Thobani Theo Tsheti
Pilot Hall Engineer Product Development
Kariega
Summary
With a rich history spanning over two decades in the field of metrology, I am a seasoned professional who has played a pivotal role in steering and contributing to a multitude of projects across diverse industries such as Automotive, Aviation, Engineering, and Mining Services. My career is distinguished by a deep-seated expertise in operating sophisticated measuring tools, including the Faro Arm, Dual CMM systems like Vento, Zeiss, and Mitutoyo, as well as Gom Atos Scanners, all within intricate project settings.
My responsibilities have consistently centered around the management and execution of projects with a strong emphasis on metrology, where I have utilized my project management skills to deliver precision and streamline processes. My recent academic accomplishment, an IT Diploma in Business Analytics, has further sharpened my capacity to harness data in making strategic business decisions. As a committed team member and an enterprising leader, I have taken the lead in mentoring emerging talents in the metrology domain, demonstrating my dedication to fostering expertise within the industry.
Overview
22
22
years of professional experience
2
2
Languages
Work History
Pilot Hall Engineer Product Development
VWSA
04.2025 - Current
- Provide support to relevant departments during Pre-Series Build phases.
- Assist the Launch Team by ensuring functionality of production facilities and achieving critical dimensional milestones (e.g., Meisterbock acceptance, surface quality improvements, and corrosion milestone compliance).
- Support Production and Quality teams in meeting series quality targets, including:Dimensional accuracy
Functional and stability assessments
Body-in-white (BIW) audits
Final vehicle audit
- Conduct fitment trials, detect problems early, and drive root cause analysis and resolution.
- Collaborate with the Process Engineer and CFT (Cross-Functional Team) leader to design and implement new or modified facilities and gauges to enhance build quality.
- Prepare and deliver written and visual reports on corrective actions during management reviews.
- Manage problem sheets by raising, tracking, and closing issues in a timely manner.
- Ensure assembly stability and coordinate resolution of non-conformities with Parts, Facilities, and Process teams.
Metrologist
Purem Eberspacher
05.2024 - 03.2025
- Providing metrology-based technical assistance to manufacturing areas through inspection and testing, using model-based inspection programs, blueprints, engineering standards, specifications, and manufacturing plans
- Performing measurements for purchased parts for incoming inspection according to the control plan (including conformity checks of material certificates as well as programs)
- Performing measurements for finished good parts according to the control plan as well as programs, initial samples
- Supporting production in the implementation and use of SPC in production according to the control plan for data analytics
- Supporting Program Quality, ASQ and SQA with metrology competence, especially in the “kick-off” meeting with suppliers
- Supporting metrology competence in special projects
- Participating in design review regarding metrology
- Participating in design of new gage concepts, tools, access
- Reason for leaving: Job security; retrenchments currently underway
Assistant Metrologist
Borbet South Africa
04.2023 - 04.2024
- Compiling PPAP/ ISIR documentation according to customer requirements
- Maintaining calibration status for all gauges and instruments
- Editing programs for Inspectors and Machine Shop Setters
- Assisting in calibration gauges and managing the calibration system
- Planning all activities in the metrology lab
- Attending project meetings, FMEA and control plan meetings
- Conducting routine testing and product audits
- Stand in for Metrologist in plant for any metrology activities
- Reason for leaving: Opportunity to lead the Metrology Lab at Purem Eberspacher
Metrology Technician
Mercedes South Africa
08.2019 - 03.2023
- Correlation analysis and revision of in-line measurement system offsets for data alignment with CMM lab results
- Analyzing the optical configuration on problematic measurement points and implementing appropriate corrective measures via feature optimization
