AutoForum May 2011

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MAY 2011

I N F O R M E D

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NEWS AFRICA

NEWS AFRICA

A N D

I N N O V A T I V E

Naacam seeks APDP changes

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UD Trucks ON TRACK

Inside HAZARDOUS UNDERRIDE GUARDS

R30 M Test Centre Sits Idle HVAC in Your SeaT Training Truck Drivers

PAGE 1

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MAY 2011

CONTENTS 22

Cover Stories 14

R30 m test centre sits idle

38

Naacam seeks APDP changes

18

HVAC in your seat

44

Hazardous underride guards

52

UD Trucks on track

56

Training truck drivers

59

Trade Talk 6

Highlights of global and local industry news

Thank you to Toyota South Africa for our cover photo.

News Forum

44

Mercedes-Benz is UK's top Consumer Superbrand

8

Expanded exports for BMW SA

8

JIMS back in October

10

MBSA in efforts to expand component supply industry

10

Wellness cluster in line for international award

12

EU transport 2050

12

Earthquake impact on Toyota still to be felt

13

Recycling programme benefits local community

14

R30m Emissions Test Centre seeks vehicles

14

AIDC makes Gauteng the leader in auto skills training

16

VW chooses emission-lowering MultiTwister from Victor Reinz

16

Naacam seeks APDP changes

18

The inside scoop on Q1 from TransUnion

20

Automakers manipulate fuel economy

22

BMW SA greens its facilities

24

52

BodyShop News 26

New enviro friendly spraying

26

Toyota slammed for salvage parts position

28

AutoForum has an ABC circulation of 13 898 ABC (July 2010 to Dec 2010)

SA is now officially part of the Brics nations and according to the reports out of the summit, there are distinct positive outcomes should the nations manage to find better ways of trading with and supporting each other. The story has certainly received its fair share of airtime both here and internationally - and it could mean massive changes in how global trading takes place in the future, possibly even toppling the Dollar. Who would believe that the challenging times we live in could get more and more interesting.

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PRODUCTION: KAZ NEL

BASF is GM's Supplier of the Year

56

Editorial

EMAIL: INFO@AUTOFORUM.CO.ZA PUBLISHER: SWIFT PUBLICATIONS & OLYMPIC PARK TRADING SUITE 446, POSTNET X033, RIVONIA 2128

www.Autoforum.co.za I N F O R M E D

I N N O V A T I V E

Advertisers Guide

Business Forum BRIC welcomes SA

36

Queue management

36

It takes all sorts to make your SME tick

38

Innovations

Abro ACD/Midas Group

Aer-O-Cure Alfa International Autocosmos/Electrolog Autozone Bosch

Integrated seat-based HVAC system

44

New Electric Park Brake for front axles

46

Bosch launches waste heat study

46

New zero initiator tyre pressure monitoring system

48

First National Battery Global Parts GMSA

Motor oil to fuel

50

Hofmann Megaplan

Federal-Mogul

Ital Machinery Leaderquip

Auto Safety

MED MISA

SAE launches driver distraction book

52

Underride guard hazard

52

Phoning while driving might not be that bad.... but only at certain times

Motor Merchandise PIA/Midas Group

53

Probe

Air Conditioning Gas – the situation as it stands

54

Commercial Vehicles

Sabat Silver Falcon/Hurricane Snap-on / John Bean Technica Turbo Exchange

UD Trucks SA not affected

56

Mercedes-Benz tweaks Atego and Axor

56

UD Trucks Victor Reinz

Hino 700 Series – a two-pedal affair

58

Wheelquip

Fuel price spurs demand for CNG trucks

60

MAN – ‘Gobalising’ with customer proximity

62

37 45 30-31, OBC 13 60 34-35, 48 47, IBC 41, 65 49 19 39, 51 11 11, 37 15 2-3 57 27 55

50 17 32-33 43 7 28 61 9 23

Insert Trysome

New Releases Latest offerings of local products

A N D

63

After-Marketplace Directory Directory listings

66

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 - May 2011

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Total and Kia join forces Total Lubricants and Kia Motors Corporation have entered into a five-year international cooperation agreement, which will see the former become Kia’s recommended partner for the sale of lubricants across the world, except in Europe and Korea.

The networks covered by the deal will gain access to Total Quartz Automotive, as well as all the oil company’s marketing expertise.

Imperial takes over MMC In March, Mitsubishi Motor Corporation (MMC) signed a distribution agreement with Imperial Holdings (IH) that will see the latter assume responsibility for the former from 1 July.

The current distributor, Mercedes-Benz South Africa (MBSA), will hand over control of MMC on 30 June, following its successful tenure as distributor for the past 16 years.

Over that time it has seen the brand consistently rated as a benchmark in Competitive Customer Satisfaction Surveys for service, and producing vehicles of high quality in the East London plant.

The new deal will see Imperial Holdings import and wholesale Mitsubishi Motors products such as the Triton model line-up, Pajero, Pajero Sport, Outlander and the Lancer models, and may include future product additions.

Joule passes 8 000 km of testing Since testing began in late 2010, SA’s first homegrown EV, the Joule, has completed a total of 8 000 kms of testing mileage. The mileage figure is testament to the reliability of these vehicles, especially when considering that each of the four marketing fleet cars were built by hand.

The Optimal Energy engineering team has used the feedback received from this testing period to update and improve the software and hardware systems. According to its producers, although the majority of the testing has been taking place on quiet roads and during off-peak times, when the cars have been spotted in traffic, the public reaction has been extremely positive.

The fleet has undergone its first full inspection and is currently in the hands of the media for initial evaluation. We look forward to the report backs.

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R1xc5l V0A0 T E

29 Lab Experiments using a Virtual Multimeter (DVOM) 188 Workshop Activity Sheets

187 Practical Video Sequences showing you Step-by Step demonstrations on how to fix cars

1041 Handout Activity Sheets

649 Knowledge Checks to confirm your knowledge

650 Theory Video Sequences and Animations showing how a car works

To purchase your subscription or for more information contact Michael Turnbull on 011 879 6065 or email michael.turnbull@technica.co.za PAGE 7

AutoForum - May 2011

Mercedes-Benz is UK's top Consumer Superbrand Mercedes-Benz was recently named the UK’s number one Consumer Superbrand for 2011, displacing last year’s winner, Microsoft, which fell to 6th on the coveted list. The annual Consumer Superbrands results are based on analysing the views of over 2 000 members of the British public. The annual survey, now in its 12th year, has become a key barometer of the strength of brands across a wide variety of sectors.

For the first time in five years the prized title went to a brand other than Microsoft or Google. Luxury watch brand Rolex placed second, same as last year, whilst the BBC came in third position, having placed in the top five for the last five years.

Wilfried Steffen, President and CEO Mercedes-Benz UK commented: “Winning the Superbrands survey is very special for Mercedes-Benz, and I am delighted that we’ve achieved the coveted number one spot in our 125th year. Everybody in the company is absolutely committed to delivering exceptional levels of customer service, and this survey result shows that these efforts are paying off.”

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Expanded exports for BMW SA

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MW SA announced recently that it will expand export operations at its manufacturing plant in Rosslyn this year.

The plant produces the BMW 3 Series Sedan, for both local and international markets, and the 3 Series xDrive all-wheel drive for export to lefthand drive markets, as well as painted 3 Series bodies and hang-on parts to other BMW markets for CKD assembly. Volumes of the latter currently average 1 800 units annually, but the project is expected to allow the SA arm of the automaker to increase numbers in the future.

As BMW SA MD, Bodo Donauer, explains: “Our export programme is critical to us and a vital facet of automotive production in South Africa. In order for us to grow our operations we need to look outside of local markets.

These new opportunities allow us to increase our export footprint, albeit in limited numbers for now, and will consequently also allow us to grow our local skills base. This is also in line with our support of Government’s call to maintain decent jobs for South Africans.”

He continued: “BMW xDrive is the world’s most advanced all-wheel drive system and its incorporation into the Rosslyn production process represents a major technology injection into South Africa. At the same time, the expansion showcases the versatility of the plant and therefore the possibility for further production opportunities in the future.”

The company has also streamlined its shipping channels supporting its export programme to the NAFTA region, and 3 Series Sedans built in Rosslyn for the North American market are now shipped directly to either the West or East Coast of the US, instead of via Bremen as was previously the case.

This change cuts SA’s lead times to the United States by as much as 16 days, meeting customers’ demand for faster turnaround times. Vehicle handling is also reduced as a result of the direct route, further enhancing the overall quality of the product.

“Why don’t you get a new truck, darling?”

“Don’t need one ... the engine’s still good.”

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Victor Reinz inside Mercedes Benz.

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AutoForum - May 2011

Trade and Industry Minister, Rob Davies, Daimler board member, Dr Wolfgang Bernard, and Mcebisi Jonas, Eastern Cape Province MEC attend supplier forum.

JIMS back in October The Johannesburg International Motor Show, which will be held from 6 - 16 October, is only a few months away. Launched officially in February by Naamsa President David Powels, the show is accredited by the International Organisation of Vehicle Manufacturers and promises over 400 exhibitors of automotive components and accessories, as well as 57 car brands, 23 truck and bus companies and other international participants. The organisers expect around 275 000 visitors - many from Africa, Europe and the Far East.

According to Powels: “The timing of the show is ideal for the South African motor industry to illustrate to the world the way in which it has restructured and realigned itself to the challenges facing the global motor industry. The South African motor industry is emerging from an extremely tough business environment in which it has been forced to re-examine the business model to ensure global competitiveness in the years ahead. Together with our partners in the supplier component industry, major focus has been placed upon localisation and value addition. Significant investment on the part of the supplier industry has resulted in a much leaner, technologically capable and skilled component industry enabling OEMs to target key strategic global markets.”

This year’s event will also include the ‘Johannesburg Truck & Bus Show’ as well as the Automotive Allied Industries ‘Autoshop’, all in an upgraded Expo Centre that offers substantial indoor and outdoor space to ensure an all-encompassing experience.

For more information go to www.jims.co.za.

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MBSA in efforts to expand component supply industry

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ast December, Daimler AG announced that it would be investing R2 billion into the Mercedes-Benz South Africa (MBSA) plant in East London for the production of the next-generation C-Class. Since that time, the group has been involved in discussions with the Department of Trade and Industry on how to best draw international component manufacturers to invest and establish large-scale production in SA, with a view to job creation and the positive impact on the local industry such infrastructure would allow.

SA Minister of the Department of Trade and Industry, Rob Davies, attends MBSA supplier forum in Germany.

This collaboration extended last month when MBSA hosted a series of talks between Government, leading SA component suppliers, and Daimler AG officials in the automaker’s home country of Germany, in an effort to debate challenges to achieving greater localisation in the SA component supply industry as well as to encourage further growth in this sector.

The delegation included the Minister of the Department of Trade and Industry, Rob Davies, who pledged Government’s commitment to finding solutions within the scope of the existing and future legislative framework, for a significant strengthening of the SA auto industry – which, according to NAAMSA figures, contributes in excess of 6% annually to the country’s GDP and is responsible for over 28 000 jobs.

Other key government representatives included the MEC of Economic Development in the Eastern Cape Province, Mcebisi Jonas, who emphasised

the provincial government’s support toward achieving a thriving automotive sector in the Eastern Cape. Nearly 50 automotive supplier representatives actively contributed to the forum.

“The Mercedes-Benz plant in East London follows exceptionally good global processes and standards outlined in the Mercedes-Benz production system for all MercedesBenz passenger cars plants,” commented Rainer Ruess, Vice President at MBSA and responsible for manufacturing and procurement.

“We will be bringing more than a dozen new technologies to SA in the car and production processes,” he continued.

“MBSA will localise more than 40% of the components for this next-generation Mercedes-Benz C-Class local manufacture. We expect to see more investors and new suppliers, all with the latest technologies coming to the country. These developments will certainly strengthen the entire automotive value chain.”

Ruess confirmed that: “With the pledged support of the SA Government, MBSA plans to make optimum use of the SA regulatory environment and leverage the advantages presented through the Government’s Industrial Policy Action Programme (IPAP), as well as the Automotive Investment Scheme (AIS) and the future Automotive Production Development Programme (APDP).”

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NEWS FORUM

AutoForum - May 2011

EU transport 2050

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he European Commission recently adopted a comprehensive strategy entitled Transport 2050, which aims to increase mobility, fuel growth and employment, while at the same time dramatically reducing the region’s dependence on imported oil, and cutting carbon emissions in transport by 60% - all by 2050.

