Gerd Gembatzke
Interim Quality Manager and Subproject Manager
Experience
Apr 2010 - Present
15 years 4 monthsInterim Quality Manager and Subproject Manager
- Liebherr: Quality Management Project Manager - reorganized the measurement lab, established measurement equipment management, installed supplier processes in the lab; managed product quality and metrology processes; led 12 employees
- Humbaur GmbH: Taskforce Lead - optimized customer, supplier, and process quality; reduced scrap rates across several areas; trained employees in 8-D methodology; provided weekly reports to the management team and CEO
- Amanngirrbach AG: Head of Quality Assurance in Köngen/Nürtingen - set up the incoming goods QA system with QSV; optimized supplier processes; implemented EMPB according to PPAP; introduced FMEA; improved test planning in the product development process; managed 8 employees; handled complaint management with customers and suppliers; provided weekly reports to the Quality Director
- VAT AG Switzerland: Senior Manager Supplier Quality - monitored supplier processes; held escalation calls with suppliers; managed complaints with suppliers and led continuous improvement; conducted process audits according to VDA 6.3; did advanced quality planning with suppliers; formed task forces for high error rates
- JuS Automotive: Head of Quality Planning - took over advanced quality planning; optimized FMEA and EMPB according to VDA or PPAP; developed test planning; coordinated task force calls with customers and suppliers in escalation mode
- EAO AG Switzerland: Project Manager and Head of Quality Assurance - oversaw projects in mechanical engineering and rail; set up a supplier management system with complaint and escalation processes; conducted audits according to IRS standards; led 10 employees in SQA, process, and advanced quality planning; introduced team meetings; provided weekly reports to the COO and monthly reports to the CEO/COO
- Manz AG: Task Force and Customer Quality - optimized acceptance of a system with 67 stations with a Tier 1 supplier for an OEM automotive customer; handled complaints with the Tier 1 supplier; managed supplier complaints related to the line; held weekly meetings with Tier 1 and OEM
- Von Ardenne Dresden: Head of Quality Management - optimized the complaint management process using 8D; performed a GAP analysis of the SAP QM module; improved advanced quality planning at the FMEA, QM plan, and test planning interfaces; led 6 employees
- Schweizer Group Hattenhofen: Head of Quality Assurance for aluminum die casting and machining - reorganized 8D complaint management for customers and suppliers; introduced statistical process control; further developed advanced quality planning; led 7 employees; provided monthly reports to plant management
- Valeo-Siemens Automotive Erlangen: APU Quality Leader - customer contact for advanced quality planning and approval processes; responsible for series release in escalation mode; adapted customer/supplier complaint procedures to Valeo 5000; led 3 employees
- BUVO Castings NL: Head of Quality Management for automotive die casting and machining - restructured advanced quality planning, risk assessment, and monitoring in series production; optimized customer/supplier complaint management; created QSV and contract adjustments in purchasing; prepared for IATF certification; led 8 employees; provided weekly reports to plant management and the CEO
- Homag AG: Taskforce Project Manager in Mechanical Engineering - optimized internal complaint handling processes; reorganized supplier quality management according to system requirements; performed a GAP analysis of the internal complaint process according to ISO 9000:2015; led a project team with 8 internal and 2 external members
- AMG/Thyssen Automobiltechnik: Head of Quality Management and QM Taskforce - improved body surface quality; validated quality improvement measures internally and for supplier parts; deescalated issues with DAG/AMG in Q-Help 3; led 12 employees; reorganized QM tasks
- Weidplas CH Automobiltechnik: Head of Quality Management - transitioned Q-Help 3 to standard supply for OEM; reorganized the QM department; validated quality measures; optimized complaint management on site; led 6 employees; provided monthly reports to plant management and the Purchasing Director
- Maquet Medical, MedTech, Complaint Handling at HCH plant - modified and managed CAPA, NC, and BOP
- Liebherr Aerospace: Project Manager for QRQC Implementation at Lindenberg plant - introduced Quick Response Quality Control; modified the customer and supplier complaint management
- Dornier Medtech: Interim Director of Quality Management at Weßling plant - revised ISO 13485 standard and prepared for certification audit; optimized supplier management, audits, CAPA, and NC; improved quality processes; led 13 employees; provided weekly reports to plant management
- Cooper Standard: Taskforce Leader at Schelklingen plant - deescalated E-actuator issues for turbochargers; increased output through quality improvements; got two-day production approved by AUDI; revised maintenance plans; optimized quality monitoring and end-of-line tests
