Gibela gearing up to become the world’s fastest train-makers

Gibela produced six train sets in August and another six in September, the most it has produced since the start of its production in 2018, becoming one of the fastest locomotive manufacturers in the world.

In the past three years, the company has ramped up production, from one train set every two months to producing six train sets in a month, each with unprecedented levels of quality, safety, comfort, speed and reliability.

“It took hard work, positivity and consistent problem-solving. We are celebrating this milestone by understanding what it took to get us here. It is unbelievable what we have been able to achieve. I am very proud,” said Loic le Gorrec, operations director at Gibela.

This is an incredible feat accomplished in the face of major disruptions affecting manufacturers worldwide, including Covid-19, the war in Ukraine and a global shortage of electronic components – all had severe operational and financial consequences for the company.

Thabo Raphahlelo, a senior production manager responsible for assembling the car-body structures and all exterior components, said producing twelve train sets in the past two months is the result of many changes in systems and processes implemented to speed up production and reach clear targets.

“In manufacturing, delays are inevitable because we are dealing with thousands of parts and hundreds of suppliers. It’s about navigating those delays and finding ways to stay on track and adhere to the plan. We have a mature, youthful team that knows what to do. Our processes are clearly defined and we are already gearing towards achieving the next target. This is stabilising the six trains per month and improving our cost,” he said.

According to the company, 80% of their staff is under 35 years old, trained and upskilled, which has seen them become world-class manufacturers.

“It is incredible to be able to harness the energy that young people have and channel it into a production of this scale,” said Le Gorrec.

Thabiso Komako, Gibela’s head of manufacturing, says the constraints that Gibela and the manufacturing industry faced over the past two years initially created uncertainty in the factory.

But he saw this as an opportunity for the team to think differently and reimagine production while creating an atmosphere that cannot be easily shaken.

The team is determined to beat its current six-train record and dominate the train-manufacturing world.