The key goals will include: abandoning conventionally-fuelled cars in cities; 40% use of sustainable low carbon fuels in aviation; at least 40% cut in shipping emissions; a 50% shift of medium distance intercity passenger and freight journeys from road to rail and waterborne transport. All of this is expected to contribute to a 60% cut in transport emissions by the middle of the century.

Wellness cluster in line for international award Ford South Africa is hoping to walk away with a Global Business Coalition (GBC) Business Action on Health Award next month, when it attends the GBC’s Tenth Anniversary Conference and Dinner, held in New York.

The automaker is one of 38 finalists for the award, having been nominated for its engine plant workplace wellness initiative in partnership with the Automotive Industry Development Centre (AIDC) and AIDS Prevention and Health Promotion Workplace Programmes in Southern Africa (AWiSA).

The initiative was launched two years ago to help automotive supplier companies to respond to the HIV/AIDS pandemic, by implementing comprehensive wellness workplace programmes with a special focus on HIV and AIDS. The programme has already experienced success with in excess of 2 000 employees having completed voluntary HIV/ AIDS counselling so far.

As Martin Weihs, the AIDC-AWiSA advisor to the project, explains: “It demonstrates the powerful impact of business engagement on health, and reinforces our commitment to developing HIV/AIDS awareness and sustainability in the automotive industry in the Eastern Cape, as well as the wider community and economy.”

The Global Business Coalition is in its tenth year, and represents business leadership and partnerships around the world in an effort to address the important global health challenges of our time, with a special focus on HIV/AIDS, tuberculosis and malaria.

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Vice President for Transport for the European Commission, Siim Kallas, said: “Transport 2050 is a roadmap for a competitive transport sector that increases mobility and cuts emissions. We can and we must do both. The widely held belief that you need to cut mobility to fight climate change is simply not true. Competitive transport systems are vital for Europe’s ability to compete in the world, for economic growth, job creation and for peoples’ everyday quality of life. Curbing mobility is not an option; neither is business as usual. We can break the transport system’s dependence on oil without sacrificing its efficiency and compromising mobility. It can be win-win.”

The plan also aims to focus on making transport safer, with a goal of close to zero fatalities in road transport by 2050. In line with this goal, the EU aims at halving road casualties by 2020, in order to become a world leader in safety and security of transport in aviation, rail and maritime.

Earthquake impact on Toyota still to be felt

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he effects of the Japan earthquake disaster earlier this year continue to haunt many businesses across the globe, with the automotive sector amongst those hardest hit.

Last month Toyota Motor Corporation (TMC) announced that production at its site in Japan would have a staggered restart from mid April, and would be shut down over the end of April to early May as planned before the tragedy, to allow for scheduled plant upgrades and maintenance.

From the 10th of this month however, until to 3 June, production would be at around half of its normal capacity, due largely to parts supply issues.

The automaker said that production levels after that period would still be decided, based on discussions with suppliers and other related companies.

The SA arm of the company planned to retain their usual levels of production until the Easter shutdown and would have to reassess their plans thereafter. As Dr. Johan van Zyl, President and CEO of TSAM explained: “Based on the information we have received from TMC we will subsequently adjust our production plans for May. TSAM will adjust its production schedule, taking into account the impact on the workforce and our dealer network. This adjustment might lead to some inconvenience for customers and we would like to apologise in advance for this.”

Econometrix Senior Economist Tony Twine is reported as estimating the damage of the quake at up to 1% of SA’s GDP, while analyst website Edmunds.com estimated that the earthquake and its aftermath could cut 2011 sales growth in the US alone by up to 50%.

NEWS FORUM

AutoForum - May 2011

Recycling programme benefits local community This month will see the first year anniversary of tyre manufacturer Goodyear’s recycling facility, housed at its Uitenhage plant in the Eastern Cape. The past twelve months have seen in excess of 28 tonnes of waste collected and sold to specialist recycling companies. The programme has created employment opportunities for employees and their families, and supports the local community as all funds generated are donated to local charities and community projects.

As Pamela Moodley, Goodyear Risk Control Manager, explains: “Globally, Goodyear aims for ‘zero waste to landfill’ and ‘zero harmful emissions’ in its tyre manufacturing processes. Here in South Africa, Goodyear is currently the only manufacturer across all industries that can boast a true zero waste policy. This is thanks to innovative developments in materials and processes, as well as our determination to reduce, reuse and recycle wherever possible.”

“However, as environmental awareness grows, more people would like to contribute personally to the health of the planet. We could all recycle our domestic waste, but there are simply not sufficient collection bins available publicly. Since Goodyear already recycles factory and office waste, it made sense for us to extend the collection system to the greater community and encourage good recycling habits.”

R30m Emissions Test Centre seeks vehicles - Roy Cokayne

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state of the art vehicle emissions test centre, built only 10 years ago, is now standing virtually idle – that is despite the introduction of a vehicle emission tax on cars from April last year, which was extended to also include bakkies from the beginning of March this year.

Bonakele Mehlomakulu, Chief Executive of the SA Bureau of Standards (SABS), admitted there was no longer any need for emissions testing to be conducted independently and the centre - built in East London by the SABS at a cost of R30 million in 2000 to take advantage of a drive by Mercedes-Benz South Africa (MBSA) to increase its vehicle exports - did not make enough money to make it viable.

Mehlomakulu explained that this was because motor manufacturers conducted their emissions testing overseas, or had built their own in-house facilities. She continued that the introduction of the vehicle emissions tax on cars and light commercial vehicles would not improve the volumes through the centre until there was a need for them to be verified by a third party.

The tax is currently based on vehicle emissions tests conducted in Europe.

“As a result, our very good laboratory established 10 years ago stands unused. Its volumes are low and we have to keep subsidising it.”

Mehlomakulu said the equipment in the centre had to be maintained and there were operational costs associated with that, but there were currently no volumes to justify its existence.

According to Hansgeorg Niefer, MBSA Chief Executive, the automaker had reduced the number of emission tests generally because of improvements in its production process. “We now have such stable processes that we don’t have to check the same sample size. If any, it is only a small number of cars that we are testing.”

However, Niefer said it was clear from the beginning that if somebody invested, such as a supplier to MBSA, they knew exactly the lifespan of the current vehicle. He said even MBSA did not know if there would be a successor to that model until a decision was taken by its parent company.

Niefer said the SABS’ business model was based on the same assumption and the SABS could not take it for granted that MBSA would “do the same thing we have done for the last 10 or 15 years”. He added the initial idea was to also attract other manufacturers to use the facility.

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Roy Cokayne is a senior financial reporter for Business Report.

NEWS FORUM

AutoForum - May 2011

AIDC makes Gauteng the leader in auto skills training

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Agency (ESDA), together with The Talhe Automotive Industry Developent Pipeline programmes. ment Company (AIDC) - a subsidiary of Blue IQ, which in turn is an The programme has also allowed agency of the Gauteng Department of Economic Development - recently host- the organisation to join forces with a number of companies to train and ed an event for over 500 learners enprovide skilled rolled in the AIDC’s labour, while also human resources The AIDC has already aiding businesses development protrained or assisted 4000 with their training grammes at the unemployed youths to requirements and CSIR in Pretoria. obtain qualifications even educating training providers. Training is provided Barlow Manilal, the AIDC CEO, took the through partnerships with private and opportunity to congratulate the learners on their achievements to acquire qualifi- public tertiary institutions such as the cations and skills as part of the Gauteng training colleges and Further Education and Training (FET) colleges in Gauteng.

Province’s Talent Pipeline Project.

The AIDC has already trained and or assisted an estimated 4 000 unemployed youths to obtain qualifications in key skills for the automotive, engineering and manufacturing sectors, through its Employment Skills Development

Even after finding employment, graduates are monitored, mentored and assisted by the AIDC which, as Manilal explains, “benefits both the employee and the over 200 companies who host our graduates, to successfully manage

expectations, ensure proper development and resolve any challenges”. It also means that AIDC’s ESDA handles all the administration, allowing participating companies to focus on their core business.

“Gauteng should be a first destination choice for out the automotive sector,” said Manilal at the event. “To achieve Government’s strategic goals to attract and retain investments in the automotive industry and subsequently sustain jobs, Gauteng must provide and enable the required skilled labour. The Automotive Production and Development Plan scheduled to commence in 2013 has sent a clear message to investors about Government’s commitment to supporting growth in the automotive industry. This forward thinking policy will, however, not reach its full potential if investors cannot source the required labour.”

VW chooses emission-lowering MultiTwister from Victor Reinz

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olkswagen recently began using Victor Reinz MultiTwister axial cyclonic air-oil separator (AOS) technology on several current and future engine platforms. This makes it the first OEM to adopt the innovative approach to reducing vehicle emissions, a system distributed within the South African market by Intrade.

The unique design of the MultiTwister technology aims to lower vehicle operating costs and emissions by reducing oil consumption, and at the same time claims to deliver longer oil life. It works by capturing excess oil and returning it to the engine crankcase, rather than burning it off. By eliminating excess oil from the combustion process, the life of components such as the catalytic converter, turbocharger, inlet valves, carbon-particulate filter, and intercooler are lengthened. And even better is the fact that the MultiTwister design can be tailored to meet the needs of specific engines by utilising different airflow geometries.

The technology debuted on the 2008 Audi RS6 V-10 BiTurbo, and will now be included on the

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2010 and 2011 Volkswagen Polo, Golf, Touran and Passat models equipped with 1.0 litre MPI, 1.2 litre TFSI and 1.4 litre TSI engines.

As Chief Technical Officer, George Constand, explains: “Our customers are constantly seeking ways to minimise the environmental impact of their engines, while at the same time providing consumer value and performance.

Our MultiTwister technology ensures engines run cleaner and also helps save consumers money by enhancing powertrain reliability and reducing oil consumption.”

The system is compact, which saves essential space in smaller engines, and durable, and unlike the more common filter separators used by OEMs, the MultiTwister AOS is designed to operate over the lifetime of the vehicle.

NEWS FORUM

AutoForum - May 2011

Naacam seeks APDP changes

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he National Association of Automotive Component and Allied Manufacturers (Naacam) has approached the Department of Trade and Industry with a number of proposed changes to the Automotive Production and Development Programme (APDP) in an attempt to boost the local content in vehicles produced in South Africa. The APDP will replace the current Motor Industry Development Programme (MIDP) from 2013.

Roger Pitot, Naacam’s Executive Director, said they did not believe the APDP, which was aimed at assisting OEMs to increase volumes and increase the scope and depth of localisation, sufficiently encouraged localisation. “We don’t see sufficient incentive in there [the APDP] for that and that is our difficulty. We made some suggestions but I’m not at liberty to talk about them. We need to talk to all parties concerned and find a way to assist component

PAGE 18

manufacturers to overcome competitive issues they are facing and ensure we do achieve more local content – and the two do go hand in hand.”

Pitot said the domestic automotive component manufacturing industry had to become more competitive and barriers to achieving this included high wage increases and steep hikes by Eskom and Transnet.

He said productivity had improved but remained an issue, but that quality was no longer a problem. Pitot continued that the meeting was with “middle level” officials at the DTI and it was agreed there should be a follow up meeting once Naacam’s proposals had been discussed with other stakeholders. He said Naacam had discussed its proposals very briefly with the National Association of Automobile Manufacturers of South Africa (Naamsa) and “will have to do so again in more depth”. Attempts

- Roy Cokayne

to obtain comment from Naamsa were unsuccessful.

According to Pitot, Naacam was not in favour of a minimum threshold level for local content for vehicles produced domestically because it would result in a problem with the World Trade Organisation (WTO). In terms of the APDP, motor manufacturers will have to meet or exceed an annual 50 000 unit production threshold in their local assembly plant to qualify for benefits in terms of the programme.

Pitot said the average local content in domestically produced vehicles could be increased to 50% without any major technological challenges. He continued that average local content was currently estimated at between 35 and 40% and annual analysis undertaken by the DTI showed that this had not changed much over the years. However, Pitot admitted there had been shifts in the local

content achieved by different manufacturers over the years as some older models were phased out, such as the Toyota Tazz, Nissan half tonne pickup and Citi Golf.

Volkswagen South Africa (VWSA) last year reported that it had exceeded its target of increasing local content in the old VW Polo from 39 to 70% and achieved local content of 68% when it launched the new VW Vivo. Local content in the next generation MercedesBenz C-Class is expected to increase to over 40% when it is launched in 2014.

