Franz Hornung
Project Management (Relocation)
Experience
Jan 2024 - Dec 2025
1 yearProject Management (Relocation)
- Product line transfer (internal 'rochade'), final production and administration transfer for some product lines (valve components in nuclear industry) to another site within the group.
Jul 2022 - Aug 2024
2 years 2 months Austria
Director Plantmanagement with full ramp up and relocation responsability
Amann Girrbach (Client)
- Ramp up management for production and logistics at a new location in Vorarlberg, Austria (Medical devices for dental industry).
- Project management to combine three old production sites into one new greenfield (build to suite) site, including value stream planning, site planning, and greenfield layout planning.
- Review of production and capacity planning.
- Test of pilot production to obtain necessary customer validations, including stepwise relocation of capacities followed by legal and customer validation, and subsequent rollout and relocation of remaining capacity.
- Time- and costtracking for the new building.
- Production and logistic processes according an greenfield approach based on an value stream analysis.
- Approach to ramp up production with complete designed shopfloor design.
- Temporary teamlead up to 60 persons.
- Support the ramp-up of relocated products/capacities as a basic part of the project.
Nov 2021 - Jan 2023
1 year 3 months Dresden, Germany
Director Logistics and Projectmanagement for warehouse relocation
Solarwatt Dresden
- Logistic director Solarwatt Dresden.
- Teamlead of approx. 35 persons in logistic department.
- Restructuring organisation in logistic and dispatch.
- Project lead for a new central warehouse to consolidate eight external warehouses into ONE new location. This involved relocation and consolidation of complete inbound, outbound, and intralogistic processes, capacity planning for the new logistic and dispatch center, and value stream analysis for logistic processes (before and after).
- Project management for all steps of the relocation process.
- Process optimization in warehouse, goods entrance and ordermanagement.
- Introduction of KPI system for regular performance tracking.
- Establish capacity planning and calculation in logistics processes and balancing workload to planned capacity demand.
Oct 2020 - Oct 2021
1 year 1 monthInterim Plantmanagement and projectmanagement for restructuring
Exide (Client)
- Interim and restructuring project at a supplier for batteries (Exide) for industrial purpose.
- Analysis of existing organisation and redesign of organisation.
- Capacity planning based on new time calculations.
- Implementation of flexible weekly capacity demand.
- Tracking of weekly CIP projects.
- Teamlead of approx. 105 persons.
Feb 2017 - Sep 2020
3 years 8 months Germany
Projectmanagement for supply Chain design for two European supplier for BMW (US) an BMW (Mex)
European Suppliers for BMW (Client)
- Process design analysis ordermanagement.
- Valuestream design for deliveries from Germany and Poland to US, including relocation of wheel assembly (CAR T1) to US South Carolina, with combined freight processes (truck/sea/train).
- Production planning options for wheel final production in South Carolina.
- Projectmanagement to build up a US distribution hub near final customer in US South Carolina.
- Ramp up OPR methode for customsoptimized import to US.
Feb 2016 - Jan 2017
1 yearIM-Operationsmanagement at a supplier for of shore heating systems
Supplier of Offshore Heating Systems (Client)
- Redesign material flow and order management.
- Define clusters of orderbook as a prerequisite for establish standards in ordermanagement.
- Team lead of 230 operators in 5 different departments.
- Process design analysis ordermanagement.
Jun 2015 - Jan 2016
8 months Switzerland
Plant management at a supplier of filter systems in Switzerland
Supplier of Filter Systems (Client)
- Optimization of organisation.
- Project lead for internal relocation project to a new site of filter systems in Kanton St. Gallen.
- New layout and material flow.
- Support to establish shorter Q-circles for better failure analysis.
- Several CIP workshops to increase productivity.
- Implementation of a bonus wage model.
- Team lead of approx. 30 persons.
Jul 2014 - May 2015
11 months Hockenheim, Germany
On-siteOperation and logistic management at a supplier of electronic devise for machining industry (ATM)
ATM (Client)
- Footprint optimization analysis of three production sites, including multi-site planning and capacity calculations with different production site options.
- Relocation of some production processes and product groups within the group to other sites.
- Recalculation of order lead time.
- Estabish of a defined stock of semi finished products.
- Optimization of organisation.
- New layout and material flow for german site at Hockenheim.
- Team lead of approx. 45 persons.
Jul 2012 - Jun 2014
2 years Tettnang, Germany
On-siteIM Management for Production, Supply Chain and Planning at a new Production site
IFM Automotive
- Design of the new production and logistic processes for the new plant.
- Project management for the relocation of an automotive business unit to the new production site.
- Responsible for ramp-up and go-live of SAP in the new site post-relocation.
- Support to get DIN ISI Audit 16949 for the new site.
- Support for IT /ERP switch from BAAN to SAP.
- Relocation planning and execution of relocation.
Jul 2007 - Jun 2012
5 years Karlsruhe, Germany
Partner
IFAO AG
- Business plan analysis and restructuring of a small-batch manufacturing operation for transmission components.
- P&L analyses and resulting action plan for optimizing processes, organization and operating results in several series production companies.
- Installation and application of a scanning tool for the evaluation of project management and R&D processes (“Lean Product Development Process”).
- Development and application of a maturity evaluation system for analysing the PDP of series suppliers.
- Redesigning a supply chain system for outdoor products.
- Analysing inbound processes to determine default risks due to quality or system weaknesses of the organization / MRP system and/or operational weaknesses.
