Mbali Mtetwa
Production Engineer
Durban
Summary
Results-driven Senior Industrial/Production Engineer with over 11 years of experience in the automotive industry, specializing in product industrialization, process optimization, and lean methodologies. Proven track record of delivering projects that enhance efficiency and drive continuous improvement, underscoring a commitment to operational excellence. Expertise in optimizing production processes and implementing quality control measures, complemented by strong skills in data analysis and project management. Recognized for effective team collaboration and adaptability to evolving project demands, ready to contribute to a dynamic organization that values innovation.
Overview
12
12
years of professional experience
2
2
Certifications
1
1
Language
Work History
Production Engineer
Volvo Group SA
02.2023 - Current
- Production Support: Provided engineering expertise to align assembly processes with design drawings and technical requirements, ensuring product quality and compliance.
- Design Interpretation: Reviewed and interpreted design drawings, addressing discrepancies and supporting assembly teams to meet design intent.
- Cross-functional Collaboration: Networked with internal and external engineering teams to share plant improvement learnings and implement best practices across production sites.
- Batch Planning: Oversaw introduction of new parts, managed deviations, and handled customer adaptation requests. Managed sequenced batch planning to optimise production for multiple variants.
- Equipment and Tooling Management: Identified needs for new machines, tools, and equipment upgrades, assessing impact on capacity, workflow, and manpower.
- Business Case Development: Prepared cost-benefit analyses and BC Ratios to evaluate ROI; presented CAPEX proposals to stakeholders for approval.
- Continuous Improvement (VPS): Initiated and implemented Focused Improvement and Cost Deployment projects within the Volvo Production Systems framework to enhance ergonomics, safety, delivery, quality, and cost performance.
- Value-Stream Mapping (VSM): Partnered with Logistics and Production teams to map current and future states, achieving a 13% increase in production capacity and reduced material lead times.
- Process Optimization: Conducted time and method studies, 4M analyses, and line balancing — achieving a 10% cycle time reduction on assembly lines.
- Kaizen & WPO Activities: Led Kaizen workshops to minimize waste, improve workflow efficiency, and boost employee morale on the production floor.
- Mentorship: Supervised and coached 8 trainees, tracking progress via logbooks and facilitating professional development through guided practical exposure.
- Process Design & Efficiency: Designed and implemented optimized manufacturing processes, reducing waste and improving production efficiency.
- Data Analysis: Analyzed production data to identify bottlenecks and optimize resource allocation, improving overall operational performance.
- Cross-functional Engineering: Collaborated with quality, logistics, and production teams to refine engineering specifications and ensure adherence to standards.
- Problem Solving: Conducted root cause analyses and implemented corrective actions to address recurring production issues.
- Documentation: Developed comprehensive engineering documentation, including process flowcharts, equipment specifications, and change notices. Analysed data trends from daily operations reports, identifying areas where efficiencies could be improved upon.
Industrial Engineer
MAHLE SA
05.2017 - 01.2023
- Mentored two junior industrial engineers for 18 months, providing training and technical support to strengthen their skills and knowledge within the business.
- Managed one graduate trainee and three in-service trainees for three years, all of whom were successfully hired into permanent positions.
- Managed the Industrial Engineering Department for six months, achieving monthly KPIs including OEE efficiency, Production Costs, BMW Industrialization Project timelines, Labour Production Cycle Time Savings, SAP Routing Accuracy, and Ergonomics Compliance.
- Led project stakeholders, cross-functional teams, and project teams, managing multiple development and industrialization projects.
- Strengthened conflict resolution abilities while resolving disagreements, facilitating Value-Stream Mapping (VSM) and Kaizen workshops, and managing cross-functional development and series projects.
- Achieved a 77% success rate in New Development & Industrialization Project Management, successfully handing over projects to production.
- Led successful projects such as BMW G01, Ford T6, Nissan H60A, and Daimler W206, while conducting VSM and Kaizen workshops.
- Delivered key project milestones:
- Process Times, Cycle Times, and Takt Times: Approved and signed MTM-UAS/Time Studies (Planning, Update & Actuals).
- Resource Utilization: Achieved below 90% utilization, with approved equipment, direct and indirect labour capacity evaluations.
- Ergonomics Standards: Achieved Green and Orange standards, approved and signed RULA, REBA, KIM-PP&MHU evaluations.
- Material Flow Optimization: Implemented Future State Value Stream Mapping (Design) for material flow, with approved and signed VSM documentation.
- Budget Control: Delivered projects within production budgets, validated through Project Acquisition vs Actual Production Cost Analysis.
- Managed operations in Pressed Plant, Engine Cooling Plant, Brazing, Injection Moulding Plant, Tube Plant, and Engine Cooling Module Plant.
- Managed SAP Routings (Business Process) creation and maintenance using various SAP transactions.
