Lwazi Boyce
Process Engineer
Uitenhage
Summary
Accomplished Process Engineer with more than 5 years of experience as a Process Engineer, in the Manufacturing (including Foundry processes) and Automotive Industry. Successful and driven individual committed to proactive planning and goal-oriented work. Mainly focused on examining current processes to pinpoint opportunities for enhancement and develop comprehensive strategies to boost efficiency, also manage the execution of these strategies and guarantee that safety protocols are adhered to.
Overview
8
8
years of professional experience
2025
2025
years of post-secondary education
2
2
Languages
Work History
Process Engineer
Dana Spicer Axle South Africa
Uitenhage
09.2022 - Current
- Maintain all associated PPAP documentation, inclusive of PFMEA, Flow Charts, Control Plans, Process Sheets, Operator Instructions etc.
- Specify/ improve our manufacturing controls systems to deliver safe and efficient manufacturing systems,
- Volume uplift studies, CAPEX and implementation,
- Traceability / SCADA implementation,
- Modify SAP/ Mapics process routing on new material/ model releases,
- Continually improve right first-time/ FTT metrics through data analysis and process improvements,
- Document changes made to processes with strict adherence to the change management control system,
- Follow/ implement controls and policies to ensure equipment safety for new/ existing equipment,
- Construct and maintain project timing plans where applicable,
- Assisting other members of the department in achieving the departmental objectives,
- Participating and contribute in cross functional APQP meetings for project launches,
- Interface with company's internal project Management, Applications Engineering and Design Engineering Teams to ensure that the product is designed for manufacture and time of introduction is known and planned for through stages of pre-production to production implementation.
- Develop, Implement, and prove out new model variants to existing lines to meet APQP gateways from Concept validation to PSW including a customer attended run at rate,
- Document process capacity and continually seeks ways to improve the bottle neck cycle time,
- Ensure that the technical requirements for the process are captured from the PFMEA and control plan, specified in the tender, ordered, and proved off against the PPAP documentation,
- Maintain action plans and RFT/ FTT trackers for Improvement focus themes,
- Attend regular meetings reporting out on action progress to improve equipment safety and RFT/ FTT performance,
- Carry out GR&R, capability studies and poke yoke detection tests to ensure processes are sufficiently robust to achieve plant RFT/ FTT targets whilst protecting the customer with defect free deliveries,
- Work closely with the maintenance and controls teams to reassess equipment/ process design to prevent repetitive downtime events,
- Provide process support to help the team diagnose equipment,
- Design and manufacture of simple jigs and fixtures plus modifications to existing tooling
- AutoCAD, Office (inclusive of Visio and Project)
Manufacturing Process Engineer
Gear Pump Manufacturing
Cape Town
01.2020 - 08.2022
- Driving Process Kaizen (Continuous Improvement)
- Implemented ISO 16112 for Compacted Graphite Iron (gear housings)
- Created a Standard Operating procedure for CNC mill (one fourth of the Pacemaker loop)
- Created a Visual Engineering Tool (VET) for the CNC mill
- Improved CNC Mill Total machine time to Planned cycle time at the gear housing process block
- Initiated 9 Value Streams (Gear Housings, Thrust Plates & Shaft End Covers, Foundry) – concurrently
Trainee Engineer/Process Engineer
Gear Pump Manufacturing
Cape Town
01.2018 - 01.2020
- Foundry Processes
- Mapping out foundry procedures (Pattern shop, molding line and assembly line, core shop, furnace melting, pouring line, shakeout, and fettling operations) and indicating quality measures
- Assisting in sample preparation for grey, compact & spheroidal graphite iron metal charges
- Monitoring pouring temperatures for the previously mentioned metal charges
- Assisting in compiling daily certificates for the samples
- Assisting in testing of samples (tests incl. Brinell hardness, tension, spectrometer test & micro analysis)
- Assisting in compiling the yearly casting defect percentage loss
- Drafted and introduced a trial instruction report for engineering changes of castings (molding line and pouring section departments)
- Revision of General Work Instructions (GWI) for foundry (Pattern shop/Maintenance, Moulding line, Core shop, Furnace/Melting, Pouring section & Fettling)
- Set up new procedure documentation (i.e., Process sheets) for Pattern shop, Moulding line, Core shop, Furnace, Pouring section & Fettling
- Time and motion studying of the various production departments (Incl. compiling excel spreadsheet reports for the production manager)
- Exposure in: Thrust plates production, Shaft End Covers production, Port End Covers production, Bearing Carriers productions, Gear Housing production, Gear/Shaft production (Turning, Hobbing & Shaving, Coning, CNC Grinding and Burnishing & Brightening operations), Gear Pump Assembly
- Key Projects: Monitoring plant compressed air pressure which affected the core shooting machines, production and calculating daily production losses (percentages), Designing a clamping fixture for torquing of gear pumps (various sizes and shapes) which is currently used by the operators in the assembly department, Pneumatic scissor lift cylinder and frame design (400 - 800 mm maximum extended height) for the molding line and pouring line storage areas inside the foundry department (Built by a sub-contractor), Brinell Hardness Tester design (to adhere to the ISO 6506-1:2014 & 6506-2:2017), Calibrating and drawing up an operations procedure for a newly purchased Brinell Hardness Tester
Technician in Training
Transnet Engineering
Cape Town
01.2017 - 01.2018
- Product Development department
- Draughting office (Solid Works)
- Locomotives
- School of Engineering (Hand Tools, Welding (Basic))
- Key Project: Modification of a water filtration system for the TFR coach line (P2 Project)
Education
Adv. Dip - Mechanical Engineering
University of South Africa
Pretoria, South Africa12-2021
N. Dip - Mechanical Engineering
Cape Peninsula University of Technology
Bellville 01.2013 - 01.2017
Skills
Microsoft Office
SolidWorks
AutoCAD
Risk Assessment Tools
AutoDesk Inventor
Project Management
Gantt Charts
undefinedPrevious Jobs
- Technician in Training, Transnet Engineering, Salt River, Western Cape, 2017
- Trainee Engineer, Gear Pump Manufacturing, Epping, Western Cape, 2018, 2020
Personal Information
- Nationality: South African
- Place of Birth: Eastern Cape
Fields Of Interest
- Renewable Energy
- Mechanical Design & Consultancy (Projects)
- Hydraulic & Pneumatic Industry
- Manufacturing & Production Industry
- Automotive Industry
- Technology
- Lean Manufacturing
- Reliability Centered-Maintenance
Accomplishments
- Scada implementation on P703 Axle shaft line, for traceability (Induction hardening, turning & grinding processes and crack detection),
- (VAVE) Cost saving of R1 M per month on insourcing processes and R40k monthly saving for additional checks through third party
Additional Information
Mr. Michael Segope
Foundry Manager
+27 76 347 3051
Mr. David Kyereahene
Plant Engineer & Maintenance Manager
david.kyereahene@dana.com
+27 76 347 3051
Mr. Victor Chivers
Program & Launch + Process Engineering Manager (Dana Spicer Axle SA)
+27 71 888 6080
Timeline
Process Engineer
Dana Spicer Axle South Africa
09.2022 - Current
Manufacturing Process Engineer
Gear Pump Manufacturing
01.2020 - 08.2022
Trainee Engineer/Process Engineer
Gear Pump Manufacturing
01.2018 - 01.2020
Technician in Training
Transnet Engineering
01.2017 - 01.2018
N. Dip - Mechanical Engineering
Cape Peninsula University of Technology
01.2013 - 01.2017
Adv. Dip - Mechanical Engineering
University of South Africa
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