Lesego Mmadira
Pretoria
Summary
Highly skilled and results-oriented with 9 years of experience in streamlining operations, improving efficiency, and driving operational excellence in the automotive industry. Proven ability to optimize processes, enhance quality, and deliver cost savings through innovative solutions. Skilled in project management, data analysis, and leading cross-functional teams. Passionate about the future of mobility and eager to contribute expertise to advance automotive technology.
Overview
9
9
years of professional experience
1
1
Certification
Work History
Lean Engineer
Electrolux SA
03.2023 - 06.2023
- Assist the development of framework and implementation of Lean Manufacturing, EMS (Electrolux manufacturing system) and CI (continuous improvement) strategies for improving the operations and processes within the SAF operations.
- Collaborate and work with cross-functional teams to identify improvement opportunities and meet operations SQCDP (Safety, Quality, Cost, Delivery, and People) objectives.
- Develop performance measurements for the key performance indicator system that is consistently tracking the right measures and provoking the right responsive behavior to ensure that improved performance of CI initiatives are sustained post intervention.
- Process optimization, work with cross functional team to identify areas of improvement using lean engineering methodologies to increase efficiency.
- Collect and analyze process data to develop sustainable solution.
- Project Management, initiate new continuous improvement projects, and guide project leaders to complete their existing projects.
- Bronze level on organization's manufacturing system, obtain a global recognition level and support other leaders to reach similar level.
- Implemented effective meeting feedback through action plan deployment and review strategy.
CI Manager
Adient SA
03.2018 - 02.2023
- Managed process improvement projects from conception to implementation, utilizing Lean principles to eliminate waste and enhance productivity.
- Cost saving initiatives (actual vs profit plan)
- Facilitate Kaizen events (Gemba walks and PDCA) to improve process efficiency.
- Process redesign and employee training for new process and compliance.
- Deployed +10 HPTs (High performing teams) to increase process quality.
- Best business practice (actual vs. benchmark gap)
- Create monthly CI newsletters and share on the company global portal.
- Conduct OPS level monthly KPI presentation to the plant manager.
- Talent acquisition, KPI development, mentoring and performance reviews.
- Energy hunt champion (HVAC, Water management, recycling)
- Lead sustainability initiatives for the plant.
- Support HSE requirements (workstation ergonomics, safety regulations adherence & employees’ safety)
- Visual management; display and visual control (planning and implementation) to regulate standards ncompliance.
- Facilitate organization’s manufacturing system to achieve benchmark goals (management team and plant manager)
Lean Implementer(CI Engineer)
Adient SA
11.2015 - 02.2018
- Provide training and mentorship to team members on process improvement methodologies and lean tools.
- AMS CI backup champion to the plant Six Sigma blackbelt.
- Established a 5S system and guided a team of thirty-four to achieve and maintain +90% 5S standard.
- Gather and analyze operations' data to identify areas of opportunity.
- High level detailed reporting to plant management in support of improving the OEE.
- Conducted kaizen workshops consisting of five cross-functional team members to increase VA activities by 10% from base.
- Manage KPI reports to support the plant Six Sigma blackbelt.
- Report and presentation of monthly engineering highlights.
- Establish quick Kaizens at shopfloor production line.
- Create and update SOP/JDS at shopfloor workstations.
- Attend startup shift meetings to support production team with problem solving.
- Quick Kaizen review through PowerPoint presentation.
Manufacturing Engineering Intern
Johnson Controls
02.2014 - 10.2015
- Update the PFEP and optimize material handling process with Logistics Engineer.
- Generated facility layout improvement ideas to the plant ME.
- Trim operations: Sewing machine layout and process optimization to increase work flow efficiency.
- Perform time studies to determine bottleneck stations.
- Activity sampling at the production shopfloor.
- Participant in monthly review with Engineering and CI manager.
- Participant in Lean Workshops waste identification conducted by plant Six Sigma blackbelt.
Education
Bachelor of Technology - Industrial Engineering
Tshwane University of Technology
Pretoria, South Africa12.2019
National Diploma - Industrial Engineering
Tshwane University of Technology
Pretoria, South Africa09.2015
Skills
- Technical Skills: Process Design, Process mapping,FMEA, Control plan, Lean tools, Core tools, Capacity Planning, and process simulation
- Soft Skills: Result-driven, Facilitation, Analytical, Problem-solving, Critical Thinking, Communication, Teamwork, Adaptability, Ethical, and strong work ethic
- Industry Knowledge: OEM QOS(Quality Operating System) for the seating production
- Learning and development skills
- TPM
- 5S methodology
- Line Balancing
- Product/Service change management
- APQP
- PPAP
Accomplishments
Projects:
- Kitting bin introduction - I have successfully lead a cross-functional departments to implement a kitting bin utilization at production line using lean tools to eliminate waste, improve visual and part presentation at assembly points, reduced head count, and improved line efficiency by 23% per annum.
- Automated production scheduling system - Developed an automated production scheduling system together with IT to eliminate parts shortage at the assembly station due to wrong scheduling of parts not queued for assembly, leading to production delays, overproduction and costly overtime. The system eliminated scheduling errors and overtimes, improving the productivity by +20% per annum.
Certification
- Core Tools Problem solving
- IATF 16949:2016 Automotive QMS
- Awarded for Plant Turnaround Strategy by Organization's EMEA VP.
- Completed Six Sigma blackbelt training.
Timeline
Lean Engineer
Electrolux SA
03.2023 - 06.2023
CI Manager
Adient SA
03.2018 - 02.2023
Lean Implementer(CI Engineer)
Adient SA
11.2015 - 02.2018
Manufacturing Engineering Intern
Johnson Controls
02.2014 - 10.2015
Bachelor of Technology - Industrial Engineering
Tshwane University of Technology
National Diploma - Industrial Engineering
Tshwane University of Technology
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