The Struandale engine plant was commissioned in 1964 and since then, produced a variety of engines, including a few legends such as the Essex V6, Kent and RoCam motors. In recent years the plant has focused its attention on producing power-plants for its Ranger models and others. I was invited by Ford SA to help build a few engines and as one can imagine, things did not go according to plan.
In 2018 Ford South Africa invested R3-billion into its production capacity which saw the installation of a sophisticated new assembly line for the brands latest line of diesel engines. This new assembly line has an installed capacity of 120 000 engines per annum. The plant has also upgraded its production facilities to include the Duratorq TDCi program which adds incremental volumes, with 22 new four-cylinder engine derivatives being exported to European markets. One of the standout motors on this line is the 2.2-litre diesel which offers between 88kW / 285Nm to 118kW and 385Nm. This motor has been known for its fuel efficiency and has been kept in the line-up for those wanting a tried and tested engine.
Ford South Africa decided that it would be a good idea to allow media to assist in assembling a few of their engines, specifically their latest 2.0-litre turbo and bi-turbo units. The Struandale plant has an installed capacity to make 120 000 of these new-generation 2.0-litre engines a year but after we visited I think that number might be slightly lower now. Visiting a manufacturing facility such as this does boggle the mind, especially when you look at the numbers. Ford currently runs 2 shifts per day, 5 days a week and results in one complete engine every 134 seconds. Doing the math, you will work out that round 576 engines are produced every day. These units are transported to the Silverton plant in Gauteng where they are installed into the locally-produced Ranger, Ranger Raptor and Everest models. Just over 500 units and various components will find their way to export markets.
It is, however, the men and women that have poured their hearts and souls into this company that makes the difference. There are 110 work stations and 96 operators per shift and they allowed us to participate, which was all laughs up until you find yourself standing there with a cylinder hear in your hands, an alarm going and a line-manager telling you that the factory has come to a stop because you are moving too slowly. My first task involved having to place a cylinder head into a machine which seamlessly and precisely placed a thermal sealer on the outer edges after which I had to place it onto the block without smudging the sealer. With a pneumatic impact wrench, I fastened a few bolts to secure the unit. The last task is to spin the engine around for the next worker on the specifically designed and mobile stand and push a green button before the alarms went off and the line started moving again.
My next task was to check the bore of engines’ cylinders. We placed a sensor on each cylinder and push a button that spun the crank allowing the sensor to do its checks. Unfortunately, my team member placed the sensor on the cylinder the wrong way around which caused a complete line shutdown and a rejected engine. Later that day another fellow motoring scribe accidentally broke the emergency stop button on a control panel causing a complete factory shutdown for about twenty minutes, remember, the factory produces an engine every 134 seconds. It was, however, a fantastic experience. The entire plant runs like a meticulously choreographed ballet with man and machine working together. If you have never been to a manufacturing facility such as this then please to enquire as many brands offer factory guided tours and it is undeniably worth going.