- Preparation and implementation of a workshop concept for an international manufacturer of outdoor products; subjects included work standardization, problem solving, logistics processes and quality control.
- Production planning adjustment to meet the requirements of sequence delivery for a supplier of insulation and lining components to the automotive industry.
- Managing HC reduction projects for series and small series products (e.g., solenoid valves, shop-floor visualization systems, door systems for rail vehicles).
- SCM Inbound for the range of parts of an OEM component factory.
- Installation and application of a scanning method in the production department (utilizing Toyota production system methods) for short-term results improvement, for an international series manufacturer.
- Implementation of shop-floor methods such as goal visualization, Kamishibi, operative levelling, waste-walk workshops, PDCA integrated management systems and introduction of 5 S standards.
- Working as Interim Manager in a variety of settings during management consultancy engagements.
Sep 1999 - Jun 2007
7 years 10 months Munich, Germany
Partner (from 01/02)
CONMOTO Consulting Group
- Implementation of a product cost reduction program for a component supplier to the rail vehicle industry.
- Interim Production Management for a component supplier to the automotive transmission manufacturing industry.
- Logistics and production system planning for a new product line at a component production unit for the commercial vehicle industry, utilizing TPS methods and multi-level production system smoothing.
- Detailed planning for sequence delivery of vehicle axis systems to an OEM factory (commercial vehicle industry).
- Bench marking of delivery variants (SCM) depending on range and type of parts.
- Various projects concerning value stream analysis and design (using a specialist tool for operative moderation and implementation).
- Re-engineering of PEP and project management processes for a component supplier to the rail industry, including segmentation.
- Evaluation of location and segmentation for a manufacturer of components for electric motors.
- Improvement of results and strategic reorientation for a tool manufacturer.
- Introduction of KANBAN automatic feedback systems for a component supplier to the automotive industry.
- Development of a traceability concept in connection with KANBAN processes and their application for documentation-requiring processes, for a component supplier to the automotive industry.
- Project management of restructuring and reorganization, followed by interim management, for a safe manufacturer in the Czech Republic, including: liquidity protection, streamlining of product structure, productivity increase, reduction of material costs, supplier management, introduction of performance measurement systems, product innovation.
Jan 1998 - Dec 1999
1 year Germany
Project Management (Relocation)
- Projectmanagement of Audi Fuel tank Audi Coupe relocation to supplier Alfmeier.
Dec 1995 - Aug 1999
3 years 9 months Treuchtlingen, Germany
Segment and Production Management, Valve Section
Alfmeier Präzision GmbH
- Unit Turnover: EUR 60 million.
- Employees: 190.
- Overall responsibility for a production area with injection moulding, assembly and test facility, as well as associated areas such as job planning, program planning, scheduling, manufacturing control and QA.
- Responsibility for Equipment: approx. 30 prefabrication machines, approx. 40 assembly and automatic testing machines.
- Responsibility for Turnover: rising from EUR 15 million to EUR 60 million.
- Implemented a number of relocations to the Czech Republic.
- Integrated QA planning into the segment organization.
- Introduced CIP and employee suggestion system.
- Introduced various shop-floor management Tools.
- Introduced KANBAN (internal and to suppliers).
- Introduced operative fault analysis methods (Shainin).
- Set up a TPM data base (condition-oriented / preventative).
- Set up a waste walk concept.
- Introduced a qualification / assignment matrix.
Oct 1990 - Dec 1995
5 years 3 months Treuchtlingen, Germany
Manager, Logistics
Alfmeier Präzision GmbH
- Implementation and launch of a new automated high rack warehousing system including warehousing software.
- Power of attorney from 01 January 1992.
- Installation of a logistics system at the new Rottenburg branch.
- Project managing the start-up of the AUDI A8 tank JIS delivery process for the EDL Center in Neckarsulm.
- Development of a logistics performance measurement system.
- Implementation of cost and inventory reduction measures.
- Production transfer from in-house (automobile manufacturer) to out-sourcing (component supplier) within 4 weeks.
- Changeover to a new MRP system (FORS).
Aug 1989 - Sep 1990
1 year 2 months Ingolstadt, Germany
Assistant Manager Logistics
AUDI AG
- Optimization of the logistics performance measurement system.
- Coordination of GVZ project planning.
Feb 1988 - Aug 1989
1 year 7 months Ingolstadt, Germany
Production Scheduler – Assembly Scheduling
AUDI AG
- Revision of A6 production plans to ensure product design is suitable for production.
Jan 1987 - Jan 1988
1 year 1 month Ingolstadt, Germany
Trainee
AUDI AG
- Training in all major business segments of AUDI AG.
Summary
- Highly competent and versatile skills in plant management, production and logistics
- Solid project management, general management and consultancy experience
- Hands on attitude with short implementation approach
- Expert in international company ramp up realisation and plant relocations
- Extensive experience of integration and crisis management, personnel reduction, social compensation plan / reconciliation of interest
- Excellent lean tools, supply chain management, CIP, value analysis /engineering and turnaround and restructuring skills
- Working knowledge of industrial law, due diligence, far east sourcing
- Experience of obtaining private equity and venture capital
- Process- and craftsman experience in refrigeration technology and heat storage construction
Languages
German
Native
English
Advanced
French
Intermediate
Italian
Intermediate
Czech
Elementary
Education
Oct 1982 - Dec 1987
Technische Universität München
Mechanical Engineering · Munich, Germany · 1.8
Certifications & licenses
EFQM Assessor
KFW advisor (cert.) for energy efficiency in industry
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