Implementation of 40 Industrial Revolution
Given Kagiso Vusimuzi Tshukudu
Industrial Engineer
Springs
Summary
In 16 years of working as an Industrial Engineer, worked in Automotive, Construction and Rail transport. Team member to Product Launches and Projects.
Mentored Industrial Engineering Graduates, trained teams in Project implementations.
Solve complex problems for organizations. Accomplished Process Engineer with more than 13 years enforcing compliance and improving steps in accomplishing goals. Successful and driven individual committed to proactive planning and goal-oriented work. Bilingual Process Engineer communicating project status and deliverables to key stakeholders. Engineering. Applying experience from more than 20 projects to augment corporate services and market share.
Overview
17
17
years of professional experience
12
12
years of post-secondary education
2
2
Certifications
5
5
Languages
Work History
Process Engineer
Supreme Spring
NIGEL
06.2019 - Current
- Reporting to Process Engineering Manager and, conduct time studies and perform process analysis to identify bottlenecks, inefficiencies, and areas for improvement within assembly line
- Develop and implement standardized work instructions, operating procedures, and quality control measures to ensure consistent and high-quality motor assembly.
- Utilize lean manufacturing principles and continuous improvement methodologies to streamline processes, reduce waste, and increase overall productivity.
- Collaborate with Product development engineering teams to provide input on design for manufacturability and assembly (DFMA) principles, ensuring smooth integration of Leaf Springs
- Monitor and report key performance indicators (KPIs) related to Leaf spring Manufacturing, such as cycle time, throughput, and defect rates, and implement corrective actions as needed
- Stay updated on industry trends, technological advancements, and best practices in Leaf Spring manufacturing and related processes
- Participate in industrialization effort during bids and mobilization phase of project
- Support Product Development Engineering department in all phases of evolution and customization of products
- Responsible for development and implementation of industrialization plan for new products
- Responsible for industrialization project deliverables in line with time, cost, and quality targets
- Support/facilitate problem-solving during prototype build
- Support with development /update of manufacturing/product data pack (i.e. assembly instructions and build history checklists)
- Responsible for layout and setup of production lines
- Perform detailed line balancing and ensure successful completion of task sequencings.
- Responsible for introduction of new manufacturing technologies, infrastructure, and equipment
- Support with development and manufacturing of aids, tools, and Jigs
- Establish operational methods and work standards and confirm task duration with aid of time and motion studies.
- Optimize productivity (man, machine, and material) by analyzing current processes and methods and identification of improvement projects in cleanroom.
- Implement Lean Manufacturing principles to continuously improve methods, processes, and production KPI's
- Perform continuous improvement in terms of standardization, technologies, architecture, best practices etc.
- Under guidance of Engineering Department
- Other ad-hoc duties as required by company
- Key Achievements: Leaf Spring Process Improvements and New Project Launches
- Leaf Blades were failing at Field amounting to R55K per month in warranties which resulted from fatigue failures managed to reduce to R12 K per month which is saving of R558 228 Per year.
- Appointed Shot peen specialist to Improve shot peening
- Key recent wins included
- Cpk improved to 1.33
- Machine uptime improved by 20%
- Consumable tonnage improved by 15%
- Electrical consumption improved by 33%
- Reason For Leaving: Career Growth
- Prepared scope of work documentation for use in project planning
- Developed documentation, diagrams, and specifications to meet project requirements and regulatory standards
- Analyzed critical line data to make recommendations for improvement
- Visited client sites to troubleshoot issues and provide one-on-one training
- Coached newly hired employees and interns while observing progress and delegating tasks
- Met weekly with team members to discuss project implementations and alleviate any issues
- Evaluated proposed project economics and identified alternative solutions and designs producing improved results
- Solicited proposals from third-parties to provide holistic costing data in proposal documentation
- Conducted root cause analysis to identify, prioritize and eliminate process losses
- Participated in project reviews to enable ongoing status tracking and reporting.
- Reviewed processes, identifying areas requiring improvement.
- Developed conceptual scope analyses of project objectives.
- Collaborated with technologists to address operating issues and support rapid recovery.