- Maintaining measuring software Caligo
- Performing accuracy and repeatability checks
- Problem-solving: analyzing results, explaining and communicating metrology results
- Measuring of series Body Shop assemblies and hang-on parts
- Checking and calibrating (adjusting) all components (CMM), probe systems, probe changer
- Ensuring data transfer to PiWeb and furnishing of measurement results
- Interpreting measuring reports
- Assisting Final Assembly Engineers with dimensional investigations for gap/ flushness, wind noise and water leak
- Extracting measurement data from PiWeb database using SQL for any special investigation and presentation for management
- Assisting Process Engineers for BIW dimensional improvements
- Reason for leaving: Son diagnosed with autism; suitable school not available in East London
Metrologist
Eberspacher SA
03.2019 - 07.2019
- Measuring incoming components from suppliers
- Measuring and checking fixtures, and assisting in line setup
- Assisting in preparation of IATF Audit related to Metrology Lab
- Updating all calibration records of the plant
- Assisting Quality Department in measuring PPAP parts
- Ensuring metrology equipment receives annual calibration
- Responsible for all supplier metrology-related concerns
- Reason for leaving: Dream was to work in an OEM; opportunity to be part of the W206 metrology launch team
Vehicle Quality Assurance Senior Metrologist
Nissan South Africa
07.2016 - 02.2019
- Measuring units that are built in the Body Shop
- Compiling weekly body accuracy results for general management
- Ensuring daily metrology activities are met
- Chairing weekly body accuracy meetings
- Assisting stamping plant with parts they produce with measurements
- Measuring of chassis to ensure accuracy
- Assisting Vehicle Quality Assurance and Parts Quality Assurance Departments with any investigation that needs dimensional verification
- Analysis of failed parts that are in the field
- Assist dealer network with out-of-specification local manufactured parts
- Verifying accessories from after-market Nissan-approved suppliers
- Assisting Process Engineers to do gap and flushness inspections
- Liaising with Product Development Engineering when a component is localized
- Ensuring the 3D Vento Dual Arm CMM, GOT ATOAS and Faro Arm are in best working condition and receive annual calibration
- Assisting suppliers to comply with Nissan measuring standards
- Working with QTF (Quality Target Finish) personnel to meet the desired target for gap and flushness of units in Body Shop
- Assisting Trim Engineers with all interior problems that are related to body accuracy
- Interacting with Quality Management, Quality Engineers and Process Engineers for all measured parts and parts that do not meet specification
- Responsible for fixture measurement and keeping all fixture reports
- Conducting Body Shop fixture and jig audits and if necessary, measure them to improve BIW
- Compiling body accuracy reports and seeking methods of improving them and maintaining a good body accuracy report
- Coordinating with external labs for calibration and weld inspection
- Assisting PQA (Parts Quality Assurance) with PPAP and PSW
- Supplier measuring audits with PQA (Parts Quality Assurance)
- Keeping the metrology lab tidy and clean using the 5S method
- Maintaining and improving customer satisfaction, ensuring long-term and short-term goals are met
- Reason for leaving: Family relocation to Eastern Cape
Metrologist
Faurecia Interior Systems (Pty) Ltd
02.2015 - 07.2016
- Working under the company quality management system
- Operating a Vento 3D DEA machine
- Operating a WLS Q Flash Hexagon Scanner
- Conducting gap and flushness checks
- Updating programs and creating new programs using PC Dmis
- Compiling all documentation for components measured
- Participating in Gage (R&R) MSA study in the inspection room
- Interacting with Quality Management, Quality Engineers and Process Engineers for all measured parts and parts that do not meet specification
- Resolving quality concerns promptly from OEM (VW SA, Daimler Chrysler, GMSA and Nissan SA) and implementing breakpoint in the plant for future reoccurrence
- Training colleagues on how to use hand-held measuring instruments
