Juanita Pienaar spoke with Kamogelo Mmutlana, Executive Head: Business Excellence, to gain insight into the company’s technological advancements, sustainability initiatives, and commitment to extending the life of Caterpillar equipment across Southern Africa.
A hub for excellence
Opened in 2012, the Barloworld Rebuild Centre (BRC) in Boksburg has evolved into a world-class hub for Caterpillar component repairs and rebuilds, serving the mining, construction, and power sectors throughout Southern Africa. “This facility was originally a Caterpillar plant,” explained Kamogelo Mmutlana, Executive Head: Business Excellence. “We purchased it and converted it into a component rebuild centre to meet customer demand and expand our component solutions offering to our customers.”
Covering 30 000 m² under roof, the BRC focuses primarily on major mining components - engines, drivetrains, hydraulics, and transmissions - with the capacity to process more than 2 000 components per year with a single shift. The centre employs around 250 people, including permanent contractors, and operates with the precision and efficiency of a manufacturing plant.
Mmutlana explained that the BRC’s business model is built on an exchange programme similar to that of the smartphone industry. “You give us your old component, and we provide a rebuilt one in return, along with a core credit,” he said. “It’s the same warranty as new, built to Caterpillar specifications, but offered at 55% to 75% of the price of a new component.”
Rebuilding machines, reducing costs
Kamogelo Mmutlana described the rebuild philosophy as a crucial part of the company’s value proposition. “By the time a component reaches us, it’s at the end of a specific economic life cycle,” he explained. “Traditionally, customers would dispose of it. Instead, we rebuild it - break it down, clean it, salvage usable parts, renew unsatisfactory parts, and reassemble it to produce another economic life.”
This process allows Barloworld to restore components to a full Caterpillar specified condition, extending their life. “We always try to position this offering at between 55% and 70% of the price of new,” said Mmutlana. “It represents a compelling value proposition - full warranty cover, lower cost, and reduced downtime.”
The turnaround time is critical for mining operations, which run 24/7. “We’ve had major failures on a Friday evening, and our team will work through the weekend to ensure the component is back in operation by Monday morning or sooner,” said Mmutlana. “Our customers can’t afford downtime, and we can’t afford to let them down.”
Technological advancements driving precision
Barloworld has invested more than R68-million in new technology at the BRC, including semi-automated salvage machinery, smart assembly tools, and digital management systems. Kamogelo Mmutlana, Executive Head of Business Excellence said the investment has improved turnaround time by nine days. “Much of the new equipment is computer numerically controlled (CNC), which ensures repeatable, high-precision work,” he explained. “We can now complete any engine repair - from block to crank - entirely in-house.”
The investment also includes a new 6 000-horsepower dynamometer for engine testing. “It allows us to test everything from small construction engines to the massive 20-cylinder units used in the largest mining trucks,” said Mmutlana.
In the assembly department, Barloworld is transitioning to Industry 4.0 tools. Mmutlana highlighted the shift from conventional air-powered tools to digital, battery-operated smart torque tools. “These tools transmit data via Wi-Fi and record every torque value applied,” he said. “They improve safety, quality, and ergonomics, ensuring our artisans go home less fatigued. It’s a major leap forward in traceability and quality assurance.”
Building skills for the future
The human element remains central to Barloworld’s technical strength. Kamogelo Mmutlana, Executive Head of Business Excellence, said the group’s investment in people is what enables its technological progress. “All these initiatives depend on capacity,” he explained. “We build that capacity by training technicians to the highest standards.”
Barloworld’s academy, which holds Caterpillar Gold Star certification, trains technicians from across Africa. “Two of our technicians recently represented us at the CAT Global Dealer Competition in Europe,” said Mmutlana. “That speaks volumes about our training quality.”
The company is also addressing South Africa’s skills shortage through a “train-to-task” programme. “Not everyone needs a full four-year apprenticeship,” said Mmutlana. “If someone shows aptitude, we can train them for a specific technical task - like engine rebuilding - giving them a career path and helping us fill vital roles faster.”
Commitment to sustainability
Barloworld’s rebuild operations play a major role in the company’s environmental, social, and governance (ESG) strategy. “We take ESG very seriously,” said Kamogelo Mmutlana, Executive Head of Business Excellence. “By rebuilding rather than replacing with new components, we reduce greenhouse gas emissions by up to 70%.”
The facility has also invested heavily in renewable energy and water management. “We’ve installed over 1 000 kilowatt peak of rooftop solar, generating around 141 000 kWh,” Mmutlana noted. “That investment - over R15 million - has already reduced our electricity bill by 19% year-on-year.”
In addition, the centre recycles and reuses water for washing components. “We’ve installed rainwater harvesting systems with more than 30 000 litres of storage,” said Mmutlana. “That allows us to operate with minimal reliance on municipal supply.”
Waste management is another focus. “Our goal is zero waste to landfill,” he added. “We recycle as much as possible and are working towards full circularity in our processes.”
Certified quality and continuous improvement
Barloworld’s BRC is one of only 19 Caterpillar dealers worldwide to achieve CAT Certified Rebuild Centre status. “It’s extremely difficult to obtain,” said Mmutlana. “Caterpillar’s standards for process control and quality are exacting, and we were recently recertified - an achievement we’re very proud of.”
Continuous improvement forms part of the company’s operating philosophy through the Barloworld Business System (BBS). “Our rapid improvement events help us identify and eliminate waste across the production line,” said Mmutlana. “It’s through this approach that innovations like smart tooling and modular parts kits were born.”
Each initiative feeds into a broader strategy of efficiency and customer responsiveness. “The market is shifting,” Mmutlana explained. “Many customers now prefer to have their own components rebuilt rather than using exchange stock. Our processes have evolved to accommodate that. At the end of the day, the customer is king.”
A vision for sustainable growth
From its origins as a Caterpillar plant to its current status as a benchmark facility, the Barloworld Rebuild Centre represents a powerful blend of technical innovation, environmental responsibility, and customer-driven excellence.
As Mmutlana summarised, “We’re not just rebuilding components - we’re rebuilding reliability, value, and sustainability for our customers. Seeing is believing, and when you walk through this facility, you can see exactly what world-class looks like.”
