Manufacturers today face a range of challenges that are evolving at a rapid pace. The nature of highly customised products requires production lines to be flexible, where-as many traditional production systems are still designed for high-volume, linear production. This rigidity can lead to operational bottlenecks when it comes to adapting to new products, especially when the complexity of product variants demands a more sophisticated approach to process and production management.
The challenge in the motor industry is intense. The pressure for OEMs to change from combustion driven cars to EVs is at the forefront of most advanced or developed countries. The term ‘disruptive innovation’ is given to describe moments like this. When a new technology comes along that completely changes the industrial structure in a sector, it’s incredibly difficult for the incumbent businesses to respond and adapt. They simply aren’t set up for it. Think about how digital photography displaced traditional film, or how smartphones have displaced traditional computers.
A general view of the machine shop of WIKA Instruments South Africa’s production facility in Denver, Johannesburg
Another pressing issue is the sustainability of operations. The balance between cost, quality and environmental responsibility is a delicate one for manufacturers striving to maintain profitability while trying to reduce their carbon footprint. And, on top of process challenges, the workforce is undergoing a major transformation. As experienced workers retire, there is an urgent need to rapidly attract and train new talent capable of thriving in this digital manufacturing environment. There is also a need to try and capitalise on large amounts of manufacturing tribal knowledge before it literally ‘walks out the door.’
However, a constant in all of this turmoil, call it what you like, is the role of measurement technology. Whether it is mechanical or chemical, methods and devices used to determine physical quantities and quality, is measurement technology. Measurement is a fundamental part of many fields, including sciences, engineering, construction, other technical fields, and everyday activities. They include length, weight, force, voltage, current, brightness, temperature, vibrations, and sound, to name a few.
The WIKA Group manufactures and supplies product for pressure, temperature, force and level measurement. This is a flange monoblock with shut-off valve
The world relies on measurement technology and solutions. Precise data, optimum runtimes and cost efficiency are essential to big decisions. Small errors in measurement can result in death or large losses of revenue. An ability to select the suitable sensors for temperature, displacement, force, acceleration, pressure and flow and the corresponding instrumentations to record the data are central to making better decisions and improving operational efficiencies. A holistic approach will give manufacturers unrivalled control and visibility over their entire production or manufacturing processes, thus ensuring traceability and accountability.
On January 02, 1946, Alexander Wiegand and Philipp Kachel founded WIKA GmbH in Klingenberg. The initial two letters of their surnames formed the company name WIKA. In 1951 Konrad Wiegand, the son of Alexander Wiegand, took over the management of the company. A decade later the company was consolidated under one roof at its present headquarters in Klingenberg.
In 1967 Ursula Wiegand took over the control of the company from her late husband.
With the inauguration of the new WIKA head office in 1988, Klingenberg was confirmed as the headquarters of the family-run company. As early as 1994, the high-quality standard of WIKA was certified to DIN ISO 9001 by the German Society for the Certification of Quality Management Systems (DQS).
“The latest CNC machine tool that WIKA Instruments South Africa purchased is a DN Solutions 2100LSYB turning center that was specifically purchased to give us more capability on the turning side and capacity. It has a maximum turning diameter of 300mm and a maximum turning length of 600mm.” The machine was supplied by Puma Machine Tools
For their 50th anniversary, WIKA was one of the leading companies worldwide for mechanical pressure and temperature measurement. In the same year, following the death of Ursula Wiegand, Alexander Wiegand, the grandson of the company’s founder, took over the management of the business.
For over 78 years, WIKA has been a renowned partner and competent specialist for any task in the field of measurement technology. With steadily growing efficiency, innovative technologies are applied when developing new products and system solutions. The reliability of the products and the readiness to face all challenges of the market have been the key factors for WIKA achieving one of the leading positions in the global market.
Within the WIKA Group, currently 11 200 employees are dedicated to maintaining and improving technology in pressure, temperature, force and level measurement, and also in the fields of flow measurement, calibration and SF6 gas solutions. WIKA engineers and technicians are continually developing innovative product solutions, improved materials and profitable production methods. In close cooperation with recognised universities, institutes and industrial companies, solutions for specific applications are developed.
One of the two Mollart deep-hole drilling machines
WIKA Instruments South Africa was established as a subsidiary in 1979. It is one of 15 subsidiaries in the WIKA Group that has a production facility. The factory manufactures mechanical pressure, temperature level and flow instruments, as well as RTDs and thermocouples. All WIKA products are manufactured according to relevant standards – SABS, BS, DIN and EN.
In February 1993, WIKA built new premises in Denver, Johannesburg. This is still the head office of WIKA Instruments South Africa today. WIKA employs over 200 people and has offices or direct representation in all 9 provinces in South Africa as well as in Sub-Saharan Africa. The facilities include a 3 500m² factory on a 10 400m² site.
