Clemens K. - Lean Expert, Project Manager, Industrialisation Expert

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Donauworth, Germany

Experience

Jan 2023 - Dec 2024

2 years

Augsburg, Germany

Production Engineer

Premium AEROTEC GmbH

Project planning, coordination and implementation of production relocations (TOW) for fiber composite parts within and outside PAG
Definition, design and continuous improvement of manufacturing processes in coordination with engineering, program management and customers (internal/external)
Interface coordinator for internal and external suppliers

Jan 2021 - Dec 2022

2 years

Career Break

Pursuit of personal goals

Jan 2020 - Dec 2021

2 years

Donauworth, Germany

Business Improvement Manager H145 Main Rotor Blades D3

Airbus Helicopters Deutschland GmbH

Achieving customer rate capability (ramp-up) at the German production site in Donauwörth

Jan 2017 - Dec 2021

5 years

Donauworth, Germany

Composite Single-Part Production

Airbus Helicopters Deutschland GmbH

Conversion into a 'Lead Factory'
-60% lead time; +30% productivity; 100% on-time delivery

Jan 2015 - Dec 2016

2 years

Donauworth, Germany

A350XWB Passenger Doors

Airbus Helicopters Deutschland GmbH

Implementation of the concept of an assembly line for all variants of structural assembly
-60% lead time; +35% productivity; 100% on-time delivery during ramp-up
Internal award: EUROCOPTER Group 'Award for Excellence' A350XWB passenger door assembly line

Jan 2013 - Dec 2015

3 years

Santiago de Querétaro, Mexico

Project Manager, Querétaro Plant

Eurocopter Deutschland GmbH

E2E implementation of a pull-flow system (green field approach) from delivery of the SA Emergency Exit Door and LR Bulk Cargo Door through final assembly lines, individual part production (machining, sheet metal fabrication, plating, painting), cutting, raw material storage to work order release
application of the EPEI method for metallic individual parts

Jan 2010 - Dec 2013

4 years

Donauworth, Germany

EPS Site Manager Donauwörth

Eurocopter Deutschland GmbH

led 11 lean transformation projects with up to -80% lead time; -50% WIP; -30% production area

Jan 2008 - Dec 2010

3 years

EPS Member of the Central Team

Eurocopter Deutschland GmbH

corporate-wide system definition and implementation
set up a training center in Paris for management from France, Germany and Spain

Jan 2006 - Dec 2008

3 years

EPS Pilot Project Manager Profit Center Airframe

Eurocopter Deutschland GmbH

executed 12 lean transformation projects with up to -60% lead time; -45% WIP; +25% productivity
internal award: EADS nomination for "Hall of Fame" and twice nominated as "Top 3 – Best Lean Manufacturing Teams"

Jan 2004 - Dec 2005

2 years

Project Manager Industrialisation NH90 External Load Carrier

Eurocopter Deutschland GmbH

led an integrated team with design, stress, engineering, and toolmaking for a "mixed" assembly line
achieved time and cost targets

Jan 2001 - Dec 2002

2 years

Subproject Manager Industrialization A318-321 Composite Torque Link

Eurocopter Deutschland GmbH

Led an integrated team of design, stress, engineering and tooling
Achieved time and cost targets

Jan 1998 - Dec 2001

4 years

Project Manager A318-321 Belly Fairing

Eurocopter Deutschland GmbH

Led an integrated team of production, work preparation, planning, control and quality assurance to transform a task- and planning-oriented composite production into a process- and consumption-oriented production line
-60% lead time; -50% work in progress; +25% productivity; 100% on-time delivery during ramp-up

Jan 1996 - Dec 1997

2 years

Donauworth, Germany

Subproject Manager A318-321 Cargo Door

Eurocopter Deutschland GmbH

Converted a dock assembly into a flow-oriented assembly line

Jan 1995 - Dec 1996

2 years

Head of Composites Department

Eurocopter Deutschland GmbH

Led three supervisor teams with about 120 employees in total

Jan 1995 - Dec 1995

1 year

Team Leader Work Preparation

Eurocopter Deutschland GmbH

Led an eleven-member work preparation team

Jan 1994 - Dec 1994

1 year

Kaizen-Workshop Leader

Eurocopter Deutschland GmbH

Process improvements in single-part production and assembly areas at the Donauwörth site

Jan 1990 - Dec 1993

4 years

Timekeeping Clerk

MBB Hubschrauber / Eurocopter Deutschland GmbH

Conducting Kaizen workshops in collaboration with Shingijutso USA
Process analyses, time studies and time recordings in single-part production and assembly areas at the Donauwörth site

Jan 1986 - Dec 1988

3 years

Self-Employed / Company Owner

Development and production of composite bass guitar necks

Jan 1983 - Dec 1985

3 years

Self-Employed / Company Owner

Production and marketing of customized windsurf boards

Summary

YEARS OF EXPERIENCE in leadership and expert roles in lean management, project management, program management and end-to-end efficiency improvement in manufacturing companies
IMPLEMENTATION OF LEAN MANAGEMENT, Lean Production and continuous improvement at national and international production sites
TRANSFORMATION OF PRODUCTION PROCESSES and production ramp-ups for large series and small batches up to one-piece flow – both for assemblies and end-products
STRONG IDENTIFICATION OF WASTE (MUDA), targeted and in-depth analysis of the current state with a constant focus on customer value – solution design in interdisciplinary and intercultural teams
OPTIMIZATION OF ENTIRE PRODUCTION SITES OR PRODUCTION LINES with significant reduction of lead times and inventories while improving productivity and quality and meeting tight deadlines
INTEGRATION AND OPTIMIZATION OF TRANSNATIONAL SUPPLY CHAINS of parts, components and finished products. Driving change management up to cultural transformation towards self-directed work with empowered actors and a positive, solution-oriented understanding of errors
ACTIVE COACHING OF KEY PLAYERS during the transformation as well as for activating and sustaining the follow-up improvement process