Pitot believed there was scope to localise more automotive components, particularly for tier one original equipment manufacturer (OEM) suppliers to buy sub components and materials locally.

However, he admitted it would be difficult to justify the investment required to produce power-trains and electronic components locally.

Several other local content initiatives are taking place. Mercedes-Benz South

Africa (MBSA) hosted a series of talks between leading SA component suppliers, the South African government and top Daimler AG officials in Germany recently (see story page 8) in a bid to encourage further local growth in the component supply industry and openly debate challenges to achieving greater localisation. This followed Daimler AG announcing in December it would be investing R2 billion into MBSA’s plant in East London for the production of the next generation C-Class.

Rainer Ruess, MBSA’s Vice President responsible for manufacturing and procurement, said the goals of the initiative were to encourage the expansion of component suppliers already based in SA, and to encourage other global component suppliers not yet producing here to join the local industry, either through joint ventures or new establishments.

Ruess said MBSA would bring more than a dozen new technologies to South Africa in the car and production processes and expect to more investors

and new suppliers come to the country, which would strengthen the entire automotive value chain.

The OEM purchasing council, established a few years ago with the aim of increasing the volumes and economies of scale of automotive component suppliers through the pooling of component orders, is also making some progress.

Evan Dold, Chairman of the OEM purchasing council, said they were working together to identify new local content opportunities and multi-OEM buyer teams were working on a number of projects and feasibility studies.

Dold said about 12 feasibility studies, involving a total of R450m additional value to the local automotive component sector, were taking place currently.

A number of feasibility studies had reached the point where they were able to commit individually or collectively, with projects worth R50 million confirmed, he said.

PAGE 19

AutoForum - May 2011

NEWS FORUM

The inside scoop on Q1 from TransUnion

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s we reported in the April issue of AutoForum, TransUnion Information Solutions recently held its first trends forum for 2011 and has since released the first quarter Vehicle Pricing Index (VPI) for this year. According to the index, which measures the yearon-year price inflation of a market weighted basket of new and used vehicles, new vehicle price inflation is back on its downward trajectory. This after the ‘blip’ in the last quarter (Q4) of 2010, when new vehicle prices rose slightly - a result of nominal annual vehicle price increases and the impact of the CO2 emission tax that came in to effect earlier that year.

New car prices rose by a mere 3.8%, which represents a marked drop compared to the 7.4% increase in the same period in 2010. At the same time, used vehicle price inflation also dropped from 4.5% in the equivalent 2010 period, to 3.4% this year – which TransUnion CEO Mike von Höne, expects to continue, provided the Rand remains strong.

The company predicts a positive outlook for the medium-term in the new car sector. The 26.5% (year to end-February 2011) improvement in new vehicle sales was attributed to

PAGE 20

the strengthening of the local economy and consumers returning to some normalisation in spending patterns, as well as the fact that the financial institutions’ finance application approval rate had increased. At the end of Q1 it stood at 35%.

Despite this, cash retained its key role in many sales, with as much as a third of sales at some franchise dealers categorised as “cash deals” - a fact attributed to consumers utilising other forms of financing, such as long- and shortterm loans.

TransUnion predicts that used car price inflation will continue its downward trend in the short-term, helping to boost used car sales by between 10 and 12% year-on-year during calendar 2011.

Von Höne commented: “While the vehicle market as a whole appears to be recovering, it will be interesting to see what happens to both the new and used sectors once the Reserve Bank begins to tighten again. What impact will this have on consumer and business confidence and hence their propensity to buy durables?”

Annual New Car Price Inflation (Y/Y % Change) - Base Year = 2008

Year

Index

Jan - Mar

Apr - Jun

Jul - Sep

Oct - Dec

Index Number

62.7

65.8

69.0

72.2

Annual VPI 67.4

y/y % Change

12.3%

10.0%

9.4%

9.2%

10.2%

Index Number

68.7

72.4

74.5

77.1

73.2

2002

2003

2004

2005

2006

y/y % Change

9.6%

10.1%

8.0%

6.9%

8.6%

Index Number

75.9

83.7

86.5

89.5

83.9

y/y % Change

10.5%

15.5%

16.1%

16.0%

14.5%

Index Number

87.6

90.6

91.6

92.1

90.5

y/y % Change

15.5%

8.3%

5.8%

3.0%

8.1%

Index Number

89.4

91.2

92

92.4

91.2

y/y % Change

2.0%

0.6%

0.5%

0.3%

0.9%

Index Number

89.6

91.4

92.1

92.4

91.4

y/y % Change

0.2%

0.2%

0.1%

0.0%

0.1%

Index Number

89.7

91.6

92.5

93.2

91.7

y/y % Change

0.2%

0.3%

0.5%

0.8%

0.4%

Index Number

92.5

95.2

96.1

96.2

95.0

2007

y/y % Change

3.1%

3.9%

3.9%

3.3%

3.5%

Index Number

96.0

99.3

101.6

103.1

100.0

2008

2009

2010

2011

y/y % Change

3.8%

4.3%

5.8%

7.1%

5.3%

Index Number

106.8

110.5

112.8

112.0

111.5

y/y % Change

11.3%

11.3%

11.0%

8.7%

10.6%

Index Number

114.7

114.8

116.2

116.9

115.7

y/y % Change

7.4%

Index Number

119.1

y/y % Change

3.8%

3.9%

3%

Year

4.3%

4.7%

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

Annual VPI

Index

Jan - Mar

Apr - Jun

Jul - Sep

Oct - Dec

Index Number

72.4

73.8

74.3

74.1

73.7

y/y % Change

7.0%

10.3%

12.5%

12.9%

10.7%

Index Number

81.2

81.1

80.9

80.4

80.9

y/y % Change

12.1%

9.8%

9.0%

8.4%

9.8%

Index Number

86.2

88.0

88.7

89.1

88.0

y/y % Change

6.3%

8.6%

9.6%

10.8%

8.8%

Index Number

98.6

99.2

99.2

98.1

98.8

y/y % Change

14.4%

12.7%

11.9%

10.2%

12.3%

Index Number

104.8

104.3

104

100.9

103.5

y/y % Change

6.2%

5.1%

4.8%

2.8%

4.7%

Index Number

104.9

103.3

101.5

98.3

102.0

y/y % Change

0.1%

-0.9%

-2.4%

-2.5%

-1.4%

(Jan - Dec)

2000

2001

Annual Used Car Price Inflation (Y/Y % Change) - Base Year = 2008

(Jan - Dec)

Index Number

101.5

99.7

98.6

97.0

99.2

y/y % Change

-3.2%

-3.5%

-2.9%

-1.4%

-2.8%

Index Number

100.8

99.7

99.2

97.7

99.4

y/y % Change

-0.7%

0.0%

0.6%

0.8%

0.2%

Index Number

102.6

100.7

99.5

97.2

100.0

y/y % Change

1.8%

1.0%

0.3%

-0.6%

0.6%

Index Number

101.5

100.0

98.9

96.6

99.2

y/y % Change

-1.1%

-0.7%

-0.6%

-0.6%

-0.8%

Index Number

106.0

105.6

103.1

99.5

103.6

y/y % Change

4.5%

5.6%

4.3%

3.1%

4.4%

Index Number

109.6

y/y % Change

3.4%

PAGE 21

AutoForum - May 2011

NEWS FORUM

Automakers manipulate fuel economy

A

new study by the University of Michigan in the US has found that automakers fine-tune vehicle fuel economy to qualify for more favourable treatment.

The finding comes shortly after an announcement that the US government will propose new fuel economy standards this year.

According to Professor Joel Slemrod, at Michigan’s Ross School of Business, and colleague Assistant Professor James Sallee, at the University of Chicago’s Harris School of Public Policy, for more than 30 years auto companies have done just enough to improve fuel economy of vehicles - in order to lower tax rates and increase rebates imposed by governments in the United States and Canada.

In response to federal policies to boost fuel mileage, manufacturers have changed vehicle weights, improved tyre-rolling resistance and added aerodynamic features to push fueleconomy rates past government-mandated thresholds.

In their study, Slemrod and Sallee focus on ‘car notches’ in policies intended to encourage the production and use of fuelefficient vehicles. Car notches are the small trigger points in the numerical values of fuel economy (say, the difference between 22.4 mpg or 9.52 km/l and 22.5 mpg or 9.57 km/l) that lead to large changes in tax liability or the amount of a subsidy.

The researchers studied the behavioural responses to the US Gas Guzzler Tax of 1978, which penalises cars with low fuel economy, and the Canadian ‘feebate’ programme of 2007, a set of taxes and rebates that together act to encourage the purchase of more fuelefficient vehicles. They also addressed another notch-like aspect of fuel economy - publicly disclosed and highly visible integer fuel economy ratings that provide information to prospective car buyers.

PAGE 22

Using data from Corporate Average Fuel Economy, the Environmental Protection Agency, Internal Revenue Service and the Canadian government, the researchers found that automakers produce and sell a significant number of ‘extra’ vehicles with fuel economy ratings just on the tax-favourable side of a notch than otherwise would be expected - and more than those cars just below a notch that are subject to a higher tax.

Slemrod and Sallee say that since automakers are required to round off mpg (km/l) values on fuel economy labels for consumers, this results in a presentation notch at every 0.5 mpg (permitting automakers to round up in their calculation of fuel economy).

The researchers say that automakers can boost fuel economy by producing lighterweight vehicles of the same model to create a better fuel economy rating or by simply modifying a vehicle to improve its fuel economy by recalibrating the engine, using low-friction lubricants, modifying the tyres or making small aerodynamic changes. All of this behaviour is perfectly legal, they add.

“Automakers are reluctant to publicise information about how local fuel economy adjustment might occur or say whether they respond to notches,” Slemrod said. “However, our conversations with experts who have worked for automakers and officials at the EPA indicate that this type of vehicle modification does indeed take place.”

AutoForum - May 2011

NEWS FORUM

BMW SA greens its facilities

B

MW South Africa is trying hard to be green and not only is the effort paying off in terms of the environment, it is also saving the automaker hard cash.

Thanks to its ‘CleanProduction’ energy-saving initiatives, which were put into place in 2006, the group was awarded the title ‘World’s Most Sustainable Automaker’ by the Dow Jones Sustainability Indexes for the 6th consecutive time in 2010. More importantly perhaps, the initiative has saved the company an estimated R48.5 million in energy overheads.

But how does one save energy in an industry that requires so much power to heat, ventilate, cool and light production areas without sacrificing quality, productivity or safety?

One way was to use only as much lighting as is required - lights are in use on production days and during work hours, and off the rest of the time. Another was using solar water heating panels in the Paint Shop for use in the ablution facilities. This will be expanded in time to come, to include high-efficiency evacuated tubes that will heat up water for the canteen facilities and for use by a further 250 employees at a different location.

By switching to a new type of body sealant that does not require oven curing, gas requirements were drastically reduced. This was further enhanced by introducing thermal jackets and reducing gas heater numbers, and the facilities recycle over 5 000 tonnes of waste every year. Of course, the automaker continues to look at ways to reduce its carbon footprint even more, and new initiatives such as re-engineering of combustion processes – including using premixed burners on gas fired ovens – as well as weekend and after-hours audits of energy behaviour, allow them to do so.

PAGE 24

The changes have seen a 28.1% drop in electricity consumption, and 32.1% lowered gas consumption. The environmentally aware thinking is also now rolling down to its sales network, with the opening of its first ‘green’ dealership - Club Motors Fountains in Pretoria.

Energy-saving adaptations that have been planned at design level include high-efficiency lighting systems with motion sensors, energyefficient heating and cooling systems, a thermally-efficient building shell, and the use of a grey water system that recovers rainwater or other non-potable water for site irrigation and the vehicle wash bay. In addition, the building makes use of natural ventilation wherever possible and an innovative daylight harvesting system. Recycled construction materials and other materials with zero or low harmful air emissions, zero or low toxicity and durable local materials were incorporated in the construction.

Of course, making these adaptations means money upfront, but the payoff long-term makes such an outlay well worth the investment. This particular dealership is expected to be able to recoup the additional cost of the investment within three to five years, and will likely show a 30% decrease in energy and water usage.

As Alheit Fischer, Dealer Principal at Club Motors Fountains, explains: “Not only does this dramatically lower operating costs to ensure the long-term sustainability of our business, but similar to the BMW EfficientDynamics technologies available in the cars we sell to our customers, our new building makes it possible for our staff to deliver better performance while using fewer resources.”

