THUBELIHLE MTHEMBU
Industrial Engineer
Durban
Summary
Experienced production engineer in automotive industry with a focus on industrial engineering. Specializes in process design, cost reduction, and enhancing safety, quality, and productivity metrics. Currently leading the development of the next generation Hilux model.
Overview
8
8
years of professional experience
1
1
Language
Work History
Manufacturing Engineer > Global Support Manf. (ICT)
Toyota Motor Corporation Head Factory Chassis Manufacturing Division
04.2024 - Current
- Support Global Support Group for Chassis new project for head factory (Honsha Plant)
- Support the spec design for fixture of new equipment and new line.
- Support project for Chassis for Toyota Land Cruiser 70, 300, Lexus LX and Toyota Coaster bus.
- Understanding of projects from global perspective and interaction with head factory engineers to broaden the understanding of automative manufacturing.
- Window person between Toyota South Africa and Toyota Motor Corporation.
- Line design for new additional divertive for Hilux.
- Review and analyses the 3D data to ensure the fabrication of the new fixtures is cost effective, good ergonomics for members to use and easy for maintenance to maintain.
- Ensure the new fixtures include some of the latest technologies that work hand in hand with members to ensure good quality of the work part and to ensure the customer receives good quality product.
- Design the layout for new lines and existing lines for efficient flow layout and ensure the line can meet the customer demands.
- Weekly working group with different engineers in different departments involved in designing new line and fixtures. This ensures different ideas are shared to achieve the common goal and objective of the company and the customer.
- Design and develop Quality Network of the new lines to ensure line are self-proofed and are designed to avoid error and bad quality built and flow out the product.
- Industry: Automotive/Manufacturing Industry
Principal Engineering Prod Engineering
Toyota South African Motors (Chassis Plant)
02.2022 - Current
- Toyota Chassis Plant is the manufacturing plant for Hilux and Fortuner chassis and lower control arms. Plant also makes the rear ream and front suspension for Corolla Cross and Corolla Quest.
- I am currently responsible for the main line of the Chassis where we build all different chassis for; SUV, B-CAB, C-CAB and D-CAB.
- Key responsibilities currently include but are not limited to.
- Project Management – Project Planning & Control, Costing & Decision Making.
- Production Support – Work Studies, Line Balancing, Layout/Routine, Standardised.
- Work Instruction & Kaizen.
- People Development – Org Structure & Co-ordination, Individual Career Management & Human Resource Management.
- Leadership – Coaching & Mentoring, Development of Effective Teams & Managing.
- Organisational Change & Innovation.
- Financial Management- Budget Control & Project Cost Management.
- Information Management – Engineering, Process Changes, Information Systems & Management Reports
- Industry: Automotive/Manufacturing Industry
Technical Expert (Product/Process Engineer)
Toyota South African Motors (Exhaust Plant)
02.2021 - 01.2022
- Plant solely makes exhaust & Instrumental Panels for different Toyota vehicles.
- We make subcomponents and full assembly exhaust for vehicles namely:
- 1. Exhaust for Hilux (Double, Single and Club Cab)
- 2. Exhaust for Fortuner
- 3. Exhaust for Corolla Quest
- 4. Exhaust for Corolla Cross (CSUV)
- 5. Instrumental Panel Reinforcement for Hilux and Fortuner
- 6. Instrumental Panel Reinforcement for Corolla Quest
- 7. Rear and Front Bumper Sub Assy for Hilux
- Time Studies line setup and line balancing
- Continuous improvements project and spec change
- Controlling of standardize work
- Cost reduction & Quality improvement
- Conduct FMEA for all lines to understand the risk, severity and how to easily recover
- Root cause analysis
- Short- and long-term project leader for lines in charger off.
- Value engineering activities/ Projects
- Theory of constraints analysis
- Lead and drive the team for process control.
- Develop the team for problem solving techniques.
- Implement activities for reduction of defects and scrap.
- Managed and lead new projects from planning to post SOP.
- Co-ordinate cross functional activities in support of ECI’s process improvements, quality improvements (867B)
- Setting & Manage consumables standards and usages (Gentani)
- Knowledge and understanding of ISO 9000 / ISO 14000 / IATF 16949
- Industry: Automotive/Manufacturing Industry
Production Engineer (Production Engineer)
Toyota South African Motors (Hiace plant)
02.2019 - 01.2021
- Report writing and upper management presentation up to SVP level.
- Process Audit for ISO 9001/ ISO 14000
- Basic understanding and Control of PLC for robot and manual stations and robotic controls
- Production line support.
- Conducting site meetings & writing scope of work.
- Projects multi-tasking, being able to work with a team and as an individual.
- Understanding of production IT systems.
