Johannesburg — THE just-in-time component supply systems that were introduced to the manufacturing world by Toyota make for efficiencies and stock holding cost reduction, but they also put pressure on logistics in terms of delivering the correct component to the right place at the right time. This is particularly true in the case of the vehicle manufacturing sector.

Barloworld Logistics in Edenvale is one of the companies specialising in this type of operation and is doing so very effectively. It runs one of the most demanding transport and logistical undertakings in SA and has entrusted the critical transport component of its operation to a fleet of 32 Hino trucks and 25 Afrit Tautliner trailers.

This complex operation acts as a cross-docking facilitator for Toyota SA's manufacturing plant in Prospecton, near Durban. This is the biggest plant of its kind in Africa, with its capacity currently being increased to be able to build more than 200000 vehicles a year.

A vital part of the manufacturing process is the just-in-time delivery of a wide range of components to the factory. The trucks carrying the components have to arrive at the designated unloading dock at the plant within a five minute "window" of an ideal time. Even a few seconds late or early is marked as a "non-achievement".

Currently Barloworld Logistics is operating at an amazing 98,5% achievement of delivery times.

"This means we require trucks that are very reliable as we cannot afford breakdowns or downtime for repairs," says Thinus Slabber, Barloworld Logistics GM.

"Using Hino trucks was also not a pre-condition of us being awarded the Toyota contract; it was a decision based on the known reliability and low operating costs of the Hino brand," he says.

The first step in the complex operation is the collection of loads of completed components or assemblies from 36 manufacturers in Gauteng -- with some suppliers having collections twice a day. Six Hino 33/254 4x2 truck-tractors and two 15/258 rigid freight-carriers are used for this purpose, which also runs to the same tight time schedules as the long-distance deliveries to the factory in KwaZulu-Natal.

Most of these loads of locally sourced components are consolidated and sorted into various destinations in the Toyota factory area before being loaded onto Afrit Tautliner interlink trailers which are hauled to and from Durban by 12 Hino 700-57/450 6x4 truck-tractors. Each of these big rigs has a turnaround time of 24 hours and their engines run for 22 hours each day. Each one-way trip takes nine hours, with one-and-a-half hours to offload and nine hours to get back to base so that the trailer can be reloaded for the next trip. This works out to an average of about 210 loads a month.

Toll fees for the fleet cost about R180000 a month, with 160000l of fuel being consumed a year, even though the long haul rigs average a creditable 45l/100km when loaded (up to 30 tons).

Barloworld Logistics is also responsible for transport at two associated Toyota manufacturing operations in Durban -- one delivers imported components from warehouses to the assembly line and the other involves delivering wheel assemblies from an outside supplier to the vicinity of the assembly line.

Seven Hinos -- two 700-57/450 6x4 truck-tractors, three 33/254 4x2 truck-tractors, and two 15/258 rigids -- are used for the first operation and five 13/237 rigid freight-carriers move the wheel assemblies.

Two drivers are used per truck for the long-haul trip, but only one is in the truck at a time. Barloworld Logistics has an accommodation facility in Harrismith where drivers change over and rest until the truck arrives on the return trip. The company has six alternative routes to and from Durban which can be used in case of accidents or bad weather. "We find this arrangement works well and have had only one serious accident in two years," says Jose da Silva of the company's Dedicated Transport Services.

"Safety is paramount in our operation, with the trucks being serviced every 20000km by Imperial Toyota Trucks at Alrode, while the trailers undergo major services three times a year. We fit only new tyres as replacements and all tyres are checked after every trip for pressure and any external damage. Wheel alignment is set every three months and we use mobile weighbridges to ensure compliance with the road ordinance and to make sure our loads are evenly distributed."

Da Silva, who is a very experienced trucking operator, says the Hinos are getting as much as 220000km on front tyres and up to 480000km on the drive axles, while the trailer tyres last about 450000km. He said that regular rotation played an important role in reducing tyre usage in his fleet.

"We have a buy-back in place, but may extend the distance," he says. "Some of our Hinos have covered almost 500000km already and we have had no problems with major components and any small niggles have been sorted out quickly, so we may operate them longer than originally planned."

There are many sophisticated tracking and control systems in place at Barloworld Logistics to ensure smooth operation of this project and there has been no theft or successful hijackings in more than two years.

Da Silva says the company is fortunate to have loyal staff and good drivers, and ascribes this to a thorough recruitment process. Sometimes up to 20 people are interviewed and tested before an appointment is made. There is a permanent driver-trainer on site to ensure high driving standards.

This is certainly a model operation and a tribute to strict discipline and dedicated staff and skilled management.