Khethukuthula Sithole
Akasia
Summary
Supplier Quality Engineer managing quality across domestic and international supplier bases for seat components and safety-critical assemblies. Drives PPAP, APQP, VDA 6.3 audits, and 8D root cause analysis to contain defects, close SCARs, and protect launch readiness. Strengthens supplier performance through PPM tracking, corrective actions, and process capability reviews across automotive manufacturing.
Overview
9
9
Languages
2
2
Certifications
13
13
years of professional experience
Work History
Supplier Quality Engineer
Yanfeng Seating
04.2026 - Current
- Supplier Management: I am responsible for all quality-related activities across the supplier base, covering both domestic (local) and international (abroad) suppliers of seat components such as foam, fabric, leather, metal frames, headrests, recliner mechanisms, and plastic trims.
- Product Scope All purchased parts and raw materials that become part of the finished seat assembly, including safety-critical components (e.g. seat belt anchors, recliner mechanisms, side airbag-integrated covers).
- Process Scope From supplier selection and qualification through to series production, including new model launches, engineering changes, and continuous improvement activities.
- 1. Supplier Qualification & Approval
- Evaluate and approve new suppliers through the Production Part Approval Process (PPAP) and Advanced Product Quality Planning (APQP)
- Conduct supplier capability assessments (process capability indices: Cpk, Ppk) before serial production
- Maintain and update the Approved Supplier List (ASL)
- 2. Supplier Auditing
- Conducted process and system audits using VDA 6.3, ISO/TS 16949 (IATF 16949), or customer-specific standards, ensuring compliance and driving continuous improvement
- Issue audit findings, track corrective action closure, and verify effectiveness
- Perform layered process audits (LPA) at both domestic and international supplier sites
- 3. Non-Conformance & Defect Management
- Investigate incoming quality defects using structured problem-solving tools: 8D, 5-Why, Ishikawa (fishbone) diagrams
- Issue Supplier Corrective Action Requests (SCARs) and monitor resolution timelines
- Manage sorting, rework, and containment activities for non-conforming material
- Apply zero-defect principles to safety-critical seat components
- 4. New Product Introduction (NPI) & Launch Support
- Support APQP milestones from design freeze through job #1 (start of production)
- Approve supplier PPAP submissions including control plans, FMEAs, measurement system analysis (MSA), and dimensional reports
- Conduct pre-production runs and First Article Inspection (FAI) at supplier facilities
- 5. Supplier Performance Monitoring
- Tracked and reported supplier KPIs including PPM (parts per million defect rate), on-time delivery, SCAR closure rate, and audit scores, enabling data-driven decision-making
- Conduct monthly or quarterly supplier performance reviews
- Manage supplier scorecards and escalate poor performers through a defined escalation matrix
- 6. Risk Management
- Identified supply chain risks related to quality, capacity, and geographic/geopolitical factors, maintaining a risk register and implementing mitigation strategies to ensure supplier reliability
- Maintain a risk register and implement contingency sourcing or dual-sourcing strategies for critical components
- Ensure business continuity planning is in place at key supplier sites
- 7. Regulatory & Customer Compliance
- Ensure suppliers comply with automotive customer-specific requirements (CSRs) from OEMs such as Toyota, BMW, Ford, etc.
- Verify material compliance with REACH, RoHS, and conflict minerals regulations
- Ensure seat components meet FMVSS, ECE, or SABS safety standards depending on the market
- 8. Cost of Poor Quality (CoPQ) Reduction
- Drive down warranty returns, field escapes, and internal rejections attributable to supplier quality
- Collaborate with procurement to impose chargeback costs for non-conformances where applicable
- Support value engineering initiatives that maintain quality while reducing component cost
- 9. Supplier Development
- Provide technical support and training to underperforming suppliers
- Lead kaizen or lean manufacturing initiatives at supplier facilities
- Build long-term quality capability and self-sufficiency within the supplier base
- 10. Cross-functional Collaboration
- Work closely with Design Engineering, Procurement, Logistics, and Production to align supplier quality activities with business goals
- Serve as the primary quality interface between the manufacturing plant and the supplier
- Communicate abroad supplier issues across time zones and language barriers, often coordinating with regional SQE counterparts
Quality Engineer
MA Automotive
05.2023 - 03.2026
- Monitored daily activities within the Quality Assurance department using ISO 9001 guidelines.
- Performing product audits, process audits and system audits on the production lines (BMW G45 Assembly and Press Shop).
- Applying BMW GS Standards and IATF 16949 Standards to meet customer requirements.
