Quality attributes heralds new Isuzu into Africa

A total of 15 African motoring journalists were at the General Motors office in Port Elizabeth, South Africa for the on and off-road test-drive of the new Isuzu Pick-up. With this latest development, the vehicle is continuing its engagement in key African markets and ongoing processes of quality management and engineering development which ensures that the new Pick-up is built in Africa, for Africa.

The new Isuzu Pick-up features a number of uniquely African solutions to the problems and challenges that were identified. For example, a larger radiator is fitted to assist in improved cooling, and the radiator fan is indeed placed behind the radiator to remove the risk of fan blade damage when entering water at speed.

The high-ride suspension design which allows for ground clearance of up to 224 mm (linked to high profile tyres) enables for enhanced peace of mind when driving on particularly bad roads.

Furthermore, specific attention was paid to under body components like fuel lines and side skirts, where special protective plates were added to prevent damage from stone rash on the move. On the engine front, all engines are capable of running on even the lowest quality fuels.

Safety is also naturally an Isuzu hallmark, and the new Pick-up has been engineered with key safety principles in mind which hold particular importance in the African context – to maximise stopping power, assist with steering input under hard braking and reduce stopping distances.

Further safety-critical factors were also considered, like impact-absorbing materials in the front end which not only reduce frontal damage in an impact but also provide enhanced protection for pedestrians, as a first line of defence.

Adding further strength to the equation is Isuzu’s legendary reputation for off-road driving capability. With certain derivatives available with four-wheel drive, traversing even the toughest of environments becomes an easy and enjoyable task thanks to great ground clearance, all-terrain tyres and an advanced 4×4 system with an electronic configuration switch which allows for easy transition between 2-Hi, 4-Hi and 4-Lo driving modes.

Engineered and built by GM in South Africa for both the domestic and export markets, the Isuzu Pick-up driven by the automobile journalists for two days followed extensive testing and engineering leading up to its launch in 2013 –covering some 1.3-million kilometres of strenuous driving in extreme conditions.

“With the 6th generation Isuzu Pick-up, General Motors have also taken unprecedented approach to its development with specific focus points directly related to the African markets in which it is designed to serve,” says Andy Alexander, quality manager at General Motors South Africa (GMSA).

“Along with our highly qualified and experienced engineering team, and involving the various departments who are jointly responsible for the design, development and production of this world-class pick-up, we left no stone unturned in the development process. The Isuzu heritage of innovation, toughness, durability, reliability and functionality was put to the ultimate test.”

With the harsh environments of the African continent dictating vehicle specifications and design – including fuel quality, road conditions, consumer demands and vehicle versatility, Isuzu engineers not only had to design and develop specific elements of the Isuzu Pick-up to cope on a long-term basis, but also ensure the quality of each and every aspect that goes into the production of an internationally renowned pick-up – to ensure complete peace of mind and trouble-free motoring for the customer.

Built-in quality (BIQ) at the Struandale plant in Port Elizabeth, South Africa, is the most important element in this regard. At every stage of the production process – from the body shop and paint shop to assembly and final inspection – each element is verified to ensure maximum quality in all respects.

Subscribing to a Global Manufacturing System (GMS) which enforces global regulations and requirements on the GMSA plant, key focus areas are monitored to ensure ultimate production quality. Exercises involved include continuous improvement principles, standardisation of tasks and processes, people involvement, short lead times and built-in quality.

The latter in particular expresses the overall goal of creating a quality product in every aspect and is measured on a tier basis. Resource and structure optimisation and the removal of all forms of physical and theoretical waste from the system also contribute to heighten BIQ. Towards the end of 2014, the Struandale plant will be evaluated at BIQ level 3, which strives to raise BIQ with less inspection intervention.

The Struandale manufacturing facility also does Global Customer Audit (GCA) on daily basis, seeing sample products pulled from the line every day which are then physically and thoroughly checked by auditors for defects or potential problems.

The GCA is carried out in General Motors plants the world over, and uses global targets and standards to not only ensure that all GM products are built to the same high standards at any given plant, but also to enable early detection and prevention of potential problems.

Resulting directly from the GCA, problems are identified and solved before a single vehicle leaves the plant. Even after vehicles have made it to the end of the production line, each and every unit is driven on a test track which encompasses evaluation during operation, checking for rattles and squeaks, and testing other dynamic aspects to ensure absolute quality verification before reaching the consumer.

MIKE OCHONMA