The AIDC’s Supplier and Enterprise Development Department (SEDD) was established to develop component manufacturers in the supply chain to conform to the international standards prescribed by the automotive manufacturing industry. The department’s service offering ranges from a combination of efficiency improvement projects related to productivity, quality assurance in accordance with ISO standards, including environmental, lean and clean production (including all green projects as related to the Government and the Province’s low carbon economy projects), to manufacturing concepts, logistics, clustering and SMME development initiatives.

The AIDC’s roll out of TPM (Total Productivity Management/ Maintenance) in South Africa, have already seen component manufacturing companies increasing their competitiveness by achieving zero accidents, breakdowns, defects and losses within the manufacturing process. The Engineering student internship programme, managed by the SEDD, is an opportunity for aspiring graduate engineers intending on applying their trade within the manufacturing sectors.

The AIDC uses its collaboration with companies participating in the various supplier development programmes as a delivery mechanism for internship programme. The programme offers companies engineering capacity in the form of interns, who are directly mentored and coached on specific projects aimed at improving the company’s productivity and efficiency. The SEDD specifically focuses on:

• Total Productive Maintenance (TPM) Programme,

• Cleaner Production Programme (including all green projects related to the Province’s low carbon economy projects),

• Lean Manufacturing Programme,

• Rapid Process Improvement Workshops (RPIW), and

• Quality Management Systems (QMS).

Other value-added services offered by the EDD include:

• Company benchmarking to ensure that they meet global best practice standards,

• Logistics and Lean manufacturing assessments

• Accredited Supervisor training, and

• Engineering student internship to support on key programmes.

 

Supplier and Enterprise Development Programmes

 

The AIDC’s Cleaner Production Programme is designed to mitigate the impact of rising utility costs and reduce the automotive industry’s carbon emission footprint. The programme employs expert specialists who make use of various tools to monitor a company’s energy and water usage, as well as their waste produced. In this way, they can implement practices and procedures to reduce their energy and water usage and reduce their wastage as well.

The AIDC has also partnered with the National Cleaner Production Centre (NCPC) to promote cleaner production methodologies. The programme has proven to be very popular amongst suppliers and is fast becoming a business essential tool.

Key activities in the programme include:

• the assessment of energy, water and materials to determine the current level of consumption and identify opportunities for reduction,

• the assessment of waste to understand the company’s current waste generation profile and identify reduction opportunities,

• an analysis of business energy and utilities to determine areas for immediate improvement,

• formulating methods to improve energy and utilities usage,

• employing lean tools in unique ways to optimise the use of energy within the facility,

• facilitating training workshops and introductory sessions on the principles and benefits of energy management systems and energy systems,

• assisting companies with the implementation of Energy Management Systems and Standards (EnMS).

The cost and duration of the programme is based on the customer’s requirements.  

The AIDC’s Cleaner Production Programme is designed to mitigate the impact of rising utility costs and reduce the automotive industry’s carbon emission footprint. The programme employs expert specialists who make use of various tools to monitor a company’s energy and water usage, as well as their waste produced. In this way, they can implement practices and procedures to reduce their energy and water usage and reduce their wastage as well.

The AIDC has also partnered with the National Cleaner Production Centre (NCPC) to promote cleaner production methodologies. The programme has proven to be very popular amongst suppliers and is fast becoming a business essential tool.

Key activities in the programme include:

• the assessment of energy, water and materials to determine the current level of consumption and identify opportunities for reduction,

• the assessment of waste to understand the company’s current waste generation profile and identify reduction opportunities,

• an analysis of business energy and utilities to determine areas for immediate improvement,

• formulating methods to improve energy and utilities usage,

• employing lean tools in unique ways to optimise the use of energy within the facility,

• facilitating training workshops and introductory sessions on the principles and benefits of energy management systems and energy systems,

• assisting companies with the implementation of Energy Management Systems and Standards (EnMS).

The cost and duration of the programme is based on the customer’s requirements.  

This AIDC’s EDD internship programme offers companies engineering capacity in the form of interns, who are directly mentored and coached on specific projects aimed at improving the company’s productivity and efficiency. These interns spend 6-12 months at the participating company, not only benefiting from the experience but also contributing to the actual improvement of production performance.

Many of the students lack industry experience and need guidance throughout this journey. The students are introduced to basic industry etiquette as well as the more hands-on engineering principles.

Students are given an industry exposure and are assisted to gain the required level of experiential training (P1 & P2) as a pre-requisite for obtaining a national diploma. Each participating company is allocated at least one student, depending on the company size and the need within the company.

In so doing the student is given an opportunity to make a value-adding impact to the success improvement of the company. Students meet on a monthly basis to interact and share their learned experiences.

The AIDC’s Lean Manufacturing Cluster Programme was established to assist companies to implement a sustainable model to improve quality, efficiency and competitiveness of suppliers in the automotive industry. In 2002, the AIDC developed the “Tirisano Cluster Programme” as a manufacturing competitiveness tool for South African automotive suppliers.

It was based on the Toyota Production Systems in Japan and tailored to meet the needs of companies locally. The focus of this programme was to improve supplier competitiveness by implementing lean manufacturing tools that targeted safety, quality, cost, delivery, and energy efficiency, whilst simultaneously transferring these skills and tools to the clients’ selected teams.

This was done by training of individuals on the shop floor, in the targeted areas, by addressing Manufacturing and Supply Chain wastages.

