RISHEN SEWPAL
Automation Specialist & Innovations Lead
Johannesburg
Summary
Resourceful Management collaboration culture driver, Strong leader and problem-solver dedicated to streamlining operations to decrease costs and promote organizational efficiency. Uses independent decision-making skills and sound judgment to positively impact company success.
Overview
9
9
years of professional experience
1
1
Language
Work History
Automation Specialist and Innovations Lead
Ford Silverton Plant
02.2023 - Current
- Maintained, troubleshot and improved Stamping Plant Pressline automation and backup strategies.
- Tested, automated and implemented security software environments to ensure plant stability.
- Troubleshot, fixed and improved electrical hardware and software.
- Performed gap analysis procedures and detailed data reviews to optimize implementation and improve plant output from 2000 to 3500 parts per shift by using Siemens PLS and Gudel automation software .
- Pivotal technical project management to resolve plant launch issues with delivery and reliability. Developed a robust quick change strategy for critical components.
- Leading and managing innovation projects to further automate the plant using Advanced Robotics and Vision systems, with the objectives of enhancing delivery, quality and cost savings.
Production Process Coach
Ford Silverton Plant
10.2022 - 02.2023
- Enhanced team performance by developing and implementing effective collaborative strategies.
- Conducted continuous improvements to enhance delivery, quality and safety.
- Analyzed and evaluated team performance metrics to identify areas of improvement.
- Encouraged everyone to cultivate strong innovation organizational culture.
- Solved complex launch issues.
- Collaborated with other coaches to share best practices, techniques, and insights for overall program improvement.
Robot Programming Specialist
KAP Automotive - Maxe
04.2022 - 09.2022
- Overall Plant automation improvements.
- Robot programming using Yaskawa on polishing applications
- Robotic programming Kuka robots for plasma cutting applications
- Simulating and validation R&D product-line for production using Autodesk Power Mill
- Robot programming using Yaskawa on polishing applications.
- Participated actively in code reviews, identifying areas for optimization or enhancement while fostering a collaborative environment.
PLC Programmer
Design Group SA
10.2021 - 03.2022
- Setup virtual simulation to interface and test PLC
- Validate plant line simulation and signal processing
- Support site with validated robotic and PLC program downloads and site uploads
- Troubleshoot and analysis PLC programs.
- Reduced downtime by troubleshooting and resolving complex issues with PLC-controlled equipment.
- Continually updated technical knowledge through relevant professional development courses, staying current with industry trends and best practices in PLC programming.
Virtual PLC and Site Commissioned
Design Group SA
07.2019 - 09.2021
- Identify complex challenges, develop processes and plant equipment control operations incorporating customized interlocks and safety boundaries.
- Test and validate PLC automation and Robotic programs virtually and onsite. Full remote site support.
- Facilitated cross-functional team collaborations for increased innovation in problem-solving efforts.
- Enhanced organizational efficiency by streamlining processes and implementing innovative strategies.
- Improved interdepartmental communication by establishing clear channels and promoting collaboration.
- Developed detailed plans based on broad guidance and direction.
- Defined clear targets and objectives and communicated to other team members.
- Planned, created, tested and deployed complex validations to produce high quality systems to meet and exceed customer expectations as well as reduce issues when commissioning and buy off.
Plant Process Simulation Leader
Design Group SA
01.2016 - 06.2019
- Lead a team of engineers on plant simulation projects for FORD, BMW, MAGNA, Mercedes and OPEL
- Simulate industrial robotic and automation operations. Creating robot programs for Kuka, Kawasaki and Fanuc using Siemens Process Simulate.
- Plan and Define the OEMs process using Siemens Process Designer. Panel build process, Station utility allocations, weld spot and sealer bead distributions.
- Validate jigs and mechatronic plant field devices.
- Full site installation of industrial robots, turn-tables, conveyors, beam transfer systems, linear rail shuttle systems, robot linear track and safety systems such as light curtains, safety zoned fencing, robotic software safety and emergency stops.
- Automation cell cycle time validation and analysis.
- Directed multi-million rand projects from conception to completion, consistently delivering on challenging deadlines and within budget.
- Mentored junior staff members, helping them develop technical skills, approach complex customer requests and advance their careers within the organization.
- Led cross-functional teams to achieve company-wide goals, fostering a culture of collaboration and innovation.
- Reduced operational expenses by implementing cost-effective solutions.
- Drove customer satisfaction rates up by refining internal procedures and enhancing external stakeholder communications.
- Applied strong leadership talents and problem-solving skills to maintain team efficiency and organize workflows.
Education
MBA - Masters of Business Administration
Regent Business School
Durban, South Africa12.2021
BSc Honours - Mechanical Engineering
University of Kwa-Zulu-Natal
Durban, South Africa12.2015
National Senior Certificate -
Rydalpark Secondary School
Durban, South Africa12.2010
Skills
SIEMENS PROCESS SIMULATE & DESIGNER
SIEMENS PLS
SIEMENS PLC & DRIVES
BECHOFF PLC & FIELD IO
NIDEC DRIVES
REXROTH DRIVES INDRAWORKS
AUTODESK POWER MILL
ALLEN BRADLEY PLC
KUKA
KAWASAKI
YASKAWA
FANUC
References
George McIntyre (Design Group - Virtual Commissioning Manager), (+27) 836 405 479, George.McIntyre@designgroup.com
Dawie Van Niekerk (FORD - Stamping Plant Operations Manager), (+27) 826 538 959, dvannie5@ford.com
Jan Groenewald (FORD - Stamping Area Manger), (+27) 713 954 350, jgroene5@ford.com
Timeline
Automation Specialist and Innovations Lead
Ford Silverton Plant
02.2023 - Current
Production Process Coach
Ford Silverton Plant
10.2022 - 02.2023
Robot Programming Specialist
KAP Automotive - Maxe
04.2022 - 09.2022
PLC Programmer
Design Group SA
10.2021 - 03.2022
Virtual PLC and Site Commissioned
Design Group SA
07.2019 - 09.2021
Plant Process Simulation Leader
Design Group SA
01.2016 - 06.2019
MBA - Masters of Business Administration
Regent Business School
BSc Honours - Mechanical Engineering
University of Kwa-Zulu-Natal
National Senior Certificate -
Rydalpark Secondary School
Similar Profiles
TUMELO ALFRED SIHLANGUTUMELO ALFRED SIHLANGU
Operator Body Shop at Ford Motor Company Silverton PlantOperator Body Shop at Ford Motor Company Silverton Plant
Themba MnisiThemba Mnisi
Quality De,Vome(PVT ME)-interior Process Engineer at Ford motor company FMCSA(Silverton)Quality De,Vome(PVT ME)-interior Process Engineer at Ford motor company FMCSA(Silverton)
Jamekia SorrelsJamekia Sorrels
General Assembler at Ford Lima Engine PlantGeneral Assembler at Ford Lima Engine Plant