Bothwell Mavhangira
Robotics and Automation Engineer
Johannesburg,GP
Summary
Results-driven Automation Controls Engineer with 8 years of experience in the Manufacturing Engineering sector, specializing in the operation, maintenance, and enhancement of advanced automated manufacturing equipment. Committed to executing tasks accurately on the first attempt, ensuring optimal performance and reliability. Strong aptitude for learning all facets of automation, complemented by a proven track record in maintaining, developing, integrating, installing, managing, and repairing equipment used for monitoring and controlling engineering systems and production processes. Passionate about driving continuous improvement and innovation within the industry.
Professional leader with background in team management and project coordination. Known for driving team performance and ensuring project milestones are met efficiently. Focused on collaborative efforts and adaptable to changing situations. Skills in conflict resolution and strategic planning contribute to reliable and effective leadership.
Overview
8
8
years of professional experience
Work History
Automation Group Leader
MA Automotive Tool & Die (Pty) Ltd
04.2024 - Current
- lead the project on conversion of 5 Relay logic press lines to PLC based control technology.
- Trained new team members by relaying information on company procedures and safety requirements.
- Monitored group performance on a regular basis, analyzing data and trends to identify areas for improvement.
- Established clear goals and expectations for the team, promoting accountability and fostering a high-performance culture.
- Supported staff with developing professional skills and abilities, uplifting team performance.
- Managed complex projects to successful completion, ensuring alignment with organizational goals and deadlines.
- Streamlined operations, reducing waste and increasing efficiency through process optimization.
- Boosted project completion rates with strategic planning and effective resource allocation.
- Recruited, interviewed and hired employees and implemented mentoring program to promote positive feedback and engagement.
- Trained personnel in equipment maintenance and enforced participation in exercises focused on developing key skills.
Automation Controls engineer
MA Automotive Tool and Die Pvt (Ltd)
07.2019 - 05.2024
- Working collaboratively with design, product excellence, production operations, Manufacturing Engineering, Process Engineering, Maintenance, and other cross functional teams as the expert to ensure production lines run in a safe, efficient manner producing high quality parts.
- Responsible for continuous process optimization of automated lines to drive equipment-related process improvement including detailed troubleshooting and root cause analysis.
- Programmed, commissioned, and repaired industrial 6-axis robots (Kuka, ABB), Sequenced complex, multi-station machinery for material pick-and-place, dispense, fastening, welding and conveyance applications.
- Programmed ladder logic and structured text on multiple PLC controller platforms (Allen-Bradley, Siemens).
- Timely and professional execution of lead equipment upgrades repair, maintenance, servicing, and modification activities on all production machines.
- Identified equipment critical spare parts and ensure sufficient coverage to prevent extended downtime situations.
- Providing hands-on support to maintenance team to troubleshoot and resolve extended downtime situations.
- Eliminated simple errors and malfunctions on complex production and assembly machines for the Stamping Press lines (G1 and G2) and General assembly lines for Mercedes W206 model.
- Worked on improving cycle time for Assembly Lines (Main Floor and side wall), and Mechanical Stamping Press Lines (G1 and G2).
- Performed efficiency testing to ensure all systems are running at their peak.
- Configured Industrial networks (ProfNet / Profibus).
- Configured and commissioned VFD, Servo Drives and encoders.
- Did program modifications for FFT lines and AWL lines (TIA portal, Step 7, ABB, and KUKA robots) as part of process improvement.
- Integrated ABB robots to PLC, welders, and other I/O equipment on MBSA and VW Production lines.
- Designed and programmed PLC and HMI for pedestal welders.
- Developed, implemented, monitored, and maintained efficient automation control processes.
- Troubleshooted robotic systems (ABB and KUKA, Panasonic), perform preventive maintenance, document test procedures (OPLs), assemble components, and prolong the life of robots.
- Understood robot fault codes, changed internal harness and gears, PC cards, and setup involved.
- Worked on Bosh 6000 and PRI7000 adaptive welding and Drives (Siemens, SEW, ABB, Lenz, Beckhoff).
- Worked Auto Sealer Systems (SCA), fault finding and programming.
- Managed all software and hardware installed on different types of equipment.
