Mechanical Technology April 2015

⎪ Power transmission, bearings, bushes and seals ⎪

A local quest for quality geared drives Following local ISO 9001: 2008 accreditation of Bonfiglioli South Africa’s reducer assembly facility in Linbro Park, Johannesburg, MechTech talks to John Beukman (left), Bonfiglioli South Africa’s newly appointed national quality assurance manager, about the importance and value of complying with global quality management systems.

A s a worldwide leader in pow- er transmission and control, Bonfiglioli is committed to achieving the highest ethi- cal and quality standards, standards that are documented in the company’s Bonfiglioli Quality Management System (QMS). Bonfiglioli is “committed to designing, manufacturing and supplying effective products and services that set a benchmark in the industry. Based on defined procedures and instructions, the Bonfiglioli QMS has been established, not only to ensure the ongoing quality of our products and processes, but also to guarantee continuous improvement”, reads the introduction to the Group’s quality document. Historically in South Africa, Bonfi­ glioli’s local assembly facility has oper- ated according the ISO 9001: 2008 certification of the global group. “But in order to manage the exigencies of supplying top-quality geared drives to southern African industry, a fully sup- ported and functional quality manage- ment system is an absolutely necessity,” says Robert Rohman, managing director of Bonfiglioli SA. Hence, following local ISO 9001 accreditation by TÜV Rheinland in late 2013, John Beukman was appointed as the company’s national quality as- surance manager in November last year. “We needed to invest in local resources to better implement the global Bonfiglioli management system as well as to man- age our locally accredited ISO 9001qual- ity system,” Rohman adds. Beukman qualified as Level 1 Inspec­ tor at the Southern African Institute of Welding before joining IQS (Inspection and Quality Services), the third party in- spection specialist. “While with IQS, I was contracted by a construction company to oversee the quality control of the auxiliary cooling systems for the Medupi Power Station project,” he tells MechTech .

Having recently returned from training in Italy on the Bonfiglioli QMS, he says that the company’s global quality system is linked to its SAP enterprise resource planning system. “Everything from com- ponent non-conformances to customer complaints and warranty claims, from anywhere in the world, is captured by the SAP system. So all information re- lating to product or service failures from branches scattered all over the world, including internal and customer reports, can be fed back, collated and analysed by the group’s global system,” Beukman explains. “The underpinning idea is that of continual improvement,” he continues. “By sharing information from across the globe, analysing it and feeding it back to management and research and de- velopment teams, the company’s service offering and its product reliability and performance can be continuously im- proved to better meet customer expecta- tions. The ultimate aim is to become the preferred partner for industrial drives, by designing, developing and manufacturing innovative products that set global quality benchmarks – regardless of where we are in the world,” he says. Bonfiglioli’s Quality Management System is implemented at three levels: corporate level, cascading down to the industrial level and then down to indi- vidual plant and business units. QMS procedures have been designed to filter down from the top, and to then feed information from the ground all the way back up to corporate level. “My role is to implement procedures at plant, branch and business unit level and to manage local quality system implementation,” he informs MechTech . “An enormous amount of research goes into the development of a new gearbox and significant amounts of time, money and effort is spent ensuring that the quality embedded in the design is

transferred, through component manu- facture and all the way down to local assembly operations. The last thing the OEM can afford is to lose the benefits of a quality design through inadequate management of the local assembly pro- cesses,” Beukman notes. All local Bonfiglioli branches are , therefore, under pressure from corpo- rate to meet global standards in the final product. “And this is where the SAP-linked analysis processes kick in. Any local problem encountered during a quality test, during commissioning or a later failure in the field is fed back for analysis. And we are also subjected to yearly quality audits from Italy to ensure that every Bonfiglioli outlet in the world is performing to the global benchmark,” he confirms. Pressure to comply with ISO 9001 quality standards is also being applied by Bonfiglioli’s local customer base. “We are operating in a much more regulated and demanding local market with cus- tomer that insist that suppliers adhere to globally accredited quality standards. Nowadays, potential clients want to look at a local manufacturing or assembly facility and inspect its quality credentials and management systems before they will even consider using that company as a supplier. This increasingly applies to South African mining and project houses, for example, which need to vet a suppliers quality systems before grant- ing approved-vendor status,” Beukman explains, adding that suppliers who don’t comply, “don’t get onto the playing field”.

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Mechanical Technology — April 2015