- Documented feasibility and implementation of third-party projects for review and future reference
- Provided technical assistance to production team when issues arose
- Managed third-party contractors, inspecting completed work and ongoing efforts to confirm quality and adherence to prescribed guidelines
- Reduced downtime and increased production capacity with strong maintenance plans
- Monitored and optimized production processes to increase throughput and improve quality
- Analyzed data to identify trends in production and maintenance costs and developed strategies to reduce expenses.
Logistics Methods Engineer
Gibela Rail Consortium
Dunnottar
06.2015 - 05.2019
- Reported to Logistics Methods Manager, Ran warehouse of 2000 square meters.
- Managed 72 Suppliers in terms of logistics and Packaging.
- Responsible for Returnable Packaging.
- Utilize strategies to improve logistics management procedures.
- Analyze and improve facility layouts and storage rack systems using SAP and AutoCAD and propose logistics solutions for customers.
- Prepare and deliver high-quality employee training to help companies eliminate overhead, material and labor costs.
- Produce and improve well-organized layouts, targeted material movement plans and detailed process maps to enhance operations.
- Lead continuous improvements in transportation quality, accuracy and efficiency for SKUs from different suppliers.
- Applied understanding of simulations, data analytics and diverse tools to construct and implement strategies for optimizing logistics.
- Eliminate downtime and maximize revenue by providing top project quality control and maintain Zero harm environment.
- Manage quality assurance program, including on-site evaluations, internal.
- Key Achievements:
- Defined warehouse solution for 8000sqm warehouse with 5000 SKU with budget of 5MZAR and Used 2.6MZAR
- Managed contract of 11 MHE Fleet
- Championed Returnable Packaging project which is continuous improvement with ROI of 120 MZAR for life of Project (10 years)
- Key recent wins included.
- With First Wave Packaging implementation we managed to save 93 MZAR in hard savings with investment of 2,8 MZAR
- With second wave Packaging implementation managed to save 46 MZAR in hard savings with investment of 1,8 MZAR
- Reason For Leaving: Supreme Spring contacted me for career growth projects.
- Proved successful working within tight deadlines and fast-paced environment.
- Demonstrated creativity and resourcefulness through development of innovative solutions.
Process Engineer
Supreme Spring
NIGEL
09.2014 - 05.2015
- Facility of 5000 square meters
- Manage 4 Interns and staff complement of 30 per area of Improvement.
- Develop documentation, including diagrams and specifications, to meet project requirements and regulatory standards.
- Develop manufacturing processes that were robust yet simple to perform.
- Review processes, identifying areas that required improvement.
- Generate reports covering analysis of key data and potential solutions.
- Design improvements to equipment to optimize worker productivity.
- Design and test process upgrades and new process systems
- Optimize productivity by designing, executing and testing new procedures.
- Develop routines and best practices to ensure product quality.
- Key Achievements:
- Streamlined processes that resulted in lean process, where saw manning reduction of 4 heads which was R300K per year.
- Reduced WIP by40%
- Key recent wins included.
- Process Quality projects which resulted soft saving of R500K
- Reason For Leaving: Head Hunted by Alstom/Gibela
- Prepared scope of work documentation for use in project planning
- Visited client sites to troubleshoot issues and provide one-on-one training.
- Coached newly hired employees and interns while observing progress and delegating tasks.
- Visited client sites to troubleshoot issues and provide one-on-one training
Manufacturing Engineer
Johnson Controls
Pretoria
02.2006 - 08.2014
- Manufacturing Engineering Manager, Lean Assessments in Constrain management, TPM, 5s, Kaizen, Kanban, visual management, culture and awareness and Seven kinds of waste.
- Kanban and Kaizen Project, Just in Time Manufacturing system Project, Value Stream Mapping
- Production Process Improvement and Problem Solving
- Provide technical solutions to meet project and product objectives.
- Working hand in hand with purchasing manager and Logistics Manager (Inventory control)
- Perform process, cell layout and material flow analysis.
- Developed manufacturing process, techniques and equipment to improve productivity.
- Verify process with actual time studies.
- Investigate and resolve manufacturing problems.
- Implement, update, maintain and audit process documentation.
