Mechanical Technology February 2015

⎪ Special report ⎪

“Due to the fact that the projects we are taking on represent sizeable volumes, we will be adopting a ‘flow line’ assembly process. We are busy implementing a new factory layout. There is also a whole lot of new equipment that we are install- ing. This represents a step change in the efficiency and utilisation of two critical factors, namely space and manpower.” Pougnet says Booyco Engineering also has a skills development programme in place. “All the components required in our designs are manufactured externally. Our factory is purely an assembly and test facility. If you look at it in simple terms, our company has invested in human capital while our own supplier base has invested in capital equipment. This is very much an intentional part of our strat- egy because it gives us huge flexibility. “At a time like this when we are ramp- ing up significantly, we are able to do it quite easily as we have both the space and the necessary skills. Given that we are going to be far busier in 2015 than we were in 2014, we have already started recruiting and training additional workers. I estimate that over the next 18 months we will probably double our num- ber of factory workers,” Pougnet says. Looking at the latest trends in the HVAC market, Pougnet says there has been a shift from traditional electrome- chanical control devices to an increased use of electronics. “This gives us enor- mous flexibility in what we can do in terms of the sophistication of the controls and how we communicate with the vehicle system, albeit a military vehicle, locomotive or coach. From CAN to MBV, we now have the necessary protocols to be able to do this. We are able to inter- face with VDUs (video display units) to inform the driver about the HVAC unit status or to alert him to any faults.” Pougnet says that Booyco Engineering uses its own proprietary designed electronic controllers and a proprietary designed ‘smart’ inverter. The ‘smart’ inverter is used in certain diesel loco- motives that have a 74 V dc power supply. Here the ‘smart’ inverter is used to translate this to a 380 V three-phase 50 Hz power supply so that conventional compressors and fans can be used. In addition, the ‘smart’ inverter controls the cycling of the compressors and the speed of the fans. “This technology did not exist 20 years ago,” Pougnet points out. The latest trend in energy efficiency is to use digital scroll compressors.

Above: The compressor assembly line at Booyco Engineering. The company is now adopting a ‘flow line’ assembly process. Left: Testing and commissioning at Booyco Engineering’s Meadowdale, Johannesburg assembly facility.

that the Transnet and PRASA business all tends to start at around the same timelines, and because Alstom has only ordered a third of the total quantity, it happens to run concurrently with the locomotive business. Thus for the first time in the history of Booyco Engineering, we have a very strong order book for a four-year period. “This allows us to start hunting for other projects immediately upon signing the current contracts. We have already identified some prospects that will give us continuity. The work we have done over the last 30 years has brought us to a point where we not only have a strong business, but an adaptable business model to carry us forward,” Pougnet says. “Our real differentiating factor is our responsiveness to our clients’ require- ments, hand-in-hand with our flexibility. An advantage of a company of our size is that we are able to make quick decisions and can change direction quite quickly. Clearly we are internationally competi- tive, in addition to being able to deliver bespoke engineering solutions. Really we are in about as good a position as a company could wish to be, being a major player in terms of long-term local contracts, but also being able to perform at a world class level. “A critical success factor for having satisfied clients is the capability to sup- port your products in the host country. Our strategy has been to set up servicing agreements with companies with the req- uisite skills, equipment and infrastructure on our behalf. We then give them the specific training, technical back up and logistical support. We have found this to be very efficient, and will continue to expand our global network on this basis,” Pougnet concludes. q

“While the size of our company prohibits us from spending millions on R&D, whatever we do must be in line with the latest trends. We like to be the early adopter of any new technology. For example, we were one of the first compa- nies in South Africa to use R134a as an environmentally friendly refrigerant, at a time when the bulk of the industry was still using R12 or R22, which have major greenhouse gas implications.” Booyco Engineering is continuing with this trend by looking at alternative refrigerants with improved environmental and thermal performance. Another trend is increasingly strin- gent performance specifications. “Performance specifications now go way beyond the simple capability of be- ing able to operate in ventilation, heating or cooling mode, how many fan speeds there are and how the temperature can be adjusted. These days, specifications include such factors as the noise level and even the electromagnetic signature that is emitted. Specifications even go so far as to include electromagnetic compat- ibility with any other electrical devices in the vicinity. “For every one of these references, there is a standard or a specification and a test method. What it has required us to do is to adapt from being good ther- modynamic engineers who design the electrical circuitry and so on to having to know a lot about many other related subjects. This has transformed us into a company where we now have engineers with different areas of specialisation.” Looking to the future, Pougnet says that the Transnet and PRASA contracts dovetail. “What is quite interesting is

Mechanical Technology — February 2015

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