Spotlighting Thuthuzela Mapoma: The Engineer Transforming Automotive Shopfloors

When you step onto an automotive production line, success is not measured in grand gestures it is won in seconds saved, waste eliminated, and machines running without a hitch. For Thuthuzela Mapoma, an Industrial Engineer and Total Productive Maintenance (TPM) Specialist at the Automotive Industry Development Centre Eastern Cape (AIDC-EC), these subtle shifts are where the real magic happens.

This Women’s Month, we spotlight Thuthuzela’s remarkable journey: a story of technical grit, international mentorship, and an unwavering belief in empowering shopfloor teams.

The Spark: From Classroom Theory to Shopfloor Reality

Thuthuzela’s passion for understanding how systems work led her to Nelson Mandela University, where she earned both her National Diploma and Bachelor of Technology in Industrial Engineering. But her true education began when she stepped onto the manufacturing floor.

Starting as an Industrial Engineering intern at Feltex Fehrer in 2017, she quickly proved that engineering isn't just about formulas on paper; it is about watching how people and machines interact. Armed with a stopwatch, standard work instruction sheets, and an eye for workflow bottlenecks, she spent her early days conducting time-and-motion studies, designing visual management systems, and learning how small process changes make massive operational impacts.

Turning Challenges into Breakthroughs

In 2018, Thuthuzela joined the AIDC EC as a Junior Industrial engineer then a Process Engineer, to now a Total Productive Maintenance Specialist taking on complex operational challenges across regional automotive suppliers and OEM environments.

One of her standout achievements came through addressing workflow bottlenecks with Lean methodologies. By leading focused kaizen events and improving material flow, she helped achieve a 12% reduction in cycle times, significantly boosting line throughput.

Her commitment to standardisation also contributed to a 46% improvement in changeover time, driven by the elimination of process waste including transport and motion waste and the disciplined implementation of 5S systems.

Her ability to translate complex Lean concepts into practical shopfloor results quickly made her a sought-after facilitator for continuous improvement initiatives.

From Japan to the Eastern Cape: Mastering the Art of Kaizen

Thuthuzela’s drive to deepen her expertise led her to the Japan International Cooperation Agency (JICA) training path. Between 2023 and 2025, she completed rigorous Kaizen certifications, culminating in a spot in the prestigious Knowledge Co-Creation Program in Japan.

Studying the birthplace of Lean manufacturing firsthand transformed her approach. Certified as a Kaizen Trainer of Trainers, she returned to South Africa not just with advanced tools, but with a philosophy: true operational excellence is built through people.

Today, as a TPM Specialist at AIDC EC, Thuthuzela leads Autonomous Maintenance (AM) routines on pilot production lines. She bridges the gap between operators and engineers coaching shopfloor workers to take direct ownership of equipment care, spot abnormalities early, and prevent downtime before it starts. Her problem-solving sessions targeting repetitive abnormalities have further reduced equipment-related recurrence, embedding sustainable Lean discipline into daily operations.

Redefining Leadership in Engineering

In an industry historically dominated by men, Thuthuzela’s journey stands as an inspiring beacon for young women in STEM. Her career shows that success in engineering is not about fitting into a mould; it is about bringing precision, empathy, and structured problem-solving to every challenge.

"When you give a shopfloor operator the tools and confidence to solve a problem on their line, you don't just fix a machine; you build trust and pride in ownership. That is how real cultural transformation happens."

As we celebrate Women’s Month, AIDC EC honours Thuthuzela Mapoma for her technical excellence, her commitment to elevating local manufacturing, and her role in paving the way for the next generation of female engineers.