NEWS AFRICA

Vehicle repair insight NEWS AFRICA

In association with BodyShop News Asia and Australian BodyShop News

Contents 26

NEW ENVIRO FRIENDLY SPRAYING

26

BASF IS GM’S SUPPLIER OF THE YEAR

28

Toyota Slammed For Salvage Parts Position

NEWS AFRICA AutoForum - May 2011

NEWS AFRICA BASF is GM's Supplier of the Year BASF was recently announced the General Motors’ Supplier of the Year for 2010 – an award that recognises the Original Equipment Manufacturer (OEM) coatings supplier for consistently performing above expectations.

It is not the first time that BASF has received the honour – over the past nine years it has claimed the award seven times, for excellence in the areas of quality, service, technology and price. What makes this latest honour that much more special, however, is the fact that 2011 has been proclaimed International Year of Chemistry, and the 2010 award names the company top chemical supplier to General Motors for automotive coating applications.

“This is a list of world class, best of the best, suppliers to the automotive market,” said Bob Socia, Vice President, Global Purchasing and Supply Chain at General Motors.

“The Supplier of the Year Award winners are part of an elite group, those who have demonstrated a sustained focus and dedication to GM’s priorities and continued success.

This is critically important given the complexity of today’s automotive marketplace.”

The Supplier of the Year programme has been in existence for the last nine years.

Jim Hentschel, Executive Director and Global Functional Leader, Body, Exterior, Dimensional Engineering, General Motors; Beate Ehle, Executive Vice President, BASF Corporation; and Randy Pappal, Executive Director and Group Global Purchasing Leader, Body/Exterior, Interior/ Safety, HCAV and Mexico, General Motors.

PAGE 26

New Enviro Friendly Spraying

T

he US refinishing industry is in a bit of a spin with a new EPA rule to lower the industry’s environmental impact about to go into effect, and 3M believes it has the solution that will allow repairers primer spraying freedom, while still meeting the federal standard.

The new rule is designed to reduce the release of targeted hazardous air pollutants, and requires anyone performing touch-up and spot repair work with coatings containing these pollutants to use hand-held devices with a maximum cup size of 3 oz or less when operating outside a paint booth. What this means is that the operations of the mobile repair units that frequently operate in parking and open areas are severely impacted.

Having to put all jobs through the paint booth creates significant challenges for facility owners in terms of cycle time, job cost and scheduling.

In response to this need, 3M has created a proprietary new 3 oz lid and liner system that fits into existing PPS systems. “The new 3 oz PPS System from 3M is intended to help customers continue business as usual and paint where they need to,” said Brian Shafer, the company’s US Marketing Manager. “We understand the need to reduce hazardous airborne pollutants, but also understand the challenges this new standard presents to professionals. By providing a simple 3 oz lid and liner to fit into existing systems, it allows mobile repair operations to stay in business without a significant investment in training and equipment. We hope to help maximise efficiency for all users.”

The new 3 oz PPS system is designed to work with the popular Accuspray System, whose atomising head delivers a large, usable pattern, provides a flat smooth finish and reduces overspray. In addition, to help business owners fully understand the details of the new rule and educate their employees on the requirements and necessary painting processes, the company has created a free online training programme, available on its website.

AutoForum - May 2011

BODYSHOP NEWS

Toyota Slammed For Salvage Parts Position

F

ARA said that Toyota had launched into what it described as a rather transparent attempt to boost sales of expensive new parts and malign perfectly good parts. It added that, in light of the 14 million Toyota recalls this past year alone (25.67 million units since 2005), it would seem that the automaker would be better served focusing more internally on its own “genuautomotive recycled ine” safety concerns and quality control.

ord recently got themselves involved in a debacle regarding non OEM parts, but they are not the only automaker to have landed in hot water regarding this fairly contentious issue. The Automotive Recyclers Association (ARA) recently slammed Toyota Motor Sales USA for its position statement on the use of aftermarket, rebuilt or recycled parts.

In its statement, Toyota recommended parts have been widely accepted for decades Recycled parts are in that repairers not use fact original equipaftermarket parts, ment manufacturer (OEM) parts. They rebuilt parts or salvaged / recycled are fully functional and are in many casparts when repairing vehicles, as they es identical to original parts, and were have not been tested to determine their new OEM parts at some point, ARA effect on vehicle crashworthiness. The ARA said that automotive recycled parts explains. “Following the logic held by Toyota, the warranties of every one of have been widely accepted for decades their vehicles that has been involved in and that there is a long track record of an accident could be in question given their successful and safe use. their assertion that parts that remain on

TURBOS, ALL THE INAL, ALL ORIG ME TI ALL THE

a vehicle post collision may only appear equivalent,” said ARA’s Chief Executive Officer, Michael Wilson. “Toyota’s press releases have failed to cite any statistics indicating that recycled parts are more dangerous than new parts. What probabilities of safety issues with recycled parts is Toyota working with? Is Toyota really asserting that their vehicles are manufactured in such a way that if someone gets into an accident with a Toyota or Lexus that every single part of the vehicle is compromised, even if the accident only affected one part of the vehicle? ARA hopes that is not what Toyota is asserting, but it seems to be the logical conclusion from its stated position on recycled parts, regarding its own vehicles.”

He said that continued efforts to limit collision repair choices will only lead to higher repair costs and insurance premiums for consumers, and that recycled

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Availability Keeps Us Ahead PAGE 28

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parts were “greener’ as no additional resources or energy were used to create a new replacement part. He added that auto recyclers provide warranties on recycled parts used in a repair, indicating that recycled parts are not used in an attempt to cut corners with customers.

At the same time, an industry trade group at the March meeting of the Collision Industry Conference (CIC) unveiled a presentation based on the results of independent studies that demonstrated the quality and safety delivered by competitively produced aftermarket body parts.

The Automotive Body Parts Association (ABPA) presented the results of various data obtained through low- and highspeed crash tests, lump mass modelling simulations and quasi-static crush tests.

Co-chair of the ABPA Legislation and Regulation Committee, Eileen Sottile, presented data that debunked information about aftermarket parts presented at not one, but two CIC meetings last

year by original equipment manufacturer (OEM) proponents. In addition to showcasing the videos of crash tests and other studies that supported the integrity of aftermarket parts, the ABPA also revealed misleading and inaccurate claims made concerning energy absorption, accident occurrence, injury frequency and airbag sensor response.

A team of engineers with extensive experience in automotive safety systems critiqued the earlier studies, highlighting the lack of data to support claims made by the car companies and the misleading conclusions which were contradicted by the ABPA’s subsequent scientific testing.

Included in the ABPA presentation was information released by the group earlier this year following a 5 mph frontend barrier test in which an aftermarket bumper reinforcement bar outperformed its original equipment supplied (OES) equivalent (see AF March Issue).

The ABPA also explored the results of a 35 mph (around 56 km/h) crash test of two 2006 Toyota Corollas, one with an aftermarket bumper reinforcement bar and the other a car company equivalent. The test resulted in identical degrees of vehicle crush (601 mm) and airbag deployment in both cars at the exact same time (7.5 milliseconds).

The performance of the two vehicles was essentially equivalent, with similar results obtained for 11 separate occupant injury criteria. The aftermarket- and the car company-equipped cars both delivered occupant safety well within the federal safety standards.

Said Sottile: “Facts are stubborn things.

Hopefully they will help put to rest some of the criticism of the aftermarket by original equipment manufacturers with whom the industry competes. ABPA looks forward to releasing additional modeling and testing data to the general public which illustrates the safety and quality of aftermarket parts.”

Microfibre the smart fabric

The term “Microfibre” refers to a wide range of fibres made from polyesters and polyamides.

The shape, size, combinations, and weaves of these fibres are selected for specific characteristics. A fibre can deliver softness, durability, absorption, wicking abilities, water repellency, electrodynamics and even filtering capabilities.

Automotive microfiber products have the exceptional ability to absorb oils, water and dust – whilst being soft enough not to scratch paintwork. These cloths are widely used by the refinish sector, vehicle dealers and car detailers to handle tasks such as removing wax from paintwork, hand polishing, quick detailing, interior cleaning and drying – mainly due to the fact that they

leave no lint or dust residues after use.

WHY ARE MICROFIBRES ABSORBENT?

Cleaning microfibers are engineered in such a way that the action of splitting the fiber creates a polyamide star shaped core in the fibre. It proportionally increases the total added surface of all the fibres and enhancing the absorption properties. Weaving patterns play an important role in exposing fibres to the surface and maximizing absorption.

DUST TRAPPING

Once split, polyester fibres will take a wedge shape whereas nylon fibres become star shaped with thin branches. These tiny angular fibres lift the smallest dust particles.

Cross section of microfiber and cotton threads showing movement to the right – illustrating how microfiber leaves no residue, contrary to cotton.

This series of technical article are supplied by Motor Merchandise.

PAGE 29

Business Forum

Business insight

AutoForum - May 2011

BRIC welcomes SA With the recent meeting of the Brics nations taking airtime in our country, what does it really mean for SA to be part of this acronym? Bric (Brazil, Russia, India and China) was coined by Jim O’Neill in his report “Building Better Global Economic BRICs” in 2001 and is now understood, according to Wikipedia, as “a symbol of the shift in global economic power away from the developed economies towards the developing world.”

The April meeting of the represented countries served to officially welcome SA to the pack, and sought ways to overcome internal differences and act as a bloc with common goals. What makes Brics important is its potential to become a major force in global economics, representative of its significant numbers. Combined, the BRICS nations account for 40% of the global population, 45% of economic growth and 18% of global trade.

The summit also represented a move to make the group more structured and to establish a permanent secretariat. Other debates such as stemming inflation, fighting debt-fueled expansionary monetary policies, reducing economic imbalances and volatility in commodity prices, pushing for even greater influence in the IMF, and even gaining more right to influence the introduction of new reserve currencies, were also covered.

Minister of Trade and Industry, Rob Davies, confirmed on his return from the summit, that Brics had commissioned a study to look at how they could do business without using convertible currencies. He said that the idea was to “cut out that leg” of trading in US Dollars and to find ways that members can use their own currencies when trading directly with each other.

The next summit takes place in India in 2012

Queue management

- Graham Bush

D

o you just love standing in queues as much as I do? Consumer research has revealed a simple point that somehow seems to evade a vast number of very large businesses, and that most of us customers find ourselves having to deal with. That point is that customers generally have no problem with new systems that help service providers to streamline their businesses. In fact, we usually appreciate the trouble taken. Most customers are quite tolerant when these same systems don’t quite do what they’re supposed to do as quickly as they should. But most customers would prefer a poor system and a good attitude than a good system and bad attitude.

Here’s a case in point: Some time back I took my cellphone in to my cellphone provider to check on two malfunctioning features. I arrived early, but still waited 20 minutes to be attended to because one of the three sales assistants was late. I booked in my phone and was asked to come back in one hour. Realising that the queue was increasing by the minute, I was in it again after 40 minutes. I got to the front after 65 minutes. My phone was not ready. I waited for another 40 minutes. Finally I asked the assistant to check what was happening. She checked and said it would be ready in 10 minutes. Twenty-five minutes later she summoned me and gave me my phone. The motherboard was damaged, so they were not allowed to work on it. And my Saturday morning was history.

Yes, the service people were polite and no, it is not their problem that my phone is problematic, but the experience left me with a poor impression of that company. My experience is not unique to service providers – waiting in queues is a common problem. But what is the solution?

PAGE 36

Graham Bush is one of Southern Africa’s leading retail gurus, and over the past 30 years has inspired thousands of business people. He has a relaxed style, and along with his humour delivers powerful and motivational talks and presentations. www.thebushkitchen.co.za

First, we are now firmly in the age of systems and call centres. Systems are designed to streamline processes.

Call centres should provide a human being with a friendly voice and some initiative to sort out your problem or put you in touch with someone who can. Management is there to manage the process. If the systems are working most of the time, then what isn’t working? Management, that’s what. They’re either too busy counting the money, locked in meetings, catching up on reports for Head Office, or planning their next campaign.

Second, it is important to train staff to be polite. In this instance they were half-way there. Now please train them to be effective, and to communicate with one another and to stop trying to fob customers off. Sixty minutes is not 125 minutes, and 10 minutes is not 25 minutes. We customers are even prepared to give you a 20% margin of error - but more than twice the estimated time smacks of over-promise and serious under-delivery.

It also struck me that most of the people standing in the queue that day, just like me, had better things to do. So, if you’re going to keep people waiting, tell them why they have to wait, and try and show that you’re doing something about it. And it’s the manager’s job to see that this happens.