- Evaluate and approve suppliers for stamped components and assemblies through supplier audits and assessments according to customer specification.
- Review and approve PPAP (Production Part Approval Process) submissions, including control plans, FMEAs, and capability studies compiled by all participating departments, Engineering for design phase, logistics and production.
- Ensure suppliers comply with industry standards (ISO 9001, IATF 16949, APQP, PPAP), which guide operations and compliance within the automotive manufacturing sector.
- Monitored supplier performance using KPIs such as PPM, defect rates, and on-time delivery for external suppliers in Poland, USA, and Canada, as well as internal suppliers within MA Automotive South Africa Group.
- Conduct dimensional and functional inspections of stamped parts by applying sampling techniques and assemblies using tools like CMM, vernier calliper's, dual gauges to measure flushness and gap.
- Verify compliance with GD&T (Geometric Dimensioning and Tolerancing) and engineering specifications which were agreed upon during the Design Phase of the G45 X3 model.
- Lead root cause analysis for supplier-related defects using methodologies like 8D, 5 Whys, Fishbone Diagrams, and Pareto Charts. Non-conforming parts at the customer coming in as Quality Alerts
- Collaborated with suppliers to implement corrective actions and preventive measures.
- Conduct on-site visits to suppliers to investigate and resolve quality issues and come up with feasible corrective actions in terms of solving the NCRs.
- Encourage suppliers to implement error-proofing (Poka-Yoke) techniques and process controls to prevent any reoccurrence failures.
- Maintain quality documentation for supplier components, including inspection reports, PPAP records, and audit findings. For referencing and benchmarking should there be any changes arising from the wear and tear of equipment during the project life span.
- Support Production and Quality Teams in resolving supplier-related issues on the assembly line, understanding the problem and conduct containment activities to keep the line running. Alert customer in a form of self-notification and conduct containment activities.
- Provide training to suppliers on quality standards, processes, and tools (APQP, PPAP, FMEA, SPC). To ensure a stable and capable process is in place to keep delivering conforming parts.
- Fostered strong relationships with suppliers to enhance collaboration and drive continuous improvement, addressing customer concerns and providing timely feedback.
- Developed and implemented a tracking system for quality assurance metrics in EOL inspection using Nexonica, enabling identification of high-contributing defects through scrap and rework pareto analysis.
- Implemented Lean Manufacturing principles throughout the production line.
- Managed document control process to verify compliance with quality, customer and environmental standards.
- Prepared defect reports and interacted with cross functional team to describe defects found in our production system.
- Lead the closing of open G8Ds both internally and externally with cross functional team through the use of root cause analysis..
- Conducted technical analysis, evaluation and testing to resolve quality-related product problems, non-conformities.
- Developed new methods for improving processes and identified areas for improvement based on data analysis using Six Sigma methodologies.
- Evaluated cause of occurrence to recommend and initiate corrective actions to prevent reoccurrence with the aid of Quality Core Tools.
- Conducted root cause analysis on defective components to identify potential sources of failure within the processes.
- Established procedures for sampling acceptance criteria based on customer expectations (customer standards). Exposure to Metrology, calibration, checking fixtures dimensional validation, GD&T tolerancing.
- Ensured compliance with applicable customer standards by creating inspection checklists.
- Apply lean manufacturing principles to eliminate waste and increase productivity, deliver quality parts to customers.
- Reduce the number of reworks on front doors, rear doors and liftgate by implementing procedures and methods to increase detection capability.
- Provided technical support to production personnel regarding quality control processes.
- I identified and implemented new technologies for data traceability and transparency to improve efficiency, reduce costs and increase productivity.
- Performed statistical analysis using Six Sigma methodology to improve product reliability, and customer requirements.
- Audited quality systems for deficiency identification, correction and prevention.
- Investigated customer complaints and worked closely with the cross-functional team on resolution daily.
- Analyzed data to identify trends in performance and quality performance, making use of the Nexonic app to identify the high contributors of NQC.
- Helped train inspectors on inspection techniques and quality review procedures.
- Evaluated process capability indices such as Cpk and Cp to assess product variability levels.
- Utilized SPC tools including histograms, scatter diagrams, and control charts to reduce the number of variations on our products.
- Conducted root cause analysis on component failures at the customer.
- Created checklists for reviewing or inspection of completed projects based on continuous improvement.
- Initiated non-conformance investigations, providing appropriate solutions.
- Coached and mentored others in proper and effective use of quality tools and systems.
- Supported new product development by ensuring compliance with customer requirements and having high quality rating.