Pressure and temperature calibration is an important part of the service offering from WIKA Instruments, which has two South African National Accreditation System-certified laboratories (for pressure and temperature calibration) and three mobile calibration laboratories.
The machine shop has to regularly perform deep-hole drilling on components used in the final product
In addition to WIKA’s core pressure, temperature and level products, WIKA South Africa also distributes products that complement this range of instrumentation. This positions WIKA as a comprehensive supplier in the African market.
“As a family-run business that acts globally, we are known worldwide as a market leader in pressure and temperature measurement, and in calibration technology. We also set the standard in the measurement of level, force and flow. We will continue widening our offering, and thus make it ever more attractive for our customers,” commented Griffith Smith, Workshop Manager at WIKA Instruments South Africa.
“As best possible we will machine or manufacture most of the components that constitute our products. There are many reasons that have allowed us to evolve with this strategy but you can say that quality and control are the main reasons.”
As best possible the company will machine or manufacture most of the components that constitute their products
“This has allowed the group’s individual subsidiaries to develop structured and comprehensive machine shops, as well as the other departments that are required for the systems and processes that are required for us to offer our clients high-precision, smart sensing technology products.”
CNC machine shop
“For example, our machine shop has 8 CNC machines on the floor and two Mollart deep-hole drilling machines besides other metal processing equipment that are associated with our processing operations. One of the CNC machines was only installed in May 2024. The DN Solutions 2100LSYB turning center was specifically purchased to give us more capability on the turning side and capacity. It has a maximum turning diameter of 300mm and a maximum turning length of 600mm.”
“The number of DN Solutions machines on the floor now stands at 7.”
“We machine mostly stainless steel components because that is what is required for our products. In the industries that we service, which includes machine building and automation, the semiconductor industry, mobile working machines, power transmission and distribution, heating, ventilation and air -conditioning technology, refrigeration technology and industrial gases, stainless steel is the standard material.”
WIKA Instruments machines mostly stainless steel components because that is what is required for their products
“We have so much experience in machining the material we almost treat it like we are machining steel. We machine from hexagon, round and square and most of it we cut to size ourselves. We can machine anywhere between 10 and 500 of a component depending on what is needed. We machine from profile and then use most of the machining processes where drilling, tapping and threading are predominant.”
Deep-hole drilling
“The two Mollart deep-hole drilling machines have been here since 2009 and 2011 respectively. We acquired them again to be able to control and maintain the concentricity and quality of the bores being drilled.”
“We were one of the first companies in South Africa to be able to offer the depths we are able to offer with these machines. We did a lot of research into the subject and wherever possible we tried to improve machining processes, for example with speeds and feeds. We consider ourselves experts in this field of deep-hole drilling and regularly offer information and know-how between subsidiaries within the group.”
Adapters and couplings for high-pressure applications are products manufactured by WIKA Instruments
“The machines still look new because we are very strict on our maintenance. When working with components and products that are very sensitive to variation you have to make sure your operating equipment is operable to micron spec.”
“We can do almost anything with regards to machining. From time to time, we machine components which are not in our general scope of supply. We are always offering our clients our precision machining capabilities and also look for outside work.”
Programming
“Programming is performed manually by skilled programmers, which is taught and trained internally. This gives the operator a real sense of responsibility as well as upskilling and not just being a machine operator.”
“The company has been driving global standards throughout its subsidiaries where manufacturing takes place. This re-enforces consistency throughout the group. So if you buy a product in Australia, Germany or South Africa they will be exactly the same.”
A diaphragm seal for process temperatures up to 450 °C. All of the components for this product are machined in-house
“We have manufactured and supplied machined products in South Africa for projects done by various WIKA subsidiaries within the group. There is often collaboration between manufacturing sites within the group where capacity is not available in the one, another can step in and assist in achieving delivery deadlines and do as much as possible in-house for accuracy and consistency.”
“Our products are used in very sensitive environments in many cases, therefore accuracy and consistency is key. This is the main reason we manufacture as much as possible in-house.”
The company also machines non-ferrous materials when required
“The group has also taken into account the megatrends of digitalisation, decarbonisation and demographic change. These pose major challenges for many industry sectors, but at the same time offer promising growth potential such as the networking of systems and processes, the expansion of renewable energies, sustainable mobility solutions, and a secure supply of food and medicine.”
“With this in mind, WIKA supports its customers with high-precision, smart sensing technology. Sensors are the senses of digitalisation. Smart in Sensing reflects the technological expertise and innovative strength of a world market leader in measurement technology. It shows that WIKA perceives the global market needs of tomorrow ‘with all senses’, and develops pioneering products, solutions and services that contribute to the success of its customers.”
For further details contact WIKA Instruments on TEL: 011 621 0000 or visit www.wika.com