Tel: 021 945 1419 Fax: 021 946 1789 Cell: 082 558 2652 E-mail: autobalance@mweb.co.za

Maybe it’s time to have a serious look at “Queue Management” in your business?

So Long Potholes?

RL-325 DRUM LATHE

RP-20 BRAKE SHOE RIVETTER

Last month the Department of Transport launched its new project to improve public roads - S’hamba Sonke (or ‘moving together’) – which will not only see upgrading and improved maintenance of SA roads, but is also expected to create up to 400 000 employment opportunities.

A budget of R6.4 billion has been earmarked for the initiative over this year and 2012, and up to 70 000 jobs are expected to be created over the initial two year period. A further R7.5 billion is allocated for the programme to continue between 2012 and 2013, with R8.2 billion budgeted for the final phase up to 2014.

LC-500 FLYWHEEL GRINDER

RC-40 LIGHT DUTY SHOE RADIUS GRINDER

Transport Minister S’bu Ndebele told the media: “We are going to improve access to schools, clinics and other social and economic opportunities by drastically upgrading our secondary road network and fixing and repairing potholes throughout the country.” Ndebele continued that the project would require the relevant municipalities and provinces to work together with the Department, and that emerging contractors will benefit immensely from the new scheme.

He also said that a pothole hotline would be launched in months to come.

AutoForum - May 2011

It takes all sorts to make your SME tick - Pavlo Phitidis

It takes all sorts to make this world, and so too, it takes all sorts to make your business function the way you dreamt it would. In the same way that you are more interested in being an entrepreneur rather than being an employee, other people are more interested in other vocations. This is fortunate because it means entrepreneurs can employ people to do the things they do not care about and are consequently not very good at.

It’s up to you to choose the right person for the right job, so you’ll need to get to know the personality types that make your business work. It’s these personality types around which the founding entrepreneur needs to grow the expanding early-stage business.

THE VISIONARY The entrepreneur is the Visionary. You are the person whose original commercial vision has created the need to employ all the other personality types, and in fact, given them their raison d’etre. While the founding entrepreneur is Visionary Number One, it is important to understand that there is indeed room within the organisation for others to lead it into the future. And they may as well be hired during your tenure. So don’t be afraid of that bright young spark who waltzes into your office one day. That brash attitude could be masking significant potential that could make you a lot of money!

THE TECHNICIAN The Technician is the person who is unusually adept at cranking out whatever product or service it is that the SME offers to the market. They will usually live,

PAGE 38

sleep and breathe whatever line of work they are in, and in fact, tinkering with gizmos is not work at all, it’s pleasure in its purest form. It is worth highlighting that in early-stage businesses the founding entrepreneur is usually both the Visionary and the Technician. This stems from the fact that great start-ups are often the result of Technicians who discover new and improved ways of doing things while in the employ of other people. As the business takes off, it is vital the original Technician surrounds himself with similarly-skilled technical types who can improve on the original concept.

THE MANAGER The Manager is the person who you want to enter an early-stage business and start setting up the systems, policies and procedures that begin to create a semblance of order. The Manager is especially valuable because the systems he starts putting in place are the ones that will give the original founding entrepreneur room to start manoeuvring himself out of the business so that it can eventually be sold as an independent asset of value.

- making thorough background checks especially worthwhile.

THE BEAN COUNTER The Bean Counter’s responsibilities go far beyond his nickname because he is of course wholly responsible for the lifeblood of the entire organisation. This is why, in any large organisation worth its salt, you will find the Chief Financial Officer situated as close to the CEO as possible without actually sitting on his lap. Even though his passion sometimes dictates otherwise, the founding entrepreneur needs to understand that good service and great products amount to nothing if the money is not coming in.

Hiring the right employees and securing the right consultants is vital because the entrepreneur cannot possibly possess all the skills required to make the dream a reality.

Good luck with your dream and happy hunting for the right people!

THE WORKER No business can function without the elbow grease of the Worker. The entrepreneur would be well served to surround himself with workers who add value to the business by displaying the traits of loyalty to the firm, dedication to the task at hand and respect for the colleagues they are required to interact with in pursuit of the company’s objectives. With reference to these three traits, past behaviour is the best indicator of future performance

Pavlo Phitidis is the CEO of Aurik Business Incubator, an organisation that works with early-stage and growth-stage entrepreneurs to build their businesses into valuable assets. Aurik also works with businesses wanting to increases their BEE scores through Enterprise Development.

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Technology and service: Quality braking worldwide

B

osch is renowned for its competence in electrical and injection systems, but few people realise that the company also has considerable competence in the sector of brake systems.

traffic authorities. With ABS clearly the most important milestone, Bosch has made brakes safer in a revolutionary way, allowing the consequences and frequency of accidents to be drastically reduced.

In the first of this two part series, we look at some of the highlights of the company’s extensive developments in the braking field.

At present, all new vehicles built in Europe have an ABS system as standard, and there is little doubt that the ESP system will soon also be standard in the near future.

Building on the ABS system - and subsequently on the ASR/TCS ESP has been a guarantee for safe driving since 1995. An intelligent system, which is already working before the driver even notices that the situation is getting precarious, and which supports the driver actively in keeping his vehicle in control (or getting it back in control again) its no wonder that various manufacturers have already been equipping their vehicles with BoschESP as standard for a number of years.

Alongside components, Bosch also manufactures complete braking systems. This means that, in addition to the major components, such as brake discs or brake calipers, Bosch also develops and applies the correct brake system for the applicable vehicle type worldwide. As working with manufacturers allows ideal selection of the perfect brake system for each vehicle model, it makes sense that the company is represented by development and application centres everywhere that vehicles are manufactured.

Bosch developed the first brake booster in 1927, and was already active in the sector of commercial vehicle brake systems. Today, the company concentrates solely on the development and production of brake systems for passenger cars and light commercial vehicles. The importance of the Bosch developments for the vehicle industry, and for the driver, is clearly evident from the accident statistics published by both vehicle manufacturers and

CAPS – Combined Active & Passive Safety CAPS combines active and passive safety systems - such as ESP and airbag control with driver assistance systems such as ACC and navigation - and then combines them with useful or further protection measures. Through the interplay of different systems, measures are taken in the case of - or even before a collision - to avoid a

collision occurring or to reduce the consequences of the collision. An example of this would be the case of an accident where the vehicle rolls over. In order to reduce the risk and the severity of injury, the CAPS system ensures that the backrests automatically move upright, bringing the driver into the correct position, windows close automatically and the fuel supply is disconnected.

Possibly even an emergency signal is sent showing the position/location of the vehicle. All this is not only already possible, it is currently being built into an increasing number of vehicles. In future, the role of precrash sensors will be even greater in such situations.

Sensitive technology – strong performance Bosch produces more than 250 million sensors each year, for use in all the application areas in a vehicle, including for modern brake systems, such as ESP. Wheel speed sensors, acceleration sensors and steering angle sensors, check and record the actual and target conditions and supply the signals to the control units several times each second.

Its only thanks to this precise and reliable data that the extreme performances of today’s systems are possible.

See our next issue for apart two in this series.

PAGE Performance driven

41

AutoForum - May 2011

INNOVATIONS

The latest automotive technology

Move over copper – here comes aluminium

E

lectric power and electronics are playing an ever-increasing role in all kinds of vehicles and until now, copper has been the conductive material of choice - despite its being heavier and more expensive than aluminium.

Before aluminium can replace copper in power supply systems, however, a number of technological challenges need to be surmounted. When temperatures are high – and there are many places in a car where that is the case – aluminium displays a distinct creep behaviour.

Conventional connectors could thus not be used, as they would become loose with time.

One possible alternative – the use of aluminium-based elements in cables and copper-based elements in connection areas – also entails problems.

Because there is a high electrochemical potential between a copper contact and an aluminium cable, this kind of wiring would be very prone to corrosion.

At the same time, joining copper to aluminium is rather demanding with the current state of technology. In order to counteract these issues, scientists have been working with the BMW Group to develop an innovative aluminium-based electrical connection concept in a project called LEIKO. A sheet metal cage, which is an electromagnetic compatibility requirement

PAGE 42

anyway, enhances the mechanical stability of the plug and guarantees the long-term support of the contact pressure spring. Because the necessary contact force is no longer provided by the contact elements themselves, the originally problematic creep behaviour of aluminium turns into a contact stabiliser and thus, a positive property. This, in turn, also guarantees a constant contact force over a lifetime of ten years.

The researchers involved have also created a special wedge-shaped geometry for the aluminium contacts – this means that the aluminium creep now allows the two contacts to snuggle closer together over time, thereby rendering the electrical connection even better. Moreover, the consistent use of aluminium alloys and the application of precious metal plating, make it possible to relocate the formation of corrosion-prone local elements to less critical locations in the system.

Aluminium does, however, have a lower electrical conductivity than copper.

In the case of high-power on-board systems, the cable cross-sections, which are about 60% larger, need to be taken into account in the construction of cable ducts and feed-throughs. One positive thing the scientists discovered was that because aluminium is very pliable, the standard values from copper cable processing, where bending radii

Laboratory version of the aluminium power plug as it is used at the e-cart

are set based on the diameter, could also be used for aluminium.

In order to determine the long-term behaviour of the coated aluminium contacts under even the rough conditions typical for motorised vehicles, the project partners, together with leading suppliers, have successfully initiated a further research project. Funded by the Bavarian Research Foundation (BFS), this project will deliver evidence on the ageing behaviour and thus the suitability of the concept by 2012.

Initial results indicate that the material substitution will lead to significant improvements in weight, cost, and ultimately emissions. “We expect the highvoltage on-board systems of most electric vehicles to be based on aluminium by 2020. Aluminium will find its way into low-voltage on-board systems as well, because the price of copper will rise significantly with increasing demand,” says Professor Udo Lindemann from the Institute of Product Development at the TU Muenchen.

Industry-first turbo directinjected flex fuel engine Buick, in the US, has announced that its 2011 Regal Turbo is the first directinjected turbocharged production car capable of running on any blend of petrol or E85 ethanol and joins more than 5 million flex-fuel models General Motors has produced over the last 15 years. The turbocharged Ecotec 2.0-litre inline fourcylinder engine is expected to help the automaker reach its goal of offering more than 50% of its production in flex-fuel models by the end of next year.

The Ecotec 2.0L turbocharged engine including the direct injection fuel system - continuous variable valve timing for both intake and exhaust valves and the turbocharger.

Since ethanol requires a richer air-fuel mixture than petrol, flex-fuel engines need higher flow-rate injectors. However, as a flex-fuel engine can potentially have any combination of petrol or up to 85% ethanol in the tank, a

sensor in the fuel system measures the blend in real-time, allowing the engine management system to automatically adjust the mixture to provide improved performance and reduced emissions and fuel consumption. The engine also boasts stainless steel fuel lines to provide extra corrosion resistance.

Turbochargers use the energy in the hot exhaust gas flow to drive a compressor that forces more air into the combustion chamber for on-demand power delivery. The twin-scroll turbocharger on the Ecotec engine provides two inlet paths to the turbine to maximise the kinetic and thermal energy delivered to the turbine.

Other changes include a new precision sand cast aluminium cylinder block that provides better durability while transmitting less noise and vibration than lost foam casting used previously.

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INNOVATIONS

AutoForum - May 2011

Integrated seat-based HVAC system the vents. By adjusting the vents, the operator can select the most comfortable cab temperature and keep the seat dry.

It works by cooling air through an evaporator provided with an expansion valve and using the cooling gas from the AC system. Air is warmed using a heater containing the fluid from the endothermic motor, and is circulated using an electric fan. The air flow is managed by an electronic voltage regulator PWM (pulse width modulator), allowing a linear voltage adjustment at the ends of the fan.

The HVAC is designed for medium-size vehicles or equipment cabins or small rooms

D

elphi Automotive has developed a new seat-based heating, ventilation and air conditioning (HVAC) system, that it says simplifies the cab design process, minimises equipment assembly, and efficiently keeps passengers comfortable.

The system is part of the E3 HVAC Seat, which combines the automotive electronics and technologies company’s Diavia HVAC application capability, with the Italian technology company COBO Group’s steering column, seat, lighting, electric and electronic devices. The seat debuted at the CONEXPO-CON/ AGG 2011 in Las Vegas in March.