- Conducted training sessions on quality improvement techniques for inspectors.
- Created standard operating procedures SOPs for quality assurance activities.
- Ensured timely closure of customer complaints by coordinating efforts across departments.
- Assessed risk potential during design reviews and suggested mitigation strategies.
- Prepared reports summarizing inspection findings and recommendations.
- Verified that all equipment used met calibration requirements.
- Performed root cause analyses and implemented corrective actions for critical operational problems.
Process Coach Quality
Ford Motor Company
11.2019 - 12.2020
- Improved business waste costs while increasing production capability, capacity, and flexibility, maintaining required quality standards.
- Improvement in process stability and worker utilization within the work packages.
- Led and assisted team leaders in optimizing production factors through work study and line balancing.
- Ensure adherence to Ford’s Global Quality Standards (GQRS, FPS) in production.
- Monitor and audit assembly processes to identify deviations from quality specifications.
- Implement error-proofing (Poka-Yoke) techniques to prevent defects.
- Lead 8D (Eight Disciplines) or Six Sigma problem-solving initiatives for quality issues arising on the production line and at the customer.
- Conduct fishbone (Ishikawa) diagrams, 5 Whys, and Pareto analysis to identify defect trends.
- Work with Engineering & Production to implement corrective and preventive actions (CAPA).
- Coach production operators and team leaders on Ford Operating System (FOS) quality principles by implementing buddy checks to ensure that there are secondary checks for assurance of quality products.
- Develop and deliver standardized work instructions (SWIs) for defect prevention, identify common and high contributors to the Non-Quality Cost of the company and work on them using the Pareto 80 20 rule.
- Conduct quality awareness training and ensure compliance with Ford’s Quality Operating System (QOS).
- Drive Kaizen events to eliminate waste and improve process efficiency.
- Support Ford Production System (FPS) initiatives to enhance quality and productivity.
- Use PDCA (Plan-Do-Check-Act) methodology to sustain improvements.
- Tracked key quality metrics (PPM, FTQ, scrap rates, warranty claims) and conducted root cause analysis with the team on high-impact issues.
- Generate daily/weekly quality reports for management review.
- Utilize Ford’s digital tools (QLS, GQRS, MES) to analyze defect trends and steer problem solving with the cross-functional team including suppliers.
- Partner with Supplier Quality Engineers (SQE) to address component defects.
- Liaise with Manufacturing Engineering to validate process changes.
- Support New Model Launches by ensuring quality readiness in production.
- Achieved production targets outlined in SQDCPME Policy Deployment at the final line inspection area.
- Analyse customer reports and give feedback to the relevant departments within the cross functional team to address all open customer complaints and close 8Ds.
- Participate in PIC Room, VRT, FCPA & JDI requirements to discuss and close any quality open points from the previous day.
- Understand, analyze & react to CBT (Current Base Test's), ECOS & VCATS line stoppages issues.
- Coordinate team building activities and drive the zero-defect mind set within team members.
- Push back reoccurring defects to responsible stations and create awareness. Put together a cross functional team to close all reoccurring defects and customer complaints.
- Clear out the BAHO reject lanes, by actioning all out of system cars due to non-conformances within the allocated turnaround time.
Industrial Engineer
Adcock Ingram
03.2019 - 08.2019
- Performing line optimization activities, using time studies and process mapping to identify bottlenecks. Reducing scrap through continuous improvement which results in the production target being met.
- Cultivated a right first-time and zero-defect mindset, motivating employees through a structured reward system.
- The bottleneck neck stations were the filling, capping, and the final packaging.
- Driving the doing right first-time mind set and adhering to the zero-defect mind set, motivating employees through the reward system.
- Performing line balancing just before start of shift.
- Observe the current working process throughout the three shifts.
- Engaged with operators and team leaders to gather input on working conditions.
- Actual output was 10 pallets on a good day with OEE of 54%.
- The team and I made use of Six sigma tools, the likes of Failure Mode Effect Analysis (FMEA), Plan Do Check Act (PDCA), 5S (Sort, set in order, Shine, Standardize and Sustain).
- Applied Six Sigma tools, including Failure Mode Effect Analysis (FMEA), Plan Do Check Act (PDCA), and 5S (Sort, Set in Order, Shine, Standardize, Sustain) to drive process improvements.
- These tools led us to a trialed objective of focusing on the maintenance and cleaning of the filler machine.
- During the month trial run of cleaning the filler machine after every shift, the maintenance manager was invited for a two-week observation to receive the department’s support and for them to be aware of the importance of the maintenance schedule.
