AUTO ELECTRICAL Bosch

Parts, Accessories & Batteries

011 651 9600

First National Battery

Industrial & Automotive Batteries

011 741 3600

Motor Electro Diesel (MED)

Auto Electrical Parts & Accessories

021 505 4000

Parts Incorporated Africa

Automotive Components & Accessories

011 879 6000

Probe Corporation

Auto Electrical Parts & Accessories

086 111 3507

Behr Hella

Air Conditioning Specialists

011 538 7500

Connoisseur Automotive

Approved A/c Equipment & UView Dye

021 419 7188

Highveld Garage Equipment

Air Conditioning Specialists

012 330 0540

Harrack Automotive Airconditioning

Air Conditioning Specialists

011 493 1400

Launch Technologies

Air Conditioning Equipment

011 397 3073

Macs Automotive

Air Conditioning Equipment

011 498 0700

Aer-O-Cure

Spray Booths, Chassis Straighteners & Welding Equipment

011 444 6454

Hurricane/Silver Falcon

Spray Booths & Chassis Straighteners

083 628 2288

Pressure Washers & Vacuum Cleaners

012 330 0540

Beissbarth

Wheel Alignment Equipment

011 651 9600

Bosch

Diagnostic Equipment

011 651 9600

Highveld Garage Equipment

Engine Analyser & Diagnostic Scanners

012 330 0540

Launch Technologies

Smartbox Super Scanner & Software

011 397 3073

Industrial Interlocking Floors

011 873 1292

Abro Global

Balancing Machines

021 945 1419

AutoZone

Aftermarket Parts & Accessories

0861 122 111

Beissbarth

Wheel Alignment Equipment

011 651 9600

Highveld Garage Equipment

Tyre & Lifting Equipment & Tools

012 330 0540

Hofmann Megaplan

Complete Range of Garage Equipment

011 472 7279/5954

Integrated Marketing

Wheel Service & Workshop Equipment

011 974 2203

Integrated Garage Equipment

Sales, Service & Repairs to all Equipment

012 549 5845

Ital Machinery

Brake & Clutch Machinery

011 483 3737

John Bean - Snap-on Equipment

Wheel Service Equipment

0861 762 766

King Tony

Tools

011 316 3812

Launch Technologies

Jacks & Lifts

011 397 3073

Alert Engine Parts

Distributors of Quality Parts

021 590 8250

Alfa Brake Drums & Discs

Brake Drums & Discs

011 608 0801/3

AutoZone

Aftermarket Parts & Accessories

0861 122 111

Bosch

Parts, Accessories & Batteries

011 651 9600

Federal-Mogul

Aftermarket Parts Manufacturer

011 630 3033

GMSA

Parts Supplier

041 365 6170

Goodyear RAM

Timing Belts, Fan Belts, Radiator Hoses & Air Springs

011 248 9300

Midas

Aftermarket Parts & Accessories

011 879 6000

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Auto Electrical Parts & Accessories

021 505 4000

Parts Incorporated Africa

Automotive Components & Accessories

011 879 6000

Safeline

Brake Parts

011 549 7333

Silverton Radiators

Engine Cooling Specialists

011 538 7500

SKF

Bearings

011 821 3500

Victor Reinz / Intrade

Automotive – Gaskets & Sealing Products

011 432 2667

AA Training Academy

Training

011 347 9300

Auto Cosmos - Electrolog

Electronic Parts (Electrical) Catalogue

012 327 6210

Bosch

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011 651 9600

Misa

Staffing Association

011 678 6328

Motor Books

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086 111 3947

AIR CONDITIONING

BODY REPAIR EQUIPMENT

CLEANING EQUIPMENT Highveld Garage Equipment DIAGNOSTIC EQUIPMENT

FLOORING Tuff Floors GARAGE EQUIPMENT & TOOLS

PARTS MANUFACTURERS & DISTRIBUTORS

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