- Design line layouts
- Design flexible manufacturing processes to eliminate set-up time.
- Verify Bills of Material on production floor
- Responsible for continuous improvement for assigned area using Sigma tracking.
- Assist with training and coaching production team from concept phase until implementation to start-up.
- Investigate and resolve Ergonomic issues - PEIL.
- Attend to Quality related customer concerns and Control Plans
- Facility of 4000 square meters.
- Manage 2 Graduate Engineers
- Warehouse improvement
- Design and development of warehouse
- Warehouse process flow analysis, systems Implementation (e.g., ABC analysis) and shelving
- Storage or warehouse optimization e.g., Total space utilization
- Project on retrieval systems in stores e.g., Barcode systems
- Compiling and improvement of Packaging procedures
- Key Achievements:
- Ford Ranger (T6 Project) Launch Capex Target was R12 million in 2010 – achieved R8 million sales– R4 million over target.
- Consistently exceeded monthly targets since Launching T6 Project in 2010
- Won Employee of year in 2011 for Launch of T6
- Key recent wins included.
- Footprint Reduction of 500 square meters
- Reason For Leaving: Head Hunted by Supreme Spring
- Resume of
- Applied project management metrics and tools in oversight of engineering and manufacturing projects and program services.
- Researched and tested design feasibility and operation of equipment, components and systems.
- Promoted Design for Manufacturability philosophy.
- Reviewed products for compliance with Design for Manufacturing (DFM) requirements.
- Completed purchase analysis to analyze customer engineering drawings and specifications.
- Designed documents and statements of proposals, lead times, technical costs and budgets and statements of work to manage supplier development efforts.
- Researched and tested design feasibility and operation of equipment, components and systems.
- Managed supplier development efforts through engineering design, technical producibility, manufacturing reviews and development of solutions
- Applied project management metrics and tools in oversight of engineering and manufacturing projects and program services.
Production Supervisor (Industrial Engineer)
Duraset, AVENG GROUP
Westonaria
07.2009 - 05.2010
- Adaptable and proficient in learning new concepts quickly and efficiently.
- Delivered services to customer locations within specific timeframes.
- Used critical thinking to break down problems, evaluate solutions and make decisions.
- Exercised leadership capabilities by successfully motivating and inspiring others.
- Demonstrated high level of initiative and creativity while tackling difficult tasks.
- Excellent communication skills, both verbal and written.
- Learned and adapted quickly to new technology and software applications.
- Resolved problems, improved operations and provided exceptional service.
- Demonstrated strong organizational and time management skills while managing multiple projects.
- Developed and maintained courteous and effective working relationships.
- Developed and maintained courteous and effective working relationships with 20 Employees.
- Proved successful working within tight deadlines and fast-paced environment.
Education
BTech - Industrial Engineering
Tshwane University of Technology
Pretoria 01.2021 - 11.2022
National Diploma - Industrial Engineering
Tshwane University of Technology
Pretoria 01.2002 - 04.2007
Matric -
Gatang Comprehensive School
Mamelodi 01.1997 - 11.2001
Skills
Problem Solving
Improvement tracking
Regulatory standards
Process flow analysis
Relationship building
Project oversight
Documents and reports
Product reliability
Strategic planning
Calibration understanding
Cost estimates
Project coordination
Lean principles
Industrial design
Returnable Packaging Implementation
Supply Chain and Logistics
Lean environments
Certification
Kepno Trego
Interests
Supply Chain
Timeline
BTech - Industrial Engineering
Tshwane University of Technology
01.2021 - 11.2022
Process Engineer
Supreme Spring
06.2019 - Current
Logistics Methods Engineer
Gibela Rail Consortium
06.2015 - 05.2019
Process Engineer
Supreme Spring
09.2014 - 05.2015
Kepno Trego
11-2010
Production Supervisor (Industrial Engineer)
Duraset, AVENG GROUP
07.2009 - 05.2010
Manufacturing Engineer
Johnson Controls
02.2006 - 08.2014
MTM-X
05-2004
National Diploma - Industrial Engineering
Tshwane University of Technology
01.2002 - 04.2007
Matric -
Gatang Comprehensive School
01.1997 - 11.2001