- This resulted in the best line optimization, with an increased OEE of 95% and 16 pallets per shift.
- This resulted in the best line optimization, with an increased OEE of 95% and 16 pallets per shift.
Production Specialist (G01 Launch)
BMW Group South Africa
01.2018 - 12.2018
- Assist in the planning and execution of new BMW G01 X3 model launch in the assembly plant by performing time studies to identify potential bottlenecks within the interior fitment line, line 41 to line 50, optimizing work packages using swim lane.
- Participate in pre-series builds (prototype and pilot production) to identify and resolve assembly challenges that can occur online and hinder output and OEE.
- Work closely with Engineering, Production, and Quality teams to ensure seamless integration of new working processes.
- Developed and documented assembly procedures for new models or process changes, creating effective Standard Operating Procedures (SOP) to enhance operational consistency.
- Ensure that all assembly processes comply with BMW Group Production System (BPS) standards Doing it Right First Time.
- Identify and implement efficiency improvements (cycle time reduction, ergonomic enhancements, error-proofing).
- Conducted root cause analysis for assembly-related defects during launch phases using problem-solving tools (5WHYS, Ishikawa diagram, PDCA) to identify and implement corrective actions.
- Conduct root cause analysis for assembly-related defects during launch phases by using problem solving tools 5WHYS, Ishikawa diagram and PDCA.
- Implement corrective actions to prevent recurring issues in production and control plans using FMEA and RFMEA for implementing error proofing in processes.
- Train assembly line workers on new processes, tools, and technologies introduced during the launch.
- Develop work instructions and training materials for new model assembly.
- Attend daily audit (Prufrigal audit and LA audit). Responsible for all interior finishes in the G01 X3 model. To check if there are any non-conforming parts/missing operations. Take back feedback to the team (whether positive or negative) and lead root cause analysis and problem solving with cross functional team to ensure no recurrence.
- Work with Logistics & Supply Chain to ensure timely availability of parts for pre-series builds, create CARs for non-conforming line supply parts.
- Attended daily audits (Prufrigal and LA audits) to assess interior finishes in G01 X3 model, identifying non-conforming parts and leading root cause analysis with cross-functional team to prevent recurrence.
- Monitor Key Performance Indicators (KPIs) such as production output, defect rates, and downtime.
- Prepare launch reports for management, highlighting risks, delays, and improvement opportunities.
- Communicate with Project Management to track launch objectives, deadlines and report progress.
- Use digital tools (SAP, MES, I-PSQ) to track production data.
- Conduct risk assessments for new assembly operations.
- Promote a zero-accident culture during launch phases.
- Perform process audits, system audits and product audits.
- Attend squeaks and rattles audit, where the final testing of the vehicle is done. This is to check for any loose components which are not tightened correctly. Sound testing, if all equipment is functioning well.
- I attended water testing audit, as I was responsible for the windshield and rear windshield fitment line. Should there be any leakages found, I will then drive back and do root cause analysis and problem solving with cross functional and follow up until problem is completely solved.
Dashboard Operator
BMW Group South Africa
04.2017 - 12.2017
- Pre-assembled dashboard components, including air vent grills, dash décor, speedometer cluster, and radio wiring, ensuring readiness for installation.
- Tighten the dashboard using torque tool Do self-check by confirming with the green light from the torque tool and screen.
- Tighten the dashboard using the torque tool Do self-check by confirming with the green light from the torque tool and screen.
- Pre-assemble the dashboard by fitting the air vent grills, dash décor speedometer cluster, clip the radio wires together and pull them to be exposed to them to be exposed to the radio connection.
- Reporting on breakdowns that occur during processing and updating the results on shop ware software.
- Troubleshooting to optimize plant efficiency and solve breakdowns.
- Troubleshot issues to enhance plant efficiency and resolve breakdowns, contributing to uninterrupted operations.
- Taking decisions based on quality control results (lab analysis).
- Collaborated with team members to ensure a smooth workflow on job sites.
- Utilized personal protective equipment during operation.
- Always utilized appropriate personal protective equipment PPE during operation.
- Managed multiple tasks simultaneously while maintaining attention to detail.
- Documented daily activities, including hours worked, materials used, and incidents, facilitating accurate reporting and process improvement.
- Documented daily activities, including hours worked, materials used, and any incidents or issues encountered.
Production Intern
BMW Group South Africa
04.2016 - 03.2017
- Support the production team in day-to-day manufacturing activities by identifying and facilitating process improvement projects, training to drive cultural change and improve overall output and performance.