The product is designed for medium-size vehicles, equipment cabins or small rooms, and has a cooling capacity of 6.2 kW and a heating capacity of 5.8 kW. It can provide climate control for the cab only, or for the cab and seat cushion, by channelling air flow from

PAGE 44

Since the seat and HVAC unit are fully integrated, plug and play installation is simple and design and assembly time are reduced. In addition, all climate control functions are incorporated into the new electronic control board with CAN BUS interface, which has been specifically designed for industrial vehicle cabins. This new control unit built in conformity with ISO 7637 and 2004/104/CE rules - is located inside the seat arm.

INNOVATIONS

AutoForum - May 2011

New Electric Park Brake for front axles

A

new Electric Park Brake (EPB) system for front axles was recently launched that promises to make the technology more affordable for a wider range of vehicle segments. The new system boasts a number of safety benefits in addition to space optimisation in the vehicle’s passenger compartment - thanks to the elimination of the handbrake lever or pedal.

TRW is extending the range and affordability of its Electric Park Brake technology to include front axle applications for smaller vehicles.

As VP Braking Engineering at manufacturing company TRW, Josef Pickenhahn, explains: “Until recently, vehicle manufacturers have been reluctant to routinely fit disc brakes to the rear axles of small cars - normally a prerequisite for EPB - because they are relatively expensive and lower cost drum brakes can comfortably meet performance specifications. TRW’s front axle EPB offers an affordable solution, requiring only small modifications to the front axle calipers and integrating the necessary electronic components and software into an existing ESC control unit.”

Similar to conventional rear EPB applications, the front axle system offers simple vehicle assembly within the wheel environment and enhances emergency braking performance through integration with ABS/ESC in the event of hydraulic failure. In addition to this, a wide range of comfort and safety features can be included, such as hill and drive away assist; ECD (electronically controlled deceleration); rollaway detection; and premium stand still management to support ‘stop and go’ and ‘auto hold’ functionality.

Pickenhahn continues: “Our front axle EPB has the potential to further reduce the cost and weight of the rear drum brake systems which no longer require shoe actuators, linkages, fixing devices, cables, or the handbrake lever itself. It’s a further example of how we’re taking existing products and improving their affordability and fuel savings potential in line with market requirements to deliver the safety and efficiency that all drivers deserve.” The new front EPB is planned for launch in 2013.

Bosch launches waste heat study

B

osch, in a joint project with its Research and Technology Centre North America and a US university, has been awarded a $1.2 million three year grant to address the most pressing engineering and scientific aspects of thermoelectric devices for vehicles.

The grant is entitled a tongue twisting “Automotive Thermoelectric Modules with Scalable Thermo- and Electro-Mechanical Interfaces”, and basically covers the study of how the solid-state devices can harvest waste heat in vehicles, by converting it to useful electrical energy and thereby can lead to an increase in overall vehicle fuel economy.

The partnership will see Bosch provide its expertise in the fields of quantum

PAGE 46

mechanics and computational fluid dynamics. Using computer simulation methods at the atomistic level, Bosch researchers will investigate how to decrease inefficiencies present in contacts between different materials in the device. Using simulations at the device level, they will seek to increase overall efficiency by appropriate design and thermal management. Overall, this research project is expected to advance development of automotive-grade durable thermoelectric devices that can harvest an increased amount of waste heat.

According to Peter Marks, Chairman, President and CEO, Robert Bosch LLC: “Nearly half of Bosch’s R&D spending goes into the development of products that protect the environment and conserve resources.”

INNOVATIONS

AutoForum - May 2011

New zero initiator tyre pressure monitoring system

T

RW Automotive Holdings has announced that it is now in mass production of its zero initiator tyre pressure monitoring system (TPMS) – what it describes as its its lowest cost auto location system ever.

According to Laurent Crosnier, Product Portfolio Director for TRW Radio Frequency Electronics: “The zero initiator system is an example of smart thinking that reduces part count and complexity, and still delivers the performance of a direct tyre pressure monitoring system with the capability to automatically identify which tyre or tyres are under-inflated and pose a potential safety risk.”

PAGE 48

Just as with the brand’s current direct TPMS systems, the technology includes four wheel-mounted sensors to directly monitor the individual tyre pressure levels, but eliminates the need for the electronic initiators previously required to locate the sensor positions.

The receiver is typically mounted under the rear of the vehicle or in the rear bumper area, and can determine front and rear sensor locations by comparing the received signal strengths. Left and right side sensor locations are determined by sensing and processing gravitational and magnetic fields.

Thus, by combining the front/rear and left/right information, the system can determine which tyre is under inflated, without the need for any initiators.

PAGE 49

INNOVATIONS

AutoForum - May 2011

Motor oil to fuel

A

report presented recently at the 241st National Meeting & Exposition of the American Chemical Society (ACS) described the development of a new process for recycling waste crankcase oil into petrol-like fuel — the first, they claim, that uses microwaves and has “excellent potential” for going into commercial use.

“Transforming used motor oil into gasoline can help solve two problems at once,” said study leader Howard Chase, Professor of Biochemical Engineering at the University of Cambridge in the UK. “It provides a new use for a waste material that’s too-often disposed of improperly, with harm to the environment. In addition, it provides a supplemental fuel source for an energy-hungry world.”

The report estimates that across the world, oil changes in commercial and private vehicles result in around 30 billion litres of used motor oil each year. In SA, the US and some other countries, some of that used oil is collected and re-refined into new lubricating oil or processed and burned to heat buildings. Chase notes, however, that such uses are far from ideal - re-refining oil and burning waste oil can be environmentally polluting. Non collected oil can pollute water and cause other serious environmental problems.

This means that scientists are always looking for new uses for that waste oil.

Among the most promising recycling techniques is pyrolysis, a process that involves heating oil at high temperatures in the absence of oxygen. The process breaks down the waste oil into a mix of gases, liquids, and a small amount of solids. The gases and liquids can then be chemically converted into petrol or diesel fuel. However, the current processes heat the oil unevenly, producing gases and liquids not easily converted into fuel.

The new pyrolysis process appears to be highly efficient, converting nearly 90% of a waste oil sample into fuel Chase says the new method overcomes this problem and uses new pyrolysis technology. In laboratory studies, samples of waste oil were mixed with a highly microwave-absorbent material and then heated in microwaves. The new pyrolysis process appears to be highly efficient, converting nearly 90% of a waste oil sample into fuel. So far, the scientists have used the process to produce a mixture of conventional petrol and diesel.

“Our results indicate that a microwaveheated process shows exceptional promise as a means for recycling problematic waste oil for use as fuel,” Chase and Lam said. “The recovery of valuable oils using this process shows advantage over traditional processes for oil recycling and suggests excellent potential for scaling the process to the commercial level.”

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PAGE 50

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AutoForum - May 2011

Auto Safety

AutoForum - May 2011 New crash tests and analysis by the Insurance Institute for Highway Safety demonstrate that underride guards on tractor-trailers can fail in relatively low-speed crashes.

SAE launches driver distraction book SAE has launched a new book entitled “Performance Metrics for Assessing Driver Distraction: The Quest for Improved Road Safety” which is a wide-ranging examination of current driver metrics research and applications, that helps better understand and measure driver’s distraction. This 264-page volume consists of 15 chapters concerning methods for assessing driving and secondary task performance.

“Government and the vehicle industry have made improving road safety and reducing driver distraction a top priority. The need for deeper expertise in these subjects is rapidly growing,” explains Dr Gary L. Rupp. “The book attempts to help fill the gap in how to measure the distraction impact on the driver of OEM or nomadic infotainment devices, including roadway infrastructure messages that are introduced into the vehicle.”

In addition to the book, the organisation has launched an online interview with Dr Linda Angell, a researcher at the US’ Virginia Tech Transportation Institute, and one of the authors of the book. The interview covers various topics, including the importance of measures used to understand driver behaviour and distraction, NHTSA’s renewed focus on addressing driver distraction, and new developments in video-based measures of driver distraction and peripheral and tactile detection tasks – all of which are vital components of emerging safety technologies.

The video can be found online at http://books.sae.org/book-r-402.

Underride guard hazard

N

ew crash tests undertaken by the US Insurance Institute for Highway Safety has found that underride guards, or ‘underrun protection devices’ in SA, on tractor-trailers can fail in relatively low-speed crashes — with deadly consequences. The Institute is petitioning the US government to require stronger underride guards that will remain in place during a crash and to mandate guards for more large trucks and trailers.

Rear guards are the main countermeasure for reducing underride deaths and injuries when a passenger vehicle crashes into the back of a tractortrailer. In 2009, 70% of the 3 163 people who died in all large truck crashes in the US were occupants of cars or other passenger vehicles. Underride makes death or serious injury more likely since the upper part of the passenger vehicle’s occupant compartment typically crushes as the truck body intrudes into the vehicle safety cage.

“Cars’ front-end structures are designed to manage a tremendous amount of crash energy in a way that minimises injuries for their occupants,” says Adrian Lund, Institute President. “Hitting the back of a large truck is a game changer. You might be riding in a vehicle that earns top marks in frontal crash tests, but if the truck’s underride guard fails — or isn’t there at all — your chances of walking away from even a relatively low-speed crash aren’t good.”

In the latest study, the Institute analysed case files from the Large Truck Crash Causation Study, a US governmental database of roughly 1 000 realworld crashes in 2001-03, to identify crash patterns leading to rear underride of heavy trucks and semi-trailers with and without guards. Underride was a common outcome of the 115 crashes involving a passenger vehicle striking the back of a heavy truck or semi-trailer. In 23 of the 28 cases in which someone in the passenger vehicle died, there was severe or catastrophic underride damage, meaning the entire front end or more of the vehicle slid beneath the truck. The study raised questions about how and why guards failed and at what speeds, prompting the Institute to conduct crash tests evaluating three semi-trailer rear guards complying with US rules. Two of the trailers are also certified to Canadian requirements, which are more stringent than the United States when it comes to strength and energy absorption.

PAGE 52

Decapitation is a serious threat in underrides. In three of the crash tests the heads of the dummies in the car made contact with either the intruding trailer or the car’s bonnet after it tore free and pushed into the occupant compartment. One such test involved a Hyundai trailer whose underride guard bent forward, sheared its attachment bolts, and broke after the test car hit it in the centre rear at 35 mph (56 km/h). This was the weakest guard tested – the trailer was manufactured by Hyundai Translead.

What are the regulations in SA? This is covered under ‘Regulation 218 - Rear underrun protection device’ · There are a few exemptions such as chassis/cabs being delivered and truck tractors for semi-trailers · The device must comply with SANS 1055, Rear underrun protection devices, and constructed to withstand a prescribed force without deflecting more than 450 mm inward from the rearmost point of the vehicle. · Underrun bumpers must be fitted to all heavy goods vehicle above 12 000 kg GVM and trailers above 3 500 kg GVM. Body builders are also compelled by law to fit them to all new trucks 8 000 kg and above · Underrun bumpers must also be free from any defect which would adversely affect their performance in absorbing impact The sad fact is that for the most part, this safety critical item is not maintained and/or damaged on many SA trucks – or absent! And that is thanks to both ignorance and lack of law enforcement.

The Institute also ran tests with overlaps of 50% and 30% to find out what happens when a car hits the trailer with only part of its front instead of head-on. The results show that even the strongest guard left as much as half of the rear of the trailer vulnerable to severe underride, and only worked as intended when the striking car engaged the centre.

The offset tests stress guards’ unsupported outboard ends. The vertical frame supports that attach guards to their trailer chassis are closer to guards’ centres than ends. Preventing underride in narrow overlap crashes like these might mean devising a new way of attaching guards to trailers to utilise the side rails, in addition to requiring manufacturers to conduct compliance tests with guards on trailers.

“Under current certification standards, the trailer, underride guard, bolts, and welding don’t have to be tested as a whole system,” Lund says. “That’s a big part of the problem. Some manufacturers do test guards on the trailer. We think all guards should be evaluated this way.

At the least, all rear guards should be as strong as the best one we tested.”

Phoning while driving might not be that bad.... but only at certain times

A

lthough many human factors/ergonomics studies conducted over the past few years indicate that drivers who talk on the phone fail to attend to the road and increase the likelihood of an accident, the monotony of driving may also pose an accident risk. New research by the University of Kansas in the US, suggests that drivers who lose focus on the road because of boredom may actually increase their attention by engaging in a secondary task, particularly during the last leg of their journey.

In a driving simulator, 45 participants drove for 30 minutes while talking on the phone. Researchers Paul Atchley and Mark Chan tested their attentiveness and short-term memory by introducing various obstacles, such as a car suddenly pulling in front of them or a popular fast food restaurant billboard flashing by. Some drivers were given a secondary task throughout the drive, some performed an additional task at the end of the trip, and some had no concurrent task.