- Converted hard-wired Mechanical Presses with old relay logic to run fully PLC Controlled and developed HMI visualization.
- Integrated new welding Jigs to existing welding cells on Toyota lines.
- Developed new control circuits for new and existing equipment.
- Troubleshot and repaired robots, and workstations to minimize downtime.
- Identified key issues causing chronic equipment failures and provided lifelong solutions.
Instrumentation and Control Engineer Trainee
Riozim Cam and Motor Mine Pvt (Ltd)
07.2018 - 05.2019
- Commissioned the SCADA system (WinCC) for Main Gold processing plant (Cam and Motor Mine).
- Installed and wired field instruments and actuators equipment to the PLCs used to monitor and control the flotation plant.
- Wired motor control panels (MCC) for induction motors i.e., power and control wiring, Schematics.
- Did all PLC hardware Configuration of all devices and networking involved.
- Took part in the development of PLC programs and HMI graphics, and configured alarms for the project.
- Configured PLC message instructions and network settings Siemens (Step 7, TIA Portal and WinCC).
- Developed instrument installation plans and loop diagrams for automation programming.
- installed and commissioned field instrumentation
- Tested all the electrical equipment after installation and commissioned the floatation plant.
- Installed, configured, and programmed the Industrial PC, and VFDs, Servo drives.
- Installed instruments that measure mass of material and flowrate, level, pressure, and temperature and analyze liquids and the PLC programming and HMI visualization involved.
Education
Bachelor of Technology (Honors degree) - Electronic Engineering
Harare Institute of Technology
06.2018
Post Graduate Diploma in project Management - undefined
Regent Business School
12.2024
KUKA Programming 1 - undefined
Mercedes Benz Learning Academy
07.2024
TIA PRO 1 - undefined
Siemens Sitrain
10.2023
TIA SERV 2 - undefined
Siemens Sitrain
10.2024
W206 Basic iNTEC Sealer system - undefined
Mercedes Benz Learning Academy
06.2024
FANUC Robot Operation & Programming - undefined
Fanuc academy
10.2024
MBA - Project Management
Regent Business School
Durban, South Africa 04.2001 -
Skills
Control and automation
Controls software development
Networking
Plant floor systems
Electrical systems
Electronic systems
PLC programming
Troubleshooting
Configuration
Siemens TIA portal
S7-1500 PLC
S7-300
Beckhoff PLCs
Allen-Bradley
HMI programming
WinCC
Ignition SCADA
Operator human machine interfaces
Robot programming
ABB
KUKA
Ladder logic
Structured text
Industrial 6-axis robots
Fanuc
Material pick-and-place
Dispense
Fastening
Welding
Conveyance applications
Stamping
Body and Assembly manufacturing operations
Drive technology
Electronics
Pneumatics
Vision systems
Cognex
AutoCAD Electrical
Performance monitoring
Mining technology
Maintenance coordination
System integration
Industrial networks
C programming
Circuit Design and analysis
Power Electronics
Current Project
Five Low slag welding cells for Toyota TSAM 640X, Develop electrical drawings, Integrate the following cell major components: two Fanuc Robots, two welding pack supply, siemens S7-1500 PLC and HMI, three turn tables, safety light barriers and door locks., Wiring of sensors, actuators and fixtures., Program PLC and Fanuc Robots
Timeline
Automation Group Leader
MA Automotive Tool & Die (Pty) Ltd
04.2024 - Current
Automation Controls engineer
MA Automotive Tool and Die Pvt (Ltd)
07.2019 - 05.2024
Instrumentation and Control Engineer Trainee
Riozim Cam and Motor Mine Pvt (Ltd)
07.2018 - 05.2019
MBA - Project Management
Regent Business School
04.2001 -
Post Graduate Diploma in project Management - undefined
Regent Business School
KUKA Programming 1 - undefined
Mercedes Benz Learning Academy
TIA PRO 1 - undefined
Siemens Sitrain
TIA SERV 2 - undefined
Siemens Sitrain
W206 Basic iNTEC Sealer system - undefined
Mercedes Benz Learning Academy
FANUC Robot Operation & Programming - undefined
Fanuc academy
Bachelor of Technology (Honors degree) - Electronic Engineering
Harare Institute of Technology