- Conducted Time Studies using MTM-UAS tools, and created Standardized Work for Production, Logistics, and Office functions.
- Conducted Value Analysis using lean tools such as Value-Stream Mapping, Line Balancing, Yamazumi, and Combination Charts.
- Facilitated Gemba Walks, Leader Management Change, and problem-solving tools such as RCA, Pareto Chart, Fishbone Diagram, 5 WHYs, and 3Ms, resulting in enhanced workflow and reduced waste.
- Recognized as a Lean Analysis Key User Tool (2019) for applying lean principles to optimize operations.
- Conducted Resource Capacity Planning Analysis using STRAT Sales Plan.
- Created analytical Excel and Power BI reports to identify process improvement areas, achieving a 10% increase in Durban Plant capacity and contributing to securing the BMW G45 project.
- Supported Sales and Acquisition business functions by analyzing business data, performing simulations, and generating data reports for various new business acquisitions.
- Achieved 3% annual direct labour time savings for three consecutive years as part of KPI performance targets.
- Managed monthly savings planning, calculations, and reporting using Power BI and Excel, improving cost transparency and tracking.
- Served as HSE Representative for four years, developing and implementing process improvements that enhanced efficiency and reduced waste.
- Analyzed production data to identify bottlenecks and streamline operations, resulting in increased output consistency.
- Collaborated with cross-functional teams to optimize resource allocation, improving project timelines and team productivity.
- Designed and conducted time studies to refine operational processes, leading to improved cycle times and reduced labour costs.
Industrial Engineer - Graduate
Toyota SA
Durban
01.2016 - 04.2017
- Conducted time study using work measurement tools to validate accuracy of labor standard time.
- Collected and organized data for use in key decision-making.
- Applied value stream mapping techniques to assess current state processes and develop future state plans aligning with organizational objectives.
- Streamlined material handling and material flow procedures to reduce overall production times and shorten lead times on custom orders.
- Conducted time and motion studies to identify opportunities for process improvements, leading to increased production efficiency.
Industrial Engineer - CI Intern
ICI Dulux SA
Durban
03.2014 - 11.2015
- Analyzed data trends to identify inefficiencies, leading to the implementation of corrective actions and improved operational performance.
- Generated detailed reports covering analysis of key data and outlining potential solutions - Production and quality reports.
- Collected and organized data for use in key decision-making.
- Reported key performance indicators (KPIs) to track progress towards operational goals - SQCDP.
- Gained valuable experience working within a manufacturing industry, applying learned concepts directly into relevant work situations.
- Sorted and organized files, spreadsheets, and reports.
- Provided reporting for forecast analysis and ad-hoc reporting in support of decision-making.
Education
Postgraduate Diploma - Business Administration
University of Witwatersrand
Johannesburg, South Africa2025
Postgraduate Diploma - Project Management
Management College of Southern Africa
Durban, South Africa2022
Degree of Bachelor of Technology - Industrial Engineering
Durban University of Technology
Durban, South Africa2017
National Diploma - Industrial Engineering
Durban University of Technology
Durban, South Africa2014
Grade 12 - Matric
Cana Combined School
Mpumalanga, South Africa2010
Skills
Project Management
People Management Skills
Critical Thinking
Business Cases
Lean Principles Applications
Presentation Skills
Material Flow Mapping through VSM
Plan-Do-Check-Act Cycle
Line Balancing: Avix and MTM-UAS
Problem-Solving
Production Engineering
Project Engineering
Industrial Engineering
Conducting 1-on-1 meetings
Conflict Management
Analytical Skills
SQCDPE Protocols
Business Data Analysis and reporting
Business Communication Skills
Customer satisfaction
Process improvement
Value stream mapping
Lean manufacturing
Kaizen methodology
Resource allocation
Data analysis
Design interpretation
Cycle time reduction
Ergonomics assessments
Stakeholder engagement
Root cause analysis
Training and mentoring
Time studies
SAP routing management
Cost deployment
Certification
Southern African Institute for Industrial Engineering (SAIIE) Membership: MSAIIE (2022)
Accomplishments
- Mathematics Best Achiever – 2009 & 2010
- Physical Sciences Best Achiever – 2010
References
Available on request
Timeline
Production Engineer
Volvo Group SA
02.2023 - Current
Industrial Engineer
MAHLE SA
05.2017 - 01.2023
Industrial Engineer - Graduate
Toyota SA
01.2016 - 04.2017
Industrial Engineer - CI Intern
ICI Dulux SA
03.2014 - 11.2015
Postgraduate Diploma - Business Administration
University of Witwatersrand
Postgraduate Diploma - Project Management
Management College of Southern Africa
Degree of Bachelor of Technology - Industrial Engineering
Durban University of Technology
National Diploma - Industrial Engineering
Durban University of Technology
Grade 12 - Matric
Cana Combined School