- Work closely with operators, production engineers, technicians, process supporters, production team leaders at line 41 -line 43 responsible for the interior fitment, car seats, radio compartment fitment and testing, front and rear windshield fitment, side skirt, centre console fitment, dash décor and hand brake fitment.
- Participate in quality control checks to ensure products meet BMW’s high GS standards.
- Assist in collecting production data (e.g., output rates per shift, defect rates per shift).
- Support the team in analyzing data to identify areas for improvement.
- Facilitated brainstorming sessions to generate actionable ideas for enhancing production efficiency.
- Contribute to brainstorming sessions for improving production efficiency.
- Coordinated continuous improvement initiatives to enhance workflow and address production line challenges.
- Support continuous improvement initiatives within the production line.
- Communicate effectively to ensure smooth operations on the production floor.
- Assist in troubleshooting minor technical issues on the production line.
- Develop skills in problem-solving, teamwork, and technical expertise. Hold problem solving sessions where we tackle open issues on our landscape by using PDCA (Plan-Do-Check-Act) technique.
- Assisted operators in developing techniques to enhance work packages and reduce waste using swim lanes.
- Constantly coming up with cost saving ideas and applying them to continuous improvement of line side image and waste reduction.
- Led value stream mapping efforts to assess current processes and outline steps for future state improvements.
- 5S Training and implementation.
Mechanical Manufacturing Tutor
Tshwane University of Technology
02.2014 - 07.2014
- Assisted students in mastering subject content and solving problems to enhance test and exam preparation.
- Guided students in understanding manufacturing processes and methods for practical application in work environments.
- Designed individualized lesson plans to meet diverse student needs.
- Facilitated engaging learning sessions that promoted critical thinking skills.
- Evaluated student progress through assessments and provided constructive feedback.
Computer Aided Draughting Tutor
Tshwane University of Technology
02.2014 - 07.2014
- Assisted students in understanding subject content and solving problems to prepare for tests and exams.
- Guided students in designing models and applying CAD systems to realize desired designs.
- Utilized SIMIO CAD solutions application to simulate 3D drawings for enhanced understanding of design principles.
Education
BTECH - Quality assurance, production engineering and project engineering
Tshwane University of Technology, Pretoria
Pretoria10-2019
Continuous Improvement Certificates - undefined
BMW Group South Africa, Pretoria
Pretoria12-2017
National Diploma - Mechanical manufacturing and Production engineering
Tshwane University of Technology, Pretoria
Pretoria10-2017
Six Sigma Green Belt - undefined
BMW Group South Africa, Pretoria
Pretoria06-2017
Beng Tech Honors Industrial Engineering - Industrial Engineering
Tshwane University of Technology
Pretoria, South Africa 04.2001 -
Skills
Quality Management System
IATF 16949
Communication Skills
Quality improvement plans
Quality system review
Process change documentation
Supplier quality management
Gauge R & R (Reproducibility & Repeatability)
Corrective action planning
Advanced product quality planning
Process capability analysis
Root-cause analysis
ISO 9001 requirements
Continuous improvement
Failure modes and effects analysis
Quality risk assessment
Quality tools (PPAP, APQP, MSA, SPC, FMEA and Control Plan)
Certification
Continuous Improvement Certificates
Timeline
Supplier Quality Engineer
Yanfeng Seating
04.2026 - Current
Quality Engineer
MA Automotive
05.2023 - 03.2026
Process Coach Quality
Ford Motor Company
11.2019 - 12.2020
Industrial Engineer
Adcock Ingram
03.2019 - 08.2019
Production Specialist (G01 Launch)
BMW Group South Africa
01.2018 - 12.2018
Dashboard Operator
BMW Group South Africa
04.2017 - 12.2017
Production Intern
BMW Group South Africa
04.2016 - 03.2017
Mechanical Manufacturing Tutor
Tshwane University of Technology
02.2014 - 07.2014
Computer Aided Draughting Tutor
Tshwane University of Technology
02.2014 - 07.2014
Beng Tech Honors Industrial Engineering - Industrial Engineering
Tshwane University of Technology
04.2001 -
Six Sigma Green Belt - undefined
BMW Group South Africa, Pretoria
National Diploma - Mechanical manufacturing and Production engineering
Tshwane University of Technology, Pretoria
Continuous Improvement Certificates - undefined
BMW Group South Africa, Pretoria
BTECH - Quality assurance, production engineering and project engineering
Tshwane University of Technology, Pretoria