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Newplant

After a decade of Volvo truck and bus CKD (completely knock-down) assembly in Gabarone, Botswana, the world's largest producer of commercial vehicle engines has moved its African assembly plant south to an industrial park just outside Durban.

According to Leif Hultman, President, Volvo Global Manufacturing, "about one and a half years ago we decided to relocate our factory in Botswana to Durban in order to improve the efficiency in production and also reduce lead time significantly. 
The R40.8 million factory has been custom designed for the production of Volvo trucks and buses for the southern African market and is part of the Global Manufacturing division within Volvo Trucks."
 

Piece by piece, like a giant Meccano set, the assembly plant puts together the Volvo truck range.

The extra-tough Volvo chassis being riveted together.

The site, located in Southgate Park, Umbogintwini on the south coast of Kwa-Zulu-Natal boasts 7422m² of under-roof factory facilities, 4475m² of which is designated for production, 1965m² for warehousing and 982m² of office space, says Glen Owen, General Manager Industrial Division: "We have a capacity to produce up to eight truck or bus units per day. We have a brand new plant and a top-class working environment and have taken great care in recruiting personnel with strong technical capabilities and a responsible work ethic. Training of all staff is extensive and ongoing." 
 

New staff, new engines - a new beginning for Volvo in southern Africa.

Cabs in waiting - ready to take their place on the production line.

Owen, who led the relocation project team, was congratulated by his senior colleagues, including Anders Lindblad, new President, Volvo Southern Africa, at the inaugural event held onsite in late-August: "In our last few months we have faced the challenge to start a new production plant with new staff and an entirely new Volvo product with the 13-litre engine and improved I-shift gearbox," says Owen. "I am pleased to say that we have met our production targets and are confident that we shall continue to produce vehicles to Volvo's high quality global standards.
 

Ready to roll - a completely built up Volvo FH 440.

"The production process features sixteen different stages, each of which is designed to gradually build the CKD kit into the final product. After the truck leaves the production line it is thoroughly checked for quality of assembly according to a stringently laid down process and is road tested before being given the final 'green-O.K.' to leave the plant."

A compliment of 60 staff is employed in current production of four truck units per day, explains Owen, with 49 people involved in the assembly line and logistic activities, and 11 in administrative duties.
 

Glen Owen shows Durban's Deputy Mayor how a Volvo cooling system works

"The plant is fitted out with the latest cranes and hoists supplied from Sweden to ensure that the latest equipment is on hand to assist in the production line," he adds. "One small example of a unique Volvo production tool is called a 'nut-runner' which has the capacity to hold a bolt with the inner part whilst the outer part can tighten the nut. This greatly improves efficiencies."

The inauguration of the plant coincided with the world conference for Volvo International Manufacturing, hosting representatives from Global Manufacturing facilities around the world (including Sweden, Belgium,USA and Brazil), meeting in Durban to share common information relevant to the industrial division, according to Hultman: "It is my utmost belief that this plant will be of strategic importance, not only for Volvo but also for the Durban region. This is yet another step towards an even deeper friendship between South Africa and Sweden," he concludes.