Drivers’ level of attention was gauged by their ability to stay in their lane, react in time to avoid an intruder car, avoid radical steering maneuvers to maintain a steady course, and accurately remember the signs that they passed.

Results from the study indicate that drivers who had to perform a concurrent task in the latter portion of the trip were more likely to stay in their lane and were less likely to commit road infractions, compared with drivers who had either a continuous or no additional task. These findings, they believe, suggest that as driving becomes monotonous and drivers’ minds drift from the road, strategically introducing an additional task, such as a talking on the phone or listening to the radio, might improve driver attention and stability.

The authors caution that “although these results suggest improvements in driving performance, there is still a degree of risk involved” when drivers perform a secondary task.

The research for this study was funded by the University of Kansas Transportation Research Institute.

PAGE 53

AS – G G N I N O I T I D N AIR CO NDS A T S T I S A N O I T THE SITUA nced a great deal of Industry has experie The Fluorochemicals t impact on the availcan nifi sig a had ich has volatility in 2010, wh d further into 2011, it hea we As . refrigerants r industry faces and ability and pricing of ou ues some of the iss is important to explain outlook for the situation we might expect as’s this article gives A-G . in 2011 ial of primary raw mater to Availability and costs r and Sulfur (the two components used pa ors oro Flu of Flu all sts co for e ne Th ori • de, the source of Flu make Hydrogen Fluori orspar mine capacised dramatically. Flu rea inc e hav ) chemicals ina, a significant Ch and rs in recent yea ties have decreased s. ort restrictions on exp source, has put trade ased by around cre de e hav ties aci bal cap sharply as availability • Chlorocarbon glo and costs have risen 50% in recent years d with Hydrogen cte rea are s lorocarbon has become tight. Ch ).

Cs (HF drofluorocarbons Fluoride to make Hy st of the raw materials co sed rea inc and supply chemicals neces• Due to the short s, the prices of Fluoro ue to do so to make fluorocarbon ntin co and 10 oughout 20 sarily rose sharply thr in 2011.

for rs have laboratories established distributo one such ing be Worryingly, very few AS A-G y! alit ng product qu rchecking and verifyi y facilities used prima rn in house laborator nts era rig ref ng uri distributor with mode ens by of incoming product The latter has ily to control quality AHRI 700 standards. of s ion cat cifi spe owing on-going foll meet the t, rke ma service to the given the innts recently launched this era rig ref rket place to test rket. “We have ma r requests from the ma ou g material entering min for on n-c no in ma crease terial pri rily being rease in suspect ma s noted a significant inc many of which besides having suspiciou les, l forms ga ille are and supplied in disposab n tio ly with local legisla Manager of A-Gas contents do not comp hael Labacher, Sales Mic s say g.” gin cka of pa South Africa. ure the on-going mary function is to ens “Our laboratory’s pri ern African markets,” uth So the to nts era rig . supply of superior ref of A-Gas South Africa er nag Ma l ica , Techn and in line ed nis says Paul Oudtshoorn og rec ally ific d are scient “All test methods use ingent quality control in keeping with the str ent with AHRI, as well as and 14001 managem ed by our ISO 9001 cifi spe as s ure ced pro systems.

HFC’s Growing demand for g economies (espeHFC’s in large growin nning or restricting Domestic demand for ba n to rise. Legislatio cially China) continues ly further increased their demand, with on the use of HCFC’s has tion rates have been chemical plant utilisa l the result that Fluoro in China. As the globa ing lud hs globally, inc will and h hig y ver are pushed to record hig ios acity utilisation rat economy recovers, cap out 2011. gh ou thr so be to ue contin R134a supply of R134a Specific situation of , global inventories and n doubling and tha From the start of 2010 re with market prices mo ials costs and high have been very tight ter ma raw in to increases close to tripling due n struggled to rebuild The industry has eve capacity utilisations. w-season”. inventories in the “lo ished product is the raw materials and fin Securing supply of market top priority for the rior R134a product be n an increase in infe ). A 10 20 ec v/D No South Africa has see m country (See AutoForu erants have recently ing imported into the anies importing refrig mp co r alle sm ly in refrigerants. cal number of cifi spe al de whom do not en purchasing a twe sprung up, some of be nce are of the differe et sector being ark erm As such they are unaw h the automotive aft wit t no or ct du pro pure hardest hit.

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courtesy of A-Gas So

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PAGE 55

AutoForum - May 2011

Mercedes-Benz tweaks Atego and Axor - Dave Scott

T

rucks don’t get facelifts. A facelift for a truck is a waste of what a truck stands for as a productive machine. What trucks get are consistent product upgrades and technical tweaks that make them safer, better at fuel consumption and more durable. There’s not one truck manufacturer that is not talking about Total Cost of Ownership (TOC) – it’s not just a subject, it is a journey.

When it comes to TOC, Mercedes-Benz is trying hard to be different, because being different is what product strategy is all about. And TOC is not confined to the vehicle – it’s the augmented product offering that includes warranty, service intervals and financial packages to name but a few. In this area Mercedes-Benz is perceived to be the leader for the present: •

• •

•

FleetBoard – in new Actros 3 this system comes as standard equipment but can be retro-fitted in all Actros 1 or Actros 2 models and selected Axor or Atego trucks. Fleet managers have immediate access to the most important information for each of their vehicles, which includes service tele-diagnostics, trip records and mapping.

CharterWay – a suite of vehicle leasing, maintenance and servicing products tailored specifically for the truck fleet owner.

Specialised driver-training – An important element to CharterWay is the curriculum offered by Mercedes-Benz, where professional truck drivers are taught in their operating environment to drive more economically and safely.

30 000 km services intervals for long-haul applications – the only pre-condition is use of synthetic lubricants. This has shifted up from 22 500 km service intervals.

While a one-year unrestricted warranty applies to the whole truck, Mercedes-Benz Commercial Vehicles offers an extended warranty on the powertrain of three years, or a specified maximum kilometre limit for all models.

•

UD Trucks SA not affected Last month UD Trucks confirmed that it had started with limited production at its three plants in Japan. At that time, two staff fatalities had been confirmed, while the remainder of the 9 500 staff it has together with Volvo Trucks in the earthquake hit country, were accounted for.

The company explained that while production levels will progressively increase as alternative supply processes come into play, production outside Japan – including with SA - will not be significantly affected.

Johan Richards, Chief Executive of UD Trucks Southern Africa confirmed that it remains in contact with the management of the UD Trucks Corporation and will keep dealers and customers informed of any new developments.

PAGE 56

•

Warranty on the Atego powertrain is three years with a 250 000 maximum kilometre limit.

The warranty kilometre limit is valid up to a mileage of 450 000 km/3 years for Actros and Axor across the board, with the exception of vehicles in start/stop operations, where the kilometre warranty limit is 250 000 km/3 years. These units are primarily tippers and concrete mixers used for heavy duty construction, where mileage covered on a per annum basis is minimal.

“Where vehicle performance and service intervals are based on hours – such as in-quarry operations or concrete pumping or crane trucks – then a limit of 5 000 engine hours would apply to the outer limit of the driveline warranty,” says Mercedes-Benz Product Manager, Christo Kleynhans, and adds: “Engine hours can be read off the engine electronic control module by a qualified technician using their proprietary software.”

The new Mercedes trucks do require a more literate driver and a different mindset, as all variants are now equipped with a multifunction steering wheel to operate the on-board computer, telephone and radio. The Axor comes standard with a communications centre, including new radio with Bluetooth capabilities, and CD player with control functions integrated

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.

through the multi-function steering wheel. The ‘new generation’ model Atego and Axor are very driver focused but the word ‘comfort’ is not in vogue with the SA transport community, they really want productivity with safety as a side issue.

Most extra-heavy 6 X 4 trucks are equipped with automated manual-shift transmissions. In line with this trend, the 9-model Atego range (GVM’s ranging from 9.5 to 15t) offers an optional Telligent automated gearshift that enables the driver to concentrate fully on driving in heavy distribution work. This automated gearshift is also kind to the transmission components and will lengthen driveline service life. Axor is standard with a 3-pedal manual shift transmission. Euro 3 level, electronically-managed, turbo-intercooled engines provide more than enough torque for every application.

The Japanese truck manufacturers dominate the heavy truck market – 8.5 to 16.5 tonne GVM. March 2011 was a typical month where European truck

brands struggled for volume where Japanese models swept away 85% of this segment.

HEAVY TRUCKS - 8,5 TO 16,5 TON GVM - MARCH 2011 RETAIL SALES Make MAN

Germany

Brazil

Japan

India

9

VW

9 3

Mercedes-Benz

Total 3

21

21

Fuso

37

37

Isuzu

89

89

UD Trucks (Nissan Diesel)

153

153

Hino

129

129

TATA 30

3

408

41

41

41

482

Kobus van Zyl and his team have a challenge on their hands for a share in his 24.000 forecast for trucks and buses in 2011, because in spite of a brilliant support package, a 42 dealer network and a sound model line up they are not getting a traditional Mercedes-Benz share. Remember the days when Merc owned 40% of the truck market? The strategy is in place, now observe the outcome.

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PAGE 57

COMMERCIAL VEHICLES

AutoForum - May 2011

Hino 700 Series – a two-pedal affair

A

n affair with a truck… you’ve got to be joking! Drivers really do love or hate their trucks and the first version of the Hino 700 Series was not easy to love, especially in truck tractor kit – chassis packaging was not compact and neat, fuel tank range was limiting and the 16-speed manual transmission required more driver training to ensure that technical faults were reigned in. All this has changed.

In broad-brush strokes covering all trucks sold over 3.5 tonne gross vehicle mass (GVM), Hino claims to be the number two brand in South Africa.

However, segmenting the market shows that Hino underperforms among the extra-heavy class trucks, over 16.5t GVM upwards. And it’s the extra-heavy market that generates good money – especially in parts and service – so there’s every reason for Hino to focus on the extra-heavy segment. As Dr Casper Kruger puts it: “We should divide our time allocation into one-third for new truck sales and two-thirds for parts and service. The latter is the basis for customer experience.”

Then there’s the product. Extra-heavies have set the trend in trucks for automated manual transmissions (AMT) where all the leading brands offer AMT as a standard feature. Hino 700 Series will now be equipped with ZF ASTronic AMT in 16-speed version and

not 12-speed as among competitive trucks also using the AS-Tronic box.

The 16-speed AS-Tronic is the spec for Australia and South Africa and is ZF’s preferred version for arduous operations. Here in summary are the claimed improvements: • Optimum protection against driver influences • Increased service intervals • Faster gearshifts that saves fuel • Extended clutch service life • Perfect communication between engine, clutch, and transmission Hino Product Manager, Dewald Olivier, offers the following viewpoint: “AMT takes any guesswork out of gear selection. Driving a truck should now be a perfect ‘green-band trip’ regardless of whether a driver is fresh at 07h00 or very tired at 19h00 after a day behind the wheel.”

But driver training does not go away.

AMT makes driver training easier as drivers do not require a shift procedure as in the range-change mechanism inside the 2 X 4 shift plus splitter (16-speed) manual transmission. It makes a good driver out of an average/poor driver but an excellent driver can still outperform AMT when he has intimate knowledge of a route and can anticipate gradients. The AS-Tronic

- Dave Scott

AMT includes a manoeuvring mode, a switch next to the shift lever that allows slow-speed operations when docking a combination and especially in reverse gear. Hino does offer driver training – Sam Senne is their expert – but Senne cannot be in two places at the same time, so there’s a queue for his services.

The ZF AS-Tronic only uses synthetic ZF approved lubricants and in long-haul applications provides a lube drain interval of 300 000 km. The least fiddling with transmission lubrication the better is the opportunity of improving component service life. An extended drain interval also reduces total cost of ownership and minimises service downtime.

Hino 700 Series chassis packaging is vastly upgraded when compared to the first units sold in South Africa a few years ago. The truck tractor models carry 800 litres of diesel in neatly mounted side tanks, while the air reservoirs are grouped with the brake-system air-drier, and there is no excessive protrusion of the rear chassis. The Japanese engineers have listened to the market - but it has taken time.

Driving a Hino 700 Series AMT is far more of a psychological task than ever before. Truck operators are concerned with drivers falling asleep behind the wheel and so-called ‘highway hypnosis’.

