cc.web.local

twitter Facebook Linkedin acp Contact Us

Manufacturing

Modular design is the key to streamline product portfolios

A new report from management consultancy Arthur D. Little warns that rising product portfolio complexity is quietly eroding profitability in the manufacturing sector, constraining digital growth, and limiting operational flexibility.

The study, Rise of Complexity in Manufacturing, highlights that companies must take decisive action to simplify their offerings and leverage modularisation to stay competitive.

“Unchecked complexity is a silent profitability killer,” the report states. “With resources limited and markets increasingly commoditised, companies must reduce product portfolio complexity to drive profitability and innovation.”

Manufacturers often expand product variants to meet customer demand, but without systematic portfolio pruning, these efforts generate hidden costs. Non-customer-facing complexity such as outdated products, excessive SKUs, and intricate internal processes can slow development, reduce scalability, and impede time to market.

The report identifies four key challenges for manufacturers: maintaining profitability amid market commoditisation, differentiating through digital solutions, ensuring supply chain resilience, and balancing legacy systems with emerging technologies such as new materials, battery-powered engines, or alternative fuels.

Arthur D. Little recommends a data-driven approach to complexity, starting with measuring the cost of complexity (CoC) across product lines and functions. A monetary proxy for CoC can capture inefficiencies in development, manufacturing, warehousing, and support, helping firms identify underperforming products for phaseout.

Strategic modularisation is highlighted as a crucial tool for managing complexity. By designing standardised, interchangeable product modules, manufacturers can simplify portfolios, accelerate time to market, and reduce costs while enabling cost-effective customisation.

The report cites Electrolux, which cut component numbers by 40% and reduced development time by 30% through modular design, and Siemens, which applied modularity to its industrial automation systems, reducing design time by 40% and improving scalability.

Arthur D. Little stresses that complexity reduction requires more than technical solutions: it demands cross-functional coordination, strong governance, and a cultural shift away from short-term gains. Companies must embed modular principles in product development, eliminate low-performing products, and ensure that both hardware and software systems are designed with simplicity in mind.

“Reducing product portfolio complexity is not a technical fix — it is a strategic transformation,” the report concludes. “By making complexity measurable, pruning underperforming products, and embedding modular design, manufacturers can release trapped value, improve speed to market, and build more resilient operations.”

The consultancy urges manufacturers to act decisively now, turning awareness of complexity into structured strategies for long-term profitability and innovation.

Toyota Tsusho’s TTMG acquires Toyota and Hino distributor in Ghana, strengthening mobility services and local operations

Toyota Tsusho Corporation, Toyota Tsusho Manufacturing Ghana Co. Limited (TTMG), a subsidiary of CFAO SAS (CFAO), has acquired the Toyota and Hino distributor business from Toyota Ghana Limited Company (TGLC) in Ghana, effective December 31, 2025

Strengthening mobility operations in Africa

Toyota Tsusho is developing four core business areas across Africa: mobility, green infrastructure, healthcare, and consumer solutions. Its mobility operations cover all 54 African countries, with the group directly operating Toyota automotive distributors in 35 of these nations, primarily in sub-Saharan Africa.

In Ghana, TGLC, which is independent of Toyota Tsusho, has previously served as the distributor for Toyota and Hino vehicles. Meanwhile, CFAO Mobility Ghana, a Toyota Tsusho group-operated distributor, has handled multiple other automotive brands in the country.

Purpose of the acquisition

This strategic acquisition brings the Toyota and Hino distributor business under the direct management of Toyota Tsusho in Ghana, allowing the company to expand its mobility value chain. Toyota Tsusho aims to offer a safe and reliable automotive experience in Ghana, consistent with its standards across Africa, including after-sales service and insurance offerings.

TTMG, which currently manages the assembly of Toyota and Suzuki vehicles in Ghana through semi knock down production, will now also take on sales functions, serving as the main customer contact while continuing its manufacturing role. Semi knock down production refers to a method where vehicle bodies are imported welded and painted, with major components assembled locally onto the chassis.

Future developments

With this acquisition, Ghana becomes the 36th African country where Toyota Tsusho directly operates a Toyota distributor, reinforcing the group’s development strategy in the region. The move is expected to improve vehicle inventory management, streamline logistics, and enhance sales to governments and international organisations.

Toyota Tsusho will also explore opportunities to optimise sales across Ghana in collaboration with CFAO Mobility Ghana, further strengthening its local presence.

Guided by the philosophy “with Africa for Africa,” the Toyota Tsusho group continues to invest in Africa’s sustainable development while providing world-class automotive products and services across the continent.

SANY opens global remanufacturing hub. (Image source: SANY)

SANY Group has officially begun operations at its first global engineering machinery remanufacturing hub, the SANY Hunan-Hainan Intelligent Manufacturing Industrial Park

The launch marks a major step in SANY’s globalisation and sustainability strategy, with the company securing CNY100 million (US$14.27mn) in orders from clients in Southeast Asia and Africa on the opening day.

The Park represents China’s first industrial facility co-developed by a pilot free trade zone (FTZ) and a pilot free trade port, advancing cross-regional collaboration between Hunan and Hainan provinces. By leveraging both provinces’ industrial strengths and policy incentives, the Park is designed to support Chinese enterprises in expanding their international footprint.

Construction of the Park began in August 2023, covering approximately 10 hectares (150 mu). With a total investment of CNY600 million (US$85.62mn), it is expected to reach an annual output value of CNY750 million (US$107.02mn) when operating at full capacity.