In 2009, following the success of the programme, the Department of Trade and Industry (dti) approved a three (3) year contract project, through UNIDO, and managed by the AIDC, who then implemented an Automotive Component Supplier Development Programme (ACSDP) with automotive companies within South Africa over a three year period.

Through the Tirisano and ACSDP, the AIDC has provided training to more than 200 automotive and/or allied sector companies in South Africa.

Companies who subscribe to the programme gain access to proven methodologies towards continuous improvement. Lean manufacturing tools are applied in accordance with the respective industry challenges encountered. The programme is managed by an experienced team of project managers and Lean Manufacturing experts.

The cost and duration of the programme is based on the customer’s requirements.

The AIDC’s Quality Management Systems (QMS) programme aims to assist companies to become ISO 9001 and ISO/TS 16949 QMS compliant. The main focus of the automotive industry is to have component suppliers who are able to produce quality products, cost-effectively and efficiently.
As part of the QMS programme, the AIDC appoints a Quality Assistant at the company for the duration of the intervention. This resource provides training on the requirements and prescribed procedures.
The participating company will receive a customised quality manual for the course.
As part of the training, the AIDC will facilitate a formal QMS Management review meeting to track progress, and then coach the representatives of the participating company so that they can continuously maintain the system.
The AIDC will also conduct internal audits to ensure that the participating company meets the minimum standards of the programme, before they can apply for an external certification audit.
The QMS ISO 9001 programme is run over 26 days, and spread over 12 months. The QMS ISO/TS 16949 programme is run over 36 days and spread over 18 months.
The cost of the programme is based on the customer’s requirements.

The AIDC’s Rapid Process Improvement Workshop (RPIW) is a continuous improvement initiative that employs an ongoing effort to improve the product or service quality by making the processes more efficient with limited or no investment.

The objective of this programme is to provide companies with better knowledge and understanding of the methodologies for problem solving and continuous improvement. At the end of this programme, company delegates are required to submit a case study to prove they have applied the knowledge gained during the learn-by-doing workshop.

The programme serves to improve the competitiveness of suppliers through the introduction of various world class manufacturing systems. The focus areas considered include initiatives geared at improving productivity, quality, cost and delivery.

The Rapid Process Improvement programme is a four (4) day learn-by-doing workshop, held at a host company (preferably a manufacturing entity) where attendees will learn the implementation of problem solving methodologies and continuous improvement. Post the workshop all attendees are required to undertake a project from their own companies and solve them by following the methods used during the workshop.

Companies are required to introduce efficiency measures and give progress of their projects six (6) weeks after the initial four day workshop. Final presentations and an awards ceremony normally follow six weeks after the project’s introduction. Each project is rated by an awards committee and the winner receives a trophy and a Recognition certificate.

The programme aims to assist companies by motivating and encouraging them to implement what they learnt during the practical and detailed 4 day workshop.

The cost and duration of the programme is based on the customer’s requirements.

In today’s fast-changing work environments, supervisors with little experience are unsure about their roles and responsibilities and cannot deal with many challenges during the daily operations of the business.

The AIDC’s Supervisor Learnership Programme aims to equip every supervisor with the essential skills and training to be able to hone their current supervisory skills and competencies, in order to improve the management and leadership of the their respective areas, have the ability to develop and lead a productive workplace team, and ensure that all team members are developed the their full potential. Features of the programme:

• On-going coaching based on manager evaluation and supervisor self-evaluation,

• Implementing a management system of benchmarking and progress, to identify the needed training and coaching,

• Practical training and workplace activities for action learning, and

• The learnership consists of 8 individual modules.

The programme runs for 22 days, and is spread over 12 months. It is an NQF Level 3 qualification and all participants receive a National Certificate in General Management.

The cost of the programme is based on the customer’s requirements.  

In the automotive sector, where the cost of inventory is very high, companies cannot afford to have projects rejected due to manufacturing defects or suffer downtime due to unreliable machinery. TPM is being used to improve and streamline the manufacturing process.

Total Productive Maintenance (TPM) originated in Japan in 1971 as a method to improve machine availability through better utilisation of maintenance and production resources. Seen as a component of world class manufacturing, its end goal is to reduce the costs of production and limit the amount of downtime at factories.

The AIDC and industry representatives visited India in September 2012, where they noted that TPM had become a global standard among Indian companies, helping that country become globally competitive.

Because of its results, TPM was deemed vital to streamline production systems in all industries in South Africa. The AIDC subsequently partnered with a Japanese management consulting firm, JMA Consulting (JMAC), to develop a TPM programme for local industries.

The JMAC TPM programme is directly linked to Japan Institute of Plant Maintenance (JIPM), the originators of TPM and the only authority that provides TPM accreditation globally. The AIDC has found that a company’s initial investment in TPM can assist to save energy and improve productivity. It is a proven initiative in the manufacturing sector everywhere in the world. Benefits of AIDC’s TPM Programme include:

• international TPM experts to visit the companies on-site for mentoring and coaching during the programme,

• international “best practices” study tour, and

• mentoring, coaching and the involvement of international experts to ensure a successful implementation of this programme.

The cost and duration of the programme is based on the customer’s requirements.

Contact Details:
Nkumbuzi-Ben-MazwiName:
 Nkumbuzi Ben-Mazwi

Position: Department Manager: Supplier and Enterprise Development

Tel: (+27) 12 564 5321

Email: nben-mazwi@aidc.co.za