Sthuthukile Nompilo Maphumulo
Process Controller (Color Coating Line) at Safal Steel- Claim this Profile
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Bio
Credentials
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Lean Six Sigma Foundations
LinkedInOct, 2023- Nov, 2024 -
Microsoft Office Excel Part One
Think360 (Pty) LTDSep, 2023- Nov, 2024 -
Learning SAP Production Planning
LinkedInAug, 2023- Nov, 2024 -
Quality Management Foundations
LinkedInFeb, 2022- Nov, 2024
Experience
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Safal Steel
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South Africa
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Mining
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100 - 200 Employee
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Process Controller (Color Coating Line)
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Jun 2016 - Present
* The role involves participating safety Tool Box talks to ensure 100% safety is maintained, adherence to organizational standards and procedures, and preparing the plant for start-up and shutdown.*Responsible for aligning, controlling and monitoring production processes using SCADA screens and communicating any deviations to the production foreman. * Achieving targeted operational results on a timely basis and operational equipment efficiency of 80%.* Using Enterprise Resource Planning systems (ERP) SAP to ensure control inventory and ensure accuracy.* Follow the FIFO system when allocating material, calculate and report tonnage produced daily, and adhere to production schedules. *Inspection of raw material, identifying defects on on the raw material before entering the line to minimize waste and delays.* Assisting in shutdown activities and maintain housekeeping standards by implementing 5S principles. Show less
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Coordinating Inventory Backlog
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Feb 2023 - Jun 2023
*Conducted daily stock takes, investigated material backlogs, and assisted with production scheduling activities to prevent overproduction.*Conducted data analysis on SAP ERP systems and root cause analysis.* Improved inventory management, reduced backlog, and increased operational efficiency.* Developed weekly technical reports.* Additional responsibilities of the role include operator training on SAP-related difficulties and regular performance reviews.
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Process Controller (Acid Regeneration Plant)
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Jun 2014 - Jun 2016
* Responsible for safe operation, starting and shutting the plant, monitoring process variables in the Acid Regeneration Plant.*Coordinated with the pickling line, monitored chemical tank levels, and liaised with the electrical and mechanical teams for faults. * Performed quality control by adjusting variables to optimize unit of operation performance.*Performed stock take consumption of chemicals. *Operated and controlled several units of operations: reactor, scrubber, absorber column, pre-concentrator(venturi), and cyclone.*Implemented 5S principles to maintain good housekeeping standards and participated in safety Tool Box talks, and assist in shutdown activities. *Investigate root causes, identify areas of improvements, and implement corrective action. Show less
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In-service Training
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Jan 2014 - Dec 2014
P1 & P2 PROJECTS• Successfully developed an operating system between Pickling Line and Acid Regeneration Plant.• Completed water mass balance project for Pickling Line for sustainability to reduce water usage intensity by 1%• Developed a production log sheet for the Pickling Line Wet Section.• Amended ARP SOP reporting to production technician.• Completed heat and mass transfer project in the absorber column.• Sample testing: for PKL and ARP (titration, ph, and conductivity), mechanical testing for MCL and CCL products (metal coating, hardness, and tensile strength), capturing of test results. Show less
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Plant Operator (Pickling Line)
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Nov 2011 - Jun 2014
EXIT SECTION• Operate plant following safe operating procedures.• Prepare plant for start-up and shutdown.• Monitor and control the process on the SCADA screen.• Daily calculate and report overall equipment effectiveness (OEE) to the production technician.• Deliver internal customer service level by inspecting the cut and split ratio of 70% and 30%• Tasked to improve the performance of the dryers and the blowers in the exit section.• Record work in progress material specifications.• Take samples to the laboratory for testing and analysis.• Use of Enterprise Resource Planning systems, Blue Box, for inventory control: stock take, stock levels.• Allocate material from their work orders.• Raw material handling using Bill of Materials (BOM) via the Material Requirement Planning systems; Blue Box.• Waste elimination: Keep rejection of material as low as 1%.• Inspect output material for quality control purposes. • Teams in monthly stock take for pickling line inventory.• Maintain good housekeeping.WET SECTION• Take acid and rinse water samples to the laboratory for testing.• Receive and analyse results for acid concentration control.• Cascade acid into acid tanks in accordance to process flow chart for concentration.• Tasked to protect product quality by ensuring correct use of acid strength, sufficient rinsing, and oiling of coils to prevent rust.• Change water usage culture.• CIP optimization for heat exchanger.• Monitor temperatures on acid tanks by means of a SCADA screen.• Daily participated in safety Tool Box talks to ensure 100% safety compliance. Show less
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Education
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2017 - 2019
Durban University of Technology
Bachelor of Technology - BTech, Business Administration -
2013 - 2017
University of South Africa/Universiteit van Suid-Afrika
National Diploma, Chemical Engineering -
2003 - 2007
umlazi comtech high school
matric
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