Positioned as a regional remanufacturing hub and resource distribution platform, the Park focuses on the maintenance and remanufacturing of core engineering machinery components as well as second-hand equipment from domestic and international markets. The facility promotes the circular reuse of industrial resources, aligning with SANY’s commitment to sustainability.

Operating under the Hainan FTZ framework, eligible value-added processing activities enjoy tariff preferences, while remanufacturing operations under bonded supervision may qualify for corporate and personal income‑tax incentives. The Park benefits from the “Dual 15%” tax-incentive policy, receiving approval for outsourced processes to enjoy a 15% corporate income-tax reduction.

“The project represents a key strategic initiative for SANY to deepen its globalisation, digitalisation, and low-carbon transformation. Moving forward, SANY will continue to actively explore new models for remanufacturing, promote the circular reuse of industrial resources, and jointly advance the global engineering machinery industry's transition toward a greener, low-carbon future,” said Tang Xiuguo, chairman of SANY.

the partnership aims to accelerate the transformation of West Africa’s manufacturing landscape. (Image source: RusselSmith)

Caracol, a global leader in robotic large-format additive manufacturing, and RusselSmith, an ISO-certified provider of innovative asset integrity and advanced manufacturing solutions for critical industries in Africa, have announced a Strategic Partnership to deploy, develop, and commercialise Caracol’s Vipra AM platforms – its robotic Wire Arc Additive Manufacturing (WAAM) technology – in West Africa

This collaboration aims to establish a world-class advanced manufacturing hub in the region, supporting the growth of local industrial capabilities and enabling the adoption of innovative and sustainable production solutions.

Under the exclusive partnership, Caracol and RusselSmith will:

  • Deploy Caracol’s robotic large-format Vipra AM technology across key West African markets.

  • Develop local expertise and capacity in advanced manufacturing.

  • Support commercialisation opportunities across diverse industrial sectors.

  • Advance regional industrialisation by providing innovative, scalable, and sustainable manufacturing solutions.

By combining Caracol’s global leadership in robotic WAAM technology with RusselSmith’s regional presence and industry expertise, the partnership aims to accelerate the transformation of West Africa’s manufacturing landscape, enhancing its role as a hub for innovation, efficiency, and industrial growth.

Riccardo Nicastro, global chief commercial officer and managing director of Middle East and Africa for Caracol, said, "The partnership between RusselSmith and Caracol is a testament of commitment towards Africa and its technology and manufacturing independence, agnostically from industries, together we are pursuing the creation of value for the whole Continent."

This initiative marks the start of a long-term collaboration that will bring two Caracol Vipra AM advanced technology platforms to the region, while also fostering talent development, promoting sustainability, and creating new economic opportunities.

Kayode Adeleke, CEO of RusselSmith, stated, "Our exclusive partnership with Caracol represents another bold stride in shaping the future of advanced manufacturing in West Africa. By introducing robotic WAAM technology through Caracol’s Vipra AM platform, we are unlocking new possibilities for industrialisation across the region. This collaboration allows us to build local expertise, accelerate the development of scalable manufacturing solutions, and create opportunities that strengthen Africa’s ability to compete globally. Together with Caracol, we are laying the foundation for a world-class hub that drives innovation, nurtures talent, and delivers sustainable growth for the industries we serve."

Brady Corporation empowers panel builders with durable, compliant, and efficient labelling systems for electrical clarity. (Image source: Brady Corporation)

In the world of electrical engineering, clarity and precision are key. A professional panel builder understands that clear identification is just as important as the wiring itself. With professional-grade labels and label printers, you can easily meet customer identification requirements and provide clear insight into even the most complex panels

Reliability you can count on

Just like a quality panel is built to last, so too should its labels. Industrial-grade labels are designed by Brady engineers to meet various requirements for panel identification. They're engineered to remain legible and stay attached when exposed to a variety of elements, including UV light, humidity, and moisture.  Customers can choose labels that fully comply with demanding marine, aviation, and defense standards. Technical data sheets are available to provide insight into label test results, helping you choose the right product for the job.

Clear, immediate insight

A cluttered or poorly labelled panel can lead to errors and safety issues. By using quality labels, you can provide immediate insight into the panel's layout and components. A wide variety of labels are available in different sizes, colours, and profiles. With clear print and various options, you can effectively identify any safety risk, cable, or component in an electrical panel. This includes controllers, I/O modules, power supplies, circuit breakers, terminal and distribution blocks, relay modules, starters, and heavy-duty connectors. Properly identifying these components makes maintenance easier and improves safety.

Fast and easy

Gone are the days of handwritten labels that can fade or fall off. Electrical panel labels can be printed efficiently on-site using a wide range of label printers. All you need are a few label rolls and a suitable printer to have a variety of panel labels at your command. The flexibility of having both benchtop and portable systems means you can print labels in the workshop or on the job site. With specialised software, you can easily design, serialise, and print the labels you need, ensuring a consistent and professional result every time. This speed and ease of use save you time and provide a professional-looking final product.

Portable Printer Family v1c lowresWant to see the benefits of reliable panel identification at a glance?

View the infographic on Brady’s website for a quick visual guide to a more professional and efficient workflow.

Brady Corporation in Africa

This email address is being protected from spambots. You need JavaScript enabled to view it.

www.bradysouthafrica.com

More Articles …