- Monitoring measuring points and compiling a monthly report of out-of-spec trends to quality management, to improve the quality of the part
- Working hand-in-hand with product development engineering of OEM to receive the latest 2D/ 3D drawings and CAD
- Raising purchase orders for new equipment for the plant and calibration items
- Seeing that measuring equipment receives the calibration on the due dates
- Calibrating of measuring fixtures
- Keeping the metrology lab tidy and clean using the 5S method
- Maintaining and improving customer satisfaction, ensuring long-term and short-term goals are met
- Reason for leaving: Career advancement
3D Zeiss Inspector
Safran Turbomeca Africa
01.2013 - 12.2014
- Working under the company quality management system
- Operating a Zeiss 3D machine that measures gears
- Updating programs on the 3D Zeiss using Gear Pro Software and Calypso software
- Linking Gear Pro programs with Calypso software for production
- Compiling all documentation for components measured
- Participating in Gage (R&R) MSA study in the inspection room
- Interacting with MRO plant for parts that are measured and giving technical support regarding metrology matters
- Reason for leaving: Company closed
Metrologist
AEL Mining Services
07.2010 - 12.2012
- Measuring components manufactured in the machine shop to the specifications of drawings, dimensionally, and surface roughness and hardness testing
- Compiling measuring reports for Quality Manager and Senior Metrologist, and interacting with Plant Engineers for parts that fail and do not meet drawing specifications
- Operating a 2D scanner to measure all cylindrical components that have tight tolerances including gauges
- Operating a 2D Dynoscope
- Participating in MDW meetings
- Operating a 3D measuring machine for complex parts that cannot be measured manually and updating the existing programs to the latest changes
- Performing daily administration duties, logging all measured parts for monthly reports
- Ensuring that measuring equipment receives calibration on the due dates
- Reason for leaving: Career advancement
Measuring Technician
Comau South Africa Body Systems
09.2003 - 09.2007
- Measuring jigs, welding fixtures and framing stations
- Operating a Faro Arm and measuring on a Mora Table
- Resolving metrology problems from fixtures using CAD data and information from engineering drawings
- Ensuring measuring equipment e.g. Faro Arm, Mora Table, Laser Tracker and Venires are in the right condition and they have received the annual calibration
- Updating all calibration records of the plant
- Reason for leaving: Retrenched, company was going through recession, plant closed down
Education
National Diploma - NQF6: Information Technology
Richfield Graduate Institute of Technology
01.2024
Certificate - N4: Electrical Engineering
East Cape Midlands College
01.2002
Grade 12 - undefined
St Thomas Senior Secondary School
01.1999
Skills
- MS Word
- MS Excel
- MS PowerPoint
- Metrology Software Packages eg Caligo
- CAD
Training
- Project Management
- Special Training: Zeiss Caligo Advanced and EagleEye
- Lean Six Sigma (Green Belt)
- IATF 16949:2016 Internal Auditor
- IATF 16949:2016 Standard Requirements
- Update Training GOM Software 2020 (GD&T and Multi-Part Inspection)
- Gom - Basic Hardware & Software
- Faro Laser Tracker & Faro CAM2 Measure
- CAM2 Measure with Faro Arm
- PC-DMIS CAD++
- Tridimensional Measurement with the Software Metrology X4 V8 SP1
- WLS Application A/M System
Timeline
Pilot Hall Engineer Product Development
VWSA
04.2025 - Current
Metrologist
Purem Eberspacher
05.2024 - 03.2025
Assistant Metrologist
Borbet South Africa
04.2023 - 04.2024
Metrology Technician
Mercedes South Africa
08.2019 - 03.2023
Metrologist
Eberspacher SA
03.2019 - 07.2019
Vehicle Quality Assurance Senior Metrologist
Nissan South Africa
07.2016 - 02.2019
Metrologist
Faurecia Interior Systems (Pty) Ltd
02.2015 - 07.2016
3D Zeiss Inspector
Safran Turbomeca Africa
01.2013 - 12.2014
Metrologist
AEL Mining Services
07.2010 - 12.2012
Measuring Technician
Comau South Africa Body Systems
09.2003 - 09.2007
Certificate - N4: Electrical Engineering
East Cape Midlands College
Grade 12 - undefined
St Thomas Senior Secondary School
National Diploma - NQF6: Information Technology
Richfield Graduate Institute of Technology
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