- IHI Charging Systems: Quality Management Department Head at Arnstadt plant - led 51 employees; set up the SQA division; formed task forces at suppliers; validated quality measures; reoriented the advanced quality planning process; provided monthly reports to plant management
- Voestalpine GmbH: Quality Management Team Leader at Dettingen plant (automotive stamping) - led 6 employees; optimized SQA and continuous improvement systems; served as the QM contact; handled internal, customer, and supplier complaints
- Minda Schenk GmbH: Quality Leader for plastic production in Köngen and Esslingen - led 28 employees; restructured advanced quality planning; adapted complaint management to TS 16494; implemented TS 16949; provided monthly reports to the CEO
- Flextronics Automotive Germany: Subproject Manager at Frickenhausen plant - led roof control units project; ran validation tests, PPAP, APQP; managed the EMPB process, FMEA, Q-engineering, design reviews; conducted audits according to VDA 6.3; did weekly reviews with the General Manager
- Carl Zeiss: Quality Project Management at Oberkochen and Shanghai plants - selected and evaluated suppliers for China; approved sites according to ISO 13485/FDA/Carl Zeiss QM; implemented IT complaint management (CAPA); reported to authorities, e.g., FDA; developed design and process FMEA according to ISO 13485; established supplier management and moved a product line to China; approved suppliers in China
Jan 2008 - Mar 2010
2 years 3 monthsDevelopment Quality Manager German Market
AGC Automotive GmbH
- Responsible for quality in development for the German market
- Coordinating quality-relevant specifications during the project phase
- Acting as interface between plant, customer, and supplier
- Approving milestones in internal project teams
- Participating in and moderating design/process FMEAs
- Qualifying suppliers in the project phase
- Coordinating quality tasks in European plants (BE, CZ, DE, HU)
- Working in a matrix organization with functional authority in all European AGC plants
- Conducting production validation for series release with customers
- Leading task forces in internal/external troubleshooting and implementing continuous improvement
- Leading Europe-wide audits according to VDA at suppliers, internal processes, and customer approvals
- Monthly reporting to the Customer Service Manager Europe and Quality Director Europe
Aug 2005 - Dec 2007
2 years 5 monthsSQA/PQA Engineer/Coordinator
Valeo Schalter und Sensoren
- Responsible for supplier development in Europe
- Implemented internal Q-system Valeo 5000 Supplier Integration and TS16949 in procurement
- Led Europe-wide audits according to Valeo 5000 and VDA at suppliers, internal processes, and customer approvals
- Operated in a matrix organization with functional authority in DE and HU
- Led various task force teams on supplier issues
- Participated in QRQC and PDCA cycles
- Defined and tracked strategic methods to improve supplier quality
- Monthly reporting to the Quality and Purchasing Director
May 2004 - Jul 2005
1 year 3 monthsExpert Supplier Quality Engineer
Harman/Becker GmbH
- Ensured quality of supplier parts in both project and series phases
- Conducted supplier evaluations and derived action plans
- Acted as interface to suppliers for quality issues
- Led Europe-wide audits according to VDA at suppliers, internal processes, and customer approvals
- Monthly reporting to the SQA/Purchasing Director
Jul 2003 - Apr 2004
10 monthsQuality Manager
GefeG GmbH & Co. und Neckarmotoren
- Led quality management in both plants
- Introduced ISO 9001:2002 certification
- Led Europe-wide audits according to VDA at suppliers, internal processes, and customer approvals
- Responsible for 7 employees (3 direct, 4 functional)
- Managed suppliers and acted as customer contact
- Managed employee target agreements
- Monthly reporting to executive management
Oct 1988 - Jun 2003
14 years 9 monthsQuality Controller to Deputy Head Quality Management
Modine Automotive GmbH
- Ensured quality in processes
- Responsible for customer quality domestically and abroad
- Participated in project phases: FMEA, APQP, PPAP, and EMPB
- Ensured incoming quality
- Led Europe-wide audits according to VDA at suppliers, internal processes, and customer approvals
- Built an SQA management system and integrated it into SAP
- Implemented internal continuous improvement to increase quality and reduce costs
- Led 6 employees with target agreements
- Reported to plant management
Languages
German
NativeEnglish
Advanced Certifications & licenses
Leadership Training TQM
Environmental Management ISO 14001
APQP Ford
FMEA Part A GFQ
PPAP Ford
Auditor Refresher GFQ
GFQ
Quality Manager Refresher GFQ-IHK-BIZ
GFQ-IHK-BIZ
PQA-Auditor Valeo in English
Valeo
IQ FMEA Training QualiKo
QualiKo
Quality Manager GFQ-IHK-BIZ
GFQ-IHK-BIZ
Auditor Certificate GFQ
GFQ
FMEA Basic Course GFQ
GFQ
Quality Auditor GFQ
GFQ
Quality Assurer GFQ-IHK-BIZ
GFQ-IHK-BIZ
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