- R28.5 million NIPP investment boosts South Africa’s rail manufacturing capacity – Lucchini South Africa has commissioned a new state-of-the-art Honor Seiki CNC vertical lathe at its Germiston facility through the National Industrial Participation Programme (NIPP).
- Strategic collaboration with Wabtec and the dtic drives localisation and job creation – The investment strengthens local rail industrialisation, enabling Lucchini to produce all locomotive and passenger train wheels domestically, reducing reliance on imports.
- Advanced precision technology enhances quality and skills development – The automated CNC system delivers improved machining accuracy, faster turnaround times, and new technical training opportunities for South African engineers and operators.
Lucchini South Africa, the leading manufacturer of forged railway wheels in Africa, has officially unveiled and commissioned its new state-of-the-art Honor Seiki CNC vertical lathe at its Germiston facility.
This major investment was made possible through the National Industrial Participation Programme (NIPP), a South African government initiative established on 1 September 1996 to offset the impact of imports in the public procurement system.
In this instance, the NIPP obligation arose from Transnet contracts awarded to Wabtec, a global rail technology company, for the supply of Class 44 and 43 diesel locomotives. These contracts, which involved more than ten million in import content, triggered an NIPP requirement, leading to an investment pledge of R28.5 million (USD 1.6 million) for the acquisition of the Honor Seiki drilling and finishing machine for Lucchini South Africa.
Wabtec undertook a rigorous selection process, interviewing its supply base to ensure that the outcome of the NIPP programme delivered on its intended objectives: skills development, increased local content, and the potential for the selected supplier to grow its export base, ultimately leading to job creation.
Advancing Local Manufacturing Capability
“This investment gives Lucchini South Africa a true competitive edge. Improving quality, reducing lead times, and positioning us to trade globally while building local capability and creating jobs,” says Gcobisa Bokleni-Toyi, Managing Director of Lucchini South Africa.
She adds: “The collaboration with Wabtec and the Department of Trade, Industry and Competition (the dtic) has created significant opportunities for Lucchini South Africa. Beyond its commercial benefits, it has introduced advanced technical skills, supported staff training, and contributed to job creation within our business, positively impacting the broader South African economy.”
The investment directly strengthens local rail industrialisation. The new machining capability enables Lucchini South Africa to produce all locomotive and passenger train wheels, including those of X’Trapolis Train (Gibela/Prasa) and Gautrain. This localisation effort increases domestic machining capacity and local content, reducing South Africa’s reliance on imported railway components.
Precision Technology and Engineering Excellence
“The automated CNC machine will enable the production of high-quality, standard forged blank steel wheels, thereby reducing production costs, improving quality, and increasing output,” explains Nico Myburgh, Operations Manager at Lucchini South Africa.
The Honor Seiki vertical lathe features cutting-edge design and capability:
- Dual-ram system – one fitted with a Sandvik Coromant Capto C10 interface for turning operations, and another with a programmable HSK100 clamping and drilling head capable of operating at any angle.
- 6-metre-diameter programmable chuck with 80-bar clamping pressure and upgraded 300 RPM speed.
- 70-bar through-spindle coolant system for enhanced performance and tool longevity.
- Programmable 140mm stroke travel, allowing the machining of wheel sizes from 36 to 48 inches with internal and external clamping for rapid changeovers.
The system includes a high-end Siemens Sinumerik CNC control platform with sister tooling capability, automatically detecting and replacing worn tools, and Renishaw precision measurement systems for both turning and drilling operations. These ensure automated tool and bore verification, maintaining exceptional repeatability and precision.
The machine also incorporates tool retract and recovery functionality to safeguard operations during load-shedding conditions. In the event of a power interruption, the machine retains its memory and resumes operation seamlessly once power is restored.
Installed entirely in-house without overseas assistance, the project was executed in collaboration with PBS Machine Tools, Honor Seiki’s South African agent.
“This achievement demonstrates that South Africa has the technical expertise and capability to install and commission world-class equipment locally,” says Myburgh.
Driving Sustainable Rail Manufacturing Growth
According to Regan Holland, Technical Manager at Lucchini South Africa, the working relationship with Wabtec under the NIPP programme dates back to 2019, when Lucchini identified the need to expand its local machining capability.
“This project has given South Africa machining capability that simply didn’t exist before, enabling us to produce wheels for Gautrain, Gibela, and other major locomotive projects,” says Holland.
He adds that the collaboration represents far more than a single equipment investment. It is a long-term dedication to developing South Africa’s rail manufacturing base and positioning the country as a hub for high-quality, locally produced railway components.
Empowering Skills and Technical Growth
For Lucchini’s technical staff, the project has been transformative. Noxolo Phonoshe, a CNC Operator who joined the company in 2017, reflects on her journey:
“I’ve gone from just pressing cycle start to programming and working with 10-micron tolerances. This machine has opened a whole new world of learning for me.”
Through comprehensive training in Visual Testing (Levels 1 and 2), Siemens Sinumerik CNC Turning (Basic and Advanced), and H-Cam Milling and Turning (Basic and Advanced), Phonoshe has progressed from basic CNC operation to high-precision programming and measurement using automated probing systems.
She now works confidently with micron-level tolerances, demonstrating how the NIPP investment is not only advancing manufacturing capability but also building human capital within South Africa’s rail engineering sector.
