Zest WEG has established a new local assembly line for its low voltage (LV) premium efficiency WEG IE3 electric motors. The facility forms part of the company’s corporate premises at Longlake, east of Johannesburg, and marks another advance from Zest WEG in driving local economic impact and sustainability.
A closer look at the new assembly line for LV IE3 motors: the first rotor being positioned.
Zest WEG CEO, Eduardo Werninghaus, says the addition of the new facility is an important contribution to local manufacturing capacity in South Africa. It improves the company’s flexibility in its electric motor supply chain, and ensures prompt delivery times for customers. The line produces WEG W22 IE3 LV motors in various sizes, which provide high reliability in all applications.
“As a Level 1 B-BBEE company, our commitment to transformation includes continuous promotion of local manufacture,” said Werninghaus. “Our focus on premium efficiency IE3 motors is also significant as it helps drive energy efficiency – a key sustainability goal for mines and other industries.”
According to Sindi Mbhalati, Operations Executive at Zest WEG, the assembly line required considerable investment in equipment. This included jib cranes for easier materials handling, an air reticulation system to feed compressed air to the pneumatic tools on the line as well as to the spray booth and packaging equipment, enhancing the efficiency of the production processes, and a state-of-the-art test panel.
As with any world class manufacturing and assembly operation, record keeping is an important cornerstone. The panel is therefore synchronised with the advanced WEG manufacturing facilities in Brazil, for complete and accurate record tracking and evaluation. Each motor undergoes routine testing – which includes winding resistance tests, accessories tests, insulation resistance tests and no-load tests.
The WEG W22 premium efficiency motors in different phases of the assembly process.
Mbhalati adds that the panel tests winding resistance per phase with an unbalance test to compare the unbalances between the resistance results, while the accessories resistance test confirms that the accessories installed in the motor are in working order. The panel also tests for insulation resistance, which provides the team with data on the health of the motor winding. A no-load test is conducted to determine the current that the motor draws at no-load and determines the unbalance of the current drawn between the phases.
“Further ensuring operational efficiency, the line is capacitated with state-of-the-art equipment including a heating and greasing facility as well as rotor assembly C-hooks,” says Mbhalati. “In addition, and importantly, the assembly line has been engineered to allow multiple shifts to be worked, should it become necessary to increase capacity and output. This type of futureproofing to accommodate market demands is in line with Zest WEG’s commitment to its customers.”
The facility has created several new jobs within the business. Most of the new employees are dedicated to the W22 motor assembly line, and some others work across the company’s various production lines.
“To ensure the highest quality standards in the assembly process, Zest WEG put its new staff through extensive technical and process training relevant to the new line,” Mbhalati says. “This included in-depth product and component training, as well as the operation of the specialised test panel.”
Among the components Zest WEG procures for assembly are rotors, stators and bearings. These are produced mainly at WEG’s manufacturing facilities in Brazil, under stringent quality conditions. They are thoroughly tested before shipment to Zest WEG. Smaller components are sourced from local suppliers wherever possible, in line with the company’s supply chain development policy.
“Governed by our ISO 9001 quality certification, the new assembly line is closely monitored by our dedicated quality department,” says Mbhalati. “All motors are tested and quality inspected prior to dispatch to customers.”
She highlights that Zest WEG’s quality control personnel are rigorously trained to assess motors during the build process as well as final quality inspection and testing. All aspects are aligned with WEG quality procedures, ensuring world class standards are maintained across all operating parameters.
For more information visit: www.zestweg.com