Top Gear UK is my favourite television show of all time, hands down. Chances are I will never get to drive (never mind own) any of the exotic machines that James, Jeremy and Richard are lucky enough to tool around in, but I will feel a bit closer to the action from now on.
That is because I recently enjoyed a guided tour of a factory where electronic systems are manufactured for some of the world’s most legendary marques (whose names unfortunately cannot be published due to confidentiality agreements). Now you are probably thinking I got whisked away to someplace in Europe or the Far East but no . . . start thinking a bit closer to home.
Pi Shurlok’s electronics manufacturing plant covers some 8300 m² of manufacturing floor space in Pietermaritzburg, KZN. The manufacturer has established a global presence in its more than four decades of existence, supplying products to eight international OEMs in Europe, the Americas and Asia.
With international exports currently comprising roughly 44% of its business, the remainder comes from in-house designed and contract manufactured products for South African vehicle OEMs. This includes body and comfort electronics, instrument packs and clusters, drive train electronics, vehicle security, communication networks, infotainment and telematics.
Automotive at its core
Of course, with its core strengths residing in the automotive sector, Pi Shurlok has some impressive credentials in this arena.
In designing instrument clusters, the company incorporates state-of-the-art technology such as electroluminescence (EL), liquid crystal display (LCD) and thin film transistor (TFT). Its instrument cluster manufacturing facility is equipped with the latest automated processes, including a world-class in-line plastics injection moulding plant.
Pi Shurlok was recently awarded a high-volume instrument cluster production programme with a large Pretoria-based OEM, becoming one of just three global manufacturing sites for this new vehicle platform.
The manufacturer also designs the hardware, software and mechanical aspects of customer-specific body and comfort control modules. Types of products supplied include door controllers, seat memory modules, body module controllers, air conditioning controllers, intelligent relays, CAN-bus controllers/gateways, relay integration modules and junction module controllers.
In terms of drive train modules, Pi Shurlok designs the hardware, software and mechanical aspects for engine management systems, chassis control modules, electronic ignition systems, diff lock controllers, diesel glow plug controllers, temperature controllers, spark timer controllers, vehicle speed data modules and 4x4 electronic shift-on-the-fly controllers.
All of these products contain full CAN and diagnostic capabilities as required by each OEM, and are fully tested and approved to each OEM’s validation requirements.
The company’s wide range of products and technologies also allows it to offer holistic vehicle security solutions like immobilisers and alarms, convenience modules, ultrasonic sensors, central locking and keyless entry systems, key fob remote controls, touch key technologies, transponder technologies and battery-backed sirens.
Diversified offering
Accreditation to global manufacturing quality standards such as ISO/TS 16949, ISO 9001, ISO 14001, ISO 15504, and a VDA-6A rating, stand Pi Shurlok in good stead not only in the automotive arena, but in general contract manufacturing as well.
According to general manager, Dion Hardy: “Our aim has been to reduce the cost of manufacture while retaining our industry recognised quality standards. By implementing numerous continuous improvements and rationalisation activities, we have increased immediately available manufacturing capacity by 47%.
“This additional capacity has already allowed Pi Shurlok to extend its customer base in the industrial market and we are actively engaged with the marketplace seeking further business opportunities. New production programmes can be brought onboard in a very short space of time with minimal investment as a result of the existing, well established infrastructure.”
Indeed, the company’s recent diversification into the industrial market has proved that it is well positioned to provide quick product turnaround times. This is underpinned by automotive-based quality systems and lean manufacturing principles.
Pi Shurlok provides a full turnkey service comprising design, industrialisation and manufacturing to clients in the automotive and industrial markets. Products range from simple populated PCBs through to complex GSM/GPS based systems. The Pietermaritzburg facility includes SMD facilities, anti-static floors, clean rooms and wave soldering equipment in inert environments, and is run and operated by a staff complement of 220 people.
The company has invested in state-of-the-art SMD assembly lines that currently include Fuji, Mydata, Juki and Yamaha placement equipment. In addition to being able to place BGAs and components down to 0201 (imperial), the facility boasts capabilities such as:
* 3D paste measurement system.
* Automatic optical inspection.
* Laser marking of PCBs.
* Component traceability.
* Lead-free manufacturing.
* X-ray equipment for BGA components.
* Flying probe for sample testing of all units.
* Plastic injection moulding.
* Wiring harness assembly.
Business development manager, William Murray, commented that “While in the past it was a challenge for global businesses to award contracts to South African companies, Pi Shurlok had significant success in acquiring contracts because of its state-of-the-art facility and well entrenched design-for-manufacture processes.
“Our use of available government-based incentive schemes such as the MIDP and APDP provides further value-add to our customers. This has greatly supported the drive to localise more products within the South African market.”
As is so often the case with South African manufacturers, much of Pi Shurlok’s success in the global market can be attributed to the fact that it is prepared to be flexible and offer low to medium volumes at internationally competitive prices.
According to Murray, the global market is also currently seeing a big push to split its eggs amongst more baskets – a consequence of the crises recently imposed by the likes of the Japanese earthquake and the floods in Thailand. As a result, more automotive OEMs are looking to countries outside of the traditional automotive hotbeds, with SA becoming an attractive option in this regard.
For more information contact William Murray, Pi Shurlok, +27 (0)33 845 4700, [email protected], www.pi-shurlok.com
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