Quality Engineer

Supplier and Quality Management:

• Process optimization, work on machine standardization, aiming to produce parts on as many machines as possible
• Selection of personnel (personnel matrix)
• Quality optimization: tracking errors using QM methods FMEA, KVP, Pareto, 8D, 5M | APQP
• Creation of inspection plans (condition, quantity, dimensions, parameters...)
• Creation of action plan and monitoring
• Supplier selection – maturity evaluation, SCR, sourcing
• Initial sample approvals and support of start-up phase as well as complaint management towards Daimler, VW, Audi for Saint-Gobain
• Conducting supplier audits
• Intervention and escalation management
• Logistics planning and production control
• Audit VDA 6.3

Aluminum die casting | Low pressure casting:

• Failure analysis of aluminum die casting parts such as gearbox covers
• Analysis of manufacturing processes with regard to production-oriented design of components
• Analysis of error prevention potentials regarding porosities
• Capacity analyses
• Optimization of machining of aluminum cast parts
• Failure analysis of aluminum low-pressure cast parts such as rear axles
• Process optimization of bending and heat treatment, parts such as stabilizers
• Optimization of welded parts

Plastic injection molding:

• Optimization of plastic injection molding process
• Optimization of molds and mold geometries for plastic injection molding
• Involvement in mold designs and constructions
• Production areas: injection molding and overmolding of aluminum tubes for VW customer components
• Testing and validation of plastic and granulate manufacturing according to technical customer specifications (MFI, Charpy, heat resistance, flame retardancy, color, etc.)
• Validation of component feed mixing and extrusion

Projects at the following customers:

• Saint-Gobain – EMPB
• Bausch in Bagnang – VW task force
• Saargummi – Daimler task force
• Kovolit Brno – VW task force
• Faurecia Kosice – Daimler task force
• Brose – timing tracking
• Continental – SQM – ADAS Lindau
• Task force – supplier selection
• BMW: escalation management
• BMW: process approvals
• BMW: APQP
• BMW: camera and radar development
• BMW: resident engineering
• BMW: analysis of error prevention regarding cracks in aluminum low-pressure casting parts
• BMW: analysis of welded parts
• BMW: manufacturability evaluation (HBW), process control plan (PLP) and FMEA review
• BMW: review of drawing specifications, analysis and agreement with CC/SC
• BMW: alignment of process planning and execution with HBW, PLP and FMEA
• BMW: analysis of data/measurements for the defined features
• BMW: correlation between the identified measurements and the data history
• BMW: analysis and evaluation of the measurement methods used, frequencies and samples
• BMW: evaluation with improvement potentials and recommendations for agreement on CC/SC
• BMW: evaluation with improvement potentials and recommendations for agreement on CC/SC features that are not capable
• Porsche AG: process and quality optimization at suppliers
• Porsche AG: bumper assembly
• Volkswagen AG: process and quality optimization at suppliers
• Volkswagen AG: process control in development
• Volkswagen AG: optimization of machining of aluminum cast parts
• Volkswagen AG: failure analysis of components made by aluminum low-pressure casting, e.g. rear axle
• Volkswagen AG: quality optimization of plastic parts in initial sampling (BEON)
• Mahle AG: production relocation from Vaihingen to Poland, plastic parts for Burkhard company
• Deutz AG: production relocation from Mühlacker to Bulgaria, coolant and fuel lines for Sihn company
• Streetscooter Aachen: prototype construction of e-transporter – responsible for parts

Additional tasks (from the 2007-2019 section):

• Supplier and complaint management using 8D reporting, quality planning (APQP, FMEA)
• Standardization and qualification of add-on parts in vehicle development, e.g. existing series parts (handles, sun visors, connectors, panels etc.) and integration into prototypes.
• Supplier and material qualification (use and adaptation of series material for prototype parts)
• Cost reduction and capacity increase by using standardized materials
• Support of prototype phases Golf, Sharan, Phaeton including supplier selection and production planning for Volkswagen in the areas of plastic parts and interior/exterior assemblies
• Approval of initial samples and process control for Daimler in the area of plastic parts and exterior assemblies

• Control and monitoring of the production processes of bumpers and bumper assembly
• Creation and updating of work instructions
• Monitoring of quality requirements
• Initiation and review of maintenance
• Monitoring of equipment
• Procurement of tools and consumables
• Leading industrial staff (approx. 100) including shift scheduling

• Supervision of staff (approx. 20)
• Work scheduling
• Setting up machines: polyester presses, thermoplastic injection molding machine, blow molding machine, polyester injection molding machine
• Production control