Neat chassis package

PAGE 58

Dr Johan

Dr Casper

van Zyl

Kruger

When you switch on cruise control with AMT and then super-heat the cab in winter - the combination of factors leads to drowsiness and extended reaction times. Add to this a poor diet plus low health levels and the risk magnifies.

The truck driving challenge is staying alert in a long-distance, monotonous environment.

The natural disaster in Japan may have an impact on Hino availability.

According to Dr Johan van Zyl, Toyota SA Motors President and CEO, all Japanese vehicle manufacturers have been affected by the earthquake and tsunami. Component suppliers, especially electronic and rubber parts have been wiped out. It seems that Just-InTime (JIT) is a problem as there’s no buffer stock. Dr van Zyl can see as far

as the 21st of April for the production capacity of Toyota SA Motors – after that the outlook is uncertain, and this includes Hino.

Kruger expects a truck market anywhere between 24 and 26 thousand units in 2011 and wants to retain that number two brand spot. Hino will also be launching new products at the Johannesburg International Motor Show this year, plus they are going to improve on the cost of ownership offering that goes with Hino - tough news for competitors and good news for truck operators.

Hino South Africa is doing the right things and we hope for their sake that the terrible tragedy in Japan has a minimal outcome for globalised production.

Unique Truck Driver Training Programme

W

ith numerous barriers to commercial driver training across most of Africa, such as a lack of professional driving schools and a clear driver training curriculum, as well as the fact that classroom-based training means drivers off the road, never mind the AIDS and HIV scourge, finding a well trained commercial driver is not easy.

In order to address this gap, North Star Alliance – a non-governmental organisation that ensures highly mobile populations, especially truck drivers and their direct and indirect contacts, have access to basic health services - and Fleet Forum - an independent association that focuses on transport issues in low- and middle-income countries - recently partnered to develop modular driver training courses.

As Paul Jansen, Director of Fleet Forum explains: “If you can’t get the driver to the classroom, you have to get the classroom to the driver. Road traffic accidents are expected to increase dramatically by 2030 to become the third leading cause of death globally.

That increase will have a particularly significant impact in low- and middleincome countries, where road traffic accidents already pose an enormous

health risk. Fleet Forum has developed an award-winning Fleet Safety Management Toolkit, which has been tested and used by several aid and development organisations in Africa and India. We now want to use that knowledge and expertise to improve fleet safety in the commercial sector as well.”

“Health and safety go hand-in-hand when it comes to keeping drivers on the road,” explains Luke Disney, Executive Director of the North Star Alliance. “We are extremely excited about our partnership with Fleet Forum and the opportunity to expand our training services to include their award-winning road safety programme. Our discussions with industry representatives in Africa and India make us confident that by bringing training products to drivers on the road, we’ll have a significant positive impact on small- and medium-sized transport operators.”

The training will be delivered through the North Star Alliance Roadside Wellness Centres, semi-mobile converted shipping containers that are placed at ‘hotspots’ such as border posts or transit towns where large numbers of truckers stop and sex work and other informal trades flourish. Health

communicators and clinicians offer a range of health services in a stigma-free setting including condoms, information on nutrition and HIV prevention, blood pressure checks, malaria treatment and antihistamines. The centres are currently located across the African continent and are being expanded to other regions. By leveraging that network, Fleet Forum believes that it can reach out to the broader transport community, using both the organisations’ unique insights: in depth knowledge of mobile populations and driver health, and fleet safety management capabilities.

“We will start our joint training programme by developing modules that focus on safe and healthy driving practices. In the immediate term, we will include modules on Eco-driving and Basic Truck Maintenance. Training truck drivers will not be the only element of this partnership. We know from experience that in order to mitigate the risk of road traffic accidents, we have to train management as well. So while drivers are being trained in the Wellness Centre, Fleet Forum staff will simultaneously train management on road traffic risk management,” said Jansen.

PAGE 59

COMMERCIAL VEHICLES

AutoForum - May 2011

Fuel Price Spurs Demand for CNG trucks

A

ccording to a release by Ford in the US, higher fuel prices, increasing government incentives and more fueling stations have seen a rapid rise in interest in compressed natural gas-powered commercial vehicles.

The automaker points to a taxi company as an example: the company will soon take delivery of 20 Transit Connect Taxis powered by CNG. The business is not alone in wanting to own natural gas fueled vehicles as orders for CNG Transit Connect Taxis are on the rise across that country.

CNG is made by compressing natural gas - mainly composed of methane - which is stored and distributed in hard containers at a pressure of 2 900 to 3 600 psi. About 85% of the CNG used in the US is produced domestically. CNG is used in traditional petrol internal combustion engines that have been modified and boasts a number of benefits.

It is nontoxic, clean-burning and significantly reduces CO, CO2 and NOx compared with petrol. According to the US Environmental Protection Agency, use of CNG can result in 30 to 40% less greenhouse gas emissions.

Another benefit is cost. According to the Department of Energy in the US, between September 2005 and January, the price per gallon equivalent of CNG peaked at $2.34 in the summer of 2008. The national average was $1.93 in January 2011, the same as it was in October 2010. To put that into perspective, the price of petrol in that country in January 2011 was close to $4 per gallon.

CNG-powered commercial vehicles to market – even during economically challenged times.

Government incentives, such as rebates or tax credits, are also encouraging fleet owners to buy or convert their vehicles to run on CNG at reduced rates. One programme is providing $300 million in funding to regional projects across the United States. The incentives are also helping fund construction of CNG fueling stations, with close on 1 000 CNG fueling stations are already operational.

Gerald Koss, Marketing Manager for Ford fleet operations, anticipates the infrastructure to support CNG vehicles will evolve and confirmed that the automaker remains committed to its plans to bring

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PAGE 61

COMMERCIAL VEHICLES

AutoForum - May 2011

MAN – ‘Gobalising’ with customer proximity

- Dave Scott

O

or take a share. We decided to do something.”

n 1 January 2011, MAN Nutzfahrzeuge AG officially became MAN Truck & Bus Aktiengesellschaft. Dr Georg Pachta-Reyhofen, Chairman of the Executive Board of MAN explains: “Our company’s new name shows employees, customers and the general public all round the world what we stand for. MAN Truck & Bus does this succinctly and is internationally understood.” That’s very true as the Internet is in English and even the French have to use English when surfing the ‘net’. The new URL is www.mantruckandbus. com. By name ‘MAN Truck & Bus’ is a step towards customer proximity – beyond a very fine product range there are customers out there!

MAN Truck & Bus is taking a serious global view: • VW Brazil has become a launch platform to boost MAN heavy trucks in South America.

• MAN has a 25% stake in SINOTRUK in China. When asked the question of whether providing the Chinese with

PAGE 62

technology will not bite back as they start to export into the markets that gave them a technical head-start, Markus Geyer, Head of Sales Region Middle East & Africa replied: “Participating in China’s truck manufacturing was a strategic decision – do nothing

• The MAN CLA range is the result of a joint venture between MAN and India’s Force Motors – we are assured that initial quality issues have been resolved and that MAN intend to grow this brand on the SA truck market. It is understood that a customer buys a MAN truck and expects a MAN truck – where it is sourced is irrelevant.

• And then there is the question of Scania, lips are sealed on this issue, although it is understood that MAN made a bid for Scania. Reviewing the investment costs of producing a diesel engine to Euro 6 standards, it was found to exceed one billion Euros. It makes sense to pool resources when faced with massive fixed investment and bring down unit costs.

customer focus through 28 dealers – it is as Geyer says: ‘about customer proximity and being the number one choice’.

It is driving this ‘customer proximity’ via 10 promises and it would be useful for local MAN operators to find out what these are in their own interests.

Decision-making at the point of sale was mentioned as a key attribute of the ‘customer proximity’ philosophy.

According to MAN Truck & Bus South Africa, the new MAN TGS introduced in September 2010 is exceeding expectations and the 40 000 km service interval is well received. Like all high-quality

brands, MAN is preaching total ownership costs – TOC. Locally MAN is ‘chipper’ about its position in SA. It is trying hard to instil a culture of speed of response and

New Releases 3/8” metric 17 piece starter set Snap-on recently highlighted its US made 3/8” Drive Metric 17 Piece Starter Set, which boasts a number of benefits including a high strength sealed head ratchet ensuring strength, precision, and durability, and a wobble engagement on extensions that provides 16 degrees of additional accessibility. In addition the set includes FLANK DRIVE® sockets that grip the fastener on the flanks/flats and increases torque by 15-20%.

The set is nickel chrome plated, which provides a wear-resistant finish and the highest quality steel on the breaker bar, so that your starter set will last long beyond what the name suggests.

For more information contact us on 0861 762 766 or email equipment@snapon.co.za

MAN has been around for 250 years and is an enduring brand. It has some really big fleets in South Africa – take the 500 MAN buses operating at Golden Arrow Bus in the Cape as an example. MAN also owns branches and is heavily invested in local assembly for trucks and buses. South Africa must take some pride that a brand like this is so well established and serves South African operators. The Middle East is embroiled in political foment, so perhaps Mr Geyer will travel more frequently from his Dubai office to visit South African customers rather than Middle Eastern customers – it is after all about ‘customer proximity’.

New Releases

AutoForum AutoForum - May 2011 - May 2011

New turbos launched at TG Festival Technology and manufacturing company Honeywell Turbo Technologies, part of Honeywell Transportation Systems, took advantage of the Johannesburg Top Gear Festival to launch its Garrett GTX series of aftermarket turbochargers.

The new turbo is interchangeable with its Garrett GT counterparts, and can be retrofitted. It boasts an 11-blade forged aluminium alloy compressor wheel, which delivers 10-20% better flow and boost pressure ratios than a GT wheel of the same size, while the mid frame turbo includes a patented dual ball bearing cartridge for enhanced durability and reduced transient response.

This new product line is now available through TurboDirect, the appointed performance distributor in the region.

www.AutoForum.co.za

Monroe launches 304 new part numbers Monroe used the latest Automechanika South Africa event to launch its new 2011 catalogue, which boasts a whopping 304 new part numbers, and supports the company’s goal of covering the vast majority of the SA car parc.

As Philip Lutz explains: “Monroe is a suspension solution provider because of the comprehensive range of suspension products and shock absorbers. Our range includes shock absorbers for passenger and commercial vehicles and off-road as well as Protection kits, Mounting kits, Steering dampers, Maxlift Lift supports and new on the market, Monroe springs and Steering and Suspension components brought in as special orders for customers willing to order bulk and carry stock.”

The Monroe range includes: Monroe Reflex Premium - for cars - advanced gas and piston technology (5 year warranty); Monroe Original - suitable for older models this value for money oil technology; Monroe Original Gas - for cars and bakkies - an advanced overseas gas technology; Monroe Original Gas-Adjust - unique four-way adjustable gas technology; Monroe Magnum - for heavy duty vehicles to ultra-heavy duty technology; Monroe Gas-Magnum - for 4x4’s, SUVs’s and bakkies – an affordable advanced heavy–duty technology and many more.

For further information contact Philip Lutz - 011 574 5602.

Federal-Mogul launches Easyvision wipers Federal-Mogul has for many years been a highly regarded innovator in the OE wiper blade category, and has now announced that its Champion brand will serve both directfit and upgrade (retrofit) applications in the distinct mid-level price point market segment. That’s thanks to its latest innovation, Easyvision.

design enables the spoiler to self-adjust to changing wind speeds for performance wiping and facilitates the use of every Easyvision blade for either left- or right-hand application.

The unique Master Connector system ensures fast, secure installation on each of the five primary directfit – top mount, top mount BMW, side pin, bayonet/push button and flat bayonet) - and two retrofit (J-hook 9x3 and 9x4) arm designs.

The range of flat blades was developed to help parts distributors, workshops and retailers maximise sales in the industry’s fastest growing wiper segment – economic replacement blades for vehicles originally equipped with flat blade technology, and for upgrades from conventional, bridge-type wipers.

The Champion Easyvision flat blade programme incorporates all seven primary wiper arm designs, covering 85% of the European car parc of all direct and retrofit applications. It boasts just 14 stock keeping units (SKUs), which is enabled through two exclusive engineering innovations – variable geometry spoiler (VGS) technology and the Master Connector system.

Breakthrough VGS technology incorporates a symmetric, flexible rubber spoiler into the blade element and has resulted in the reduced SKU count of the product. The patent-pending

PAGE 64

Champion’s wiper blade innovation, Easyvision, serves directfit and retrofit applications and features variable geometry spoiler technology and the Master Connector system.

PAGE 65

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