Disrupted Factory

Before the Tesla Model S redefined the industry, a team in Cape Town had already built the future. So why have you never heard of the Joule? 
While Silicon Valley was in its infancy, South African engineers were solving the EV puzzle: 6-seat capacity, 180-mile range, and a modular interior designed for global export. In this episode of The Disrupted Factory, I sit down with Gerhard Swart, former CTO of Optimal Energy, to discuss the high-stakes engineering behind the Joule and the heartbreaking 9.2-billion-rand industrialization "chasm" that swallowed the project whole. 
We go from the glitz of the Geneva Motor Show — where the Joule stood toe-to-toe with Lamborghinis — to the grim reality of being ordered to destroy the tooling when the government pulled the plug. But this isn't just a story of what was lost. 
We dive into Gerhard’s current work on the Square Kilometre Array (SKA)—the most ambitious radio telescope project in human history. Whether you are an EV enthusiast, a space nerd, or a systems engineer, this is a masterclass in why some of the world’s greatest innovations never make it to the driveway. 
Keen to get your hands on Gerhard's book - Hope Arising - click here: Official Site: https://joulebook.co.za/ Exclusive Books: https://tinyurl.com/ExclusiveBooksJoule Amazon: https://tinyurl.com/5dhtfmra 
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The Mr. Miyagi of LEAN brings his wisdom and teachings to our first LIVE podcast!

In this episode of The Disrupted Factory, we sit down with Vitor Ferreira, the Mr. Miyagi of LEAN. After four decades across Michelin and Bridgestone, he’s trained more than 8,000 people and earned a reputation for cutting through noise with simple, practical truth.

Vitor explains why the world’s best manufacturers, no matter the culture, all share the same obsession: finding and fighting waste. That mindset, he says, is the competitive advantage. When Vitor talks 5S, he strips away the buzzwords: it’s not about neatness, it’s about making waste visible so productivity can rise!

He also shares the lesson that shaped his entire career: respect the operator. They’re the true masters of the process. 

From there, Vitor breaks down the Five Principles of Lean, the Seven Wastes (TIM WOODS), and introduces his own “Ninth Waste”: resistance to change. And because tools only matter when they move numbers, he shows how SMED took a tire changeover from more than twelve hours to just two!

Finally, he calls out the uncomfortable truth: too many ISO and Lean programmes have become tick-box exercises. As AI speeds up the pace of change, he argues that leaders must stop firefighting and start focusing on effectiveness, capability and real financial impact.

If you enjoyed this conversation with the Mr. Miyagi of LEAN, hit Like, drop a comment and Subscribe to The Disrupted Factory for more straight-talk insights from the people ACTUALLY shaping modern manufacturing. 

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In this roundtable discussion at the Nelson Mandela Bay Business Chamber, we unpack the future of mobility, the politics, the infrastructure challenges, and whether EV adoption makes sense for Africa right now. South Africa’s automotive component sector plays a vital role in keeping the country’s manufacturing economy moving. In this episode, we unpack the key takeaways from the NAACAM Show, where industry leaders, government officials and business partners came together to discuss the road ahead. The conversation explores how localisation, skills development and digital readiness can drive growth, and why reforms such as the APDP2 review are so important for restoring competitiveness. We also look at the growing focus on electrification, the role of software in modern vehicles, and how initiatives like ODIN and MESITA are helping to prepare young people for the factory floor of the future. Along the way, the guests share frank views on infrastructure challenges, cybersecurity risks and the practical steps needed to strengthen South Africa’s automotive supply chain.
Beth Dealtry is the Executive Director of NAACAM, representing South Africa’s automotive component manufacturers. With a background in industry development and stakeholder engagement, she has been instrumental in driving collaboration between government, business and training institutions to strengthen the local manufacturing base. Martin Zano is the Managing Director of Eberspächer South Africa and a leading voice on electrification and future mobility. He brings deep insight into the evolution of propulsion technologies and the practical steps needed to prepare local manufacturers for the global transition to new energy vehicles.

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Right now, Africa is a dumping ground for second-hand imports, killing local industry, jobs, and growth. If every African country shut that tap tomorrow, our market could jump from 1 million to 3 million new vehicles a year — instantly.

In part 2 of my conversation with Justin Barnes, we break down why Africa’s auto industry is stuck, what needs to change, and how countries like India and China built policies that turned them into automotive giants. Spoiler: it’s not about population size — it’s about serious strategy!

Join us as we explore the uncomfortable truths, the massive opportunities, and why Africa could be the next big growth story in global automotive. We also dive into some shocking facts like why Africa has more people who can afford new cars than India… but only sells a fraction of the vehicles!

If you liked part 2 of our podcast with Justin, consider hitting that subscribe button. That way you'll always be notified when we release new industry related content!

#AfricanAutomotive #FutureOfAfrica #AutoIndustry #Jendamark #DisruptedFactory
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In this candid and insightful episode of The Disrupted Factory, Yanesh speaks to industrial policy expert Justin Barnes about South Africa’s automotive industry, currently facing severe challenges. They discuss the consequences of weakening infrastructure, global trade shifts, and Nissan’s exit from the local market. Justin highlights gaps between government policies and industrial realities, explores the viability of local OEM operations, and shares his views on why Africa might not yet be ready for large-scale electric vehicle production. Essential listening for understanding the future of manufacturing in South Africa.

Justin Barnes is an industrial development specialist with nearly 30 years of experience dedicated to building thriving manufacturing ecosystems across Africa. With a career spanning engagements in 37 countries, Justin has guided major industrial strategy and policy projects, notably through his leadership roles at B&M Analysts and the Toyota Wessels Institute for Manufacturing Studies (TWIMS). Passionate about African industrialisation, Justin recently founded a new venture focusing on sustainable, labour-intensive manufacturing, aiming to unlock socio-economic growth and empower the continent’s greatest asset - its people.
Subscribe to our YouTube channel to watch all our episodes, plus bonus weekly video content
Connect with our host, Yanesh Naidoo, on LinkedIn
Become a Facebook fan of the podcast
Find us on TikTok
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Learn more about Jendamark