Manufacturing and testing
More than R350-million worth of specialised equipment has been installed.
Gibela has implemented a lean manufacturing process – essentially minimising wastage – and applied cutting-edge technologies – many of them firsts in the global rail industry.
In the first two stages, parts are manufactured to supply the car body shell with assembly lines.
In the first two stages,
parts are manufactured to supply the car body shell with assembly lines.
Long profiles preparation
In the third stage,
four major sub-assemblies, frames, sidewalls, roofs and ends are assembled as cars.
This stage involves:
Car body shell assembly
In the fourth stage,
cars and motor units are fitted with electrical wiring and equipment, piping, floors, doors, windows, interior linings, seating, branding, etc.
Thereafter, both cars and motor units are mounted on bogies that incorporate the axles, wheels and braking system.
This stages involves:
In the final four stages,
each separate car and motor unit is extensively tested statically and coupled as six-car trains.
Each train is then tested both statically and dynamically, the latter on Gibela’s own 1.2km on-site test track, and then put through a final inspection before dispatch to the customer, PRASA.
The final stages include:
Final inspection and dispatch
More than a million kilometres of cumulative mileage have been reached since the start of the trains’ commercial operations in Pretoria North.