- Compile SOP and Work elements sheet
- Co-ordinate cross functional activities in support of ECI’s, process improvements, quality improvements, productivity improvements, and continuous kaizen by using TPS Principles.
- Carry out activities detailed in the Production Engineering operational and trial operational plan
- Assist in the training & guidance of production members.
- Process improvement.
- Supporting production line, solving ergonomics risk, using various lean techniques such as fish bone (cause and effect diagram).
- Involved in a 4-best project (line improvement strategy).
- Quality checks: iron filling, NP check (Number and Position check for spot-welding).
- Part takes on the ALC localization of Quantum underbody and side members, incorporated the new work with current production on stations affected by the change that includes the design of new trollies, equipment and layout design and changes.
- Engineer in training for ALC project, responsible of 5 Quantum weld shop stations; Rear Floor, FSH, Nutting, Engine Compartment and Underbody Tack.
- Included time studies, process set up, practical training for members, and quality confirmation of robot cells.
- Managing robot cells in terms of process improvements, Kaizen, welding guns workability, robot PLC control and standardize work compilation
- Industry: Automotive/Manufacturing Industry
Production Engineering Trainee
Toyota South African Motors (Hiace Plant)
02.2018 - 02.2019
- Ergonomics evaluation and improvements
- Regular engineering start-up checks to ensure smooth daily operation for the plant.
- Basic understanding of spot-weld for robotics and manual welding guns. Improving/ facilitating robotics welding condition for quality output.
- Line balance, Job man spec using the company standard format, standardize work, training & ISO Audit.
- Quality, Safety, Cost, Cycle Time Improvements
- Quality confirmation: NP (Number and Position checks related to spot-weld, Torque, Iron Filings.
- Process set up and improvements.
- KY Training – Risk Assessment/Danger Prediction
- Leading and planning projects from initial phase until SOP.
- Member Training on new processes and product.
- Involvement in Multifunctional projects.
- Industry: Automotive/Manufacturing Industry
Education
Bachelor of Engineering - Industrial Engineering
Durban University of Technology
Durban, South AfricaBachelor of Technology - Industrial Engineering
Durban University of Technology
01.2021
National Diploma - Industrial Engineering
Durban University of Technology
01.2018
Matric - undefined
Ngebeza High School
01.2013
Skills
MS Word, Excel
Outlook, Visio, Pp
DraftSight 2D
Catia V5
AutoCAD (3D)
PowerPoint
AutoCAD LT (2D)
Siml8 (Simulation)
A3 Problem Solving
Lean Tools
Project Management as per varsity subject
JIG Total Productive Maintenance & Accuracy
4S 1 (Housekeeping)
Bottleneck Analysis (5why, 4M root cause analysis)
Kaizen, Muda, PDCA
Standardized Work
Theory of constraints
Continuous Improvement
Being able to work under pressure
Work on one or two projects at a time
Working without supervision and being able to deliver on time
Waste reduction in process
Cost reduction kaizen based on understanding process
Poke-yoke (Error proofing)
Just In Time
Personal Information
- Ethnicity: Black
- Date of Birth: 1996-05-21
- Gender: Male
- Nationality: South African
- Driving License: Yes (Code 10)
Covid Vaccination
Vaccinated
References
- Nirode Manikchand, Toyota South African Motors, Toyota Exhaust Plant Engineering Manager, 2021-2022, +27 84 505 2463, nmanikchand@toyota.co.za
- Rethabile Happy Mokhoabane, Toyota South African Motors, Toyota Chassis Plant Engineering, 2022-2023, +27 71 520 2441, rmokhoabane@toyota.co.za
- Ryota Hayashi, Toyota Motor Corporation (TMC Head Factory), Chassis Manufacturing Division (Honsha Plant), 2024 to present, +81 90 6389 6476, Ryota_hayashi_aa@mail.toyota.co.jp
Timeline
Manufacturing Engineer > Global Support Manf. (ICT)
Toyota Motor Corporation Head Factory Chassis Manufacturing Division
04.2024 - Current
Principal Engineering Prod Engineering
Toyota South African Motors (Chassis Plant)
02.2022 - Current
Technical Expert (Product/Process Engineer)
Toyota South African Motors (Exhaust Plant)
02.2021 - 01.2022
Production Engineer (Production Engineer)
Toyota South African Motors (Hiace plant)
02.2019 - 01.2021
Production Engineering Trainee
Toyota South African Motors (Hiace Plant)
02.2018 - 02.2019
Bachelor of Technology - Industrial Engineering
Durban University of Technology
Matric - undefined
Ngebeza High School
Bachelor of Engineering - Industrial Engineering
Durban University of Technology
National Diploma - Industrial Engineering
Durban University of Technology