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Johannes Pfleger

Interim Director Operations

Johannes Pfleger
Grafenrheinfeld, Germany

Experience

Apr 2023 - Aug 2023
5 months
Wiener Neustadt, Austria

Interim Director Operations

ZKW Elektronik GmbH

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  • Built stabilization base
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3 years 1 month

Founder, Interim Manager & Project Manager

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Emden, Germany

Head of Business Development

Dirks Industrial GmbH & Co. KG

  • Installed PMO
  • Organized multi-project industrializations and set up organization for JIS site VW ID4 & ID7 module assemblies, AKL cable harnesses, and logistics
  • Coordinated TISAX and ISO 9001 certifications
  • Implemented automotive business development (sales, project governance, PMO, technical planning)
Jan 2020 - Dec 2021
2 years

Director Manufacturing Engineering & Footprint Project China E-Drives

ZF Friedrichshafen AG

  • Co-designed and implemented matrix organization
  • Defined and implemented production strategy for e-drives
  • Led site setup and industrialization in China
Jan 2014 - Dec 2020
7 years
Schweinfurt, Germany

Director Operations Clutch Systems

ZF Friedrichshafen AG

  • Made production plants profitable
  • Built and deployed global production network
  • Managed projects and crises
  • Responsible for global engineering and production systems
Jan 2011 - Dec 2013
3 years
Mexico

Director of Major Projects for Active Drive Modules & Licensing

ZF Friedrichshafen AG

  • Secured R&D and industrialization launches
  • Provided highly productive SOPs
  • Implemented licensed manufacturing legally and technically
Jan 2008 - Dec 2010
3 years
Schweinfurt, Germany

Production and Project Manager Lean Factory

ZF Friedrichshafen AG

  • Ensured daily operations
  • Led factory planning and execution
  • Secured product launches
Jan 2006 - Dec 2007
2 years
Schweinfurt, Germany

Global Production System Roll-Out Coordinator

ZF Friedrichshafen AG

  • Implemented operational anchoring of the global production system
  • Conducted methodological adaptation to local requirements worldwide
Jan 2002 - Dec 2005
4 years
Howell, United States

Operations Manager

Carcoustics USA Inc.

  • Optimized costs
  • Improved acquisition capability
  • Increased performance
  • Conducted operational due diligence for NAFTA M&A projects
  • Introduced TS 16949 and ISO 14001 and implemented SAP R/3
  • Implemented layout, product launches, and low-cost automation for new projects
Jan 1999 - Dec 2002
4 years
San Luis Potosi, Mexico

Plant & Project Manager

ThyssenKrupp SASA

  • Ensured customer supply in North America
  • Successfully executed plant relocations and new plant planning
  • Integrated organizational development
  • Designed a greenfield plant, selected the site, and conducted ramp-ups
Jan 1997 - Dec 1998
2 years
Évreux, France

Production & Project Manager

Philips Composants BU Magnetic Products

  • Implemented cultural change in production
  • Optimized KPI results
  • Supported due diligence projects with the buyer
Jan 1994 - Dec 1996
3 years
Tlalnepantla de Baz, Mexico

Process Manager

ThyssenKrupp SASA

  • Established work planning
  • Implemented investments
  • Introduced continuous improvement process (CIP)
  • Made production planning and control operational
  • Set up KPI system and Material Requirements Planning (MRP)

Summary

  • Projects: 31 successfully completed core projects (project list in the appendix)
  • 24 locations (Europe, Americas, Asia)
  • Budgets up to €100M
  • Revenues up to €1,000M / year
  • Productivity increase up to 200%, ROI 1-3 years
  • PEP projects maturity level at project completion > 90%, targeted QKT, OEE SOP +3 months = 75-82%
  • Span of control up to 12 direct reports, 5 matrix reports, 2,500 staff members

Skills

  • Leadership Skills Leading Complex & Multicultural Tasks & Teams, Sustainable Conflict Management, Dynamic Stakeholder Engagement, Leading Change-driven Projects

  • Management Leadership & Areas Day-to-day Operations Management, Strategic And Operational Planning, Business Planning, Production, Hse, Manufacturing Engineering, Industrial Engineering, Logistics Management, Quality Management, Supply Chain, Launch Management, Automation, Digitalization, Maintenance, Toolmaking, Investment Planning, P&l, Controlling, Cost Accounting, Costing, Small And Large Series, Business Development

  • Interface Management Task Force, Compact Kpi System & Reporting, Oee Deep Drill, Shop Floor Management, Qklsm, Customer-supplier Management, Supplier Development, Level Talks, Go & See & Immerse, Idea System, Fast Teams, Auditing, Layered Audits, Balanced Scorecard

  • Interpersonal Communication Conflict Management, Multi-skilling, Aging Workforce, Group Processes, Employee Representation Negotiation And Mediation, Coaching, Change Management & Organization, Leading In The Matrix, Workforce Planning, Organizational Development, Crisis Management, Production System, Intralogistics, Global Production Network

  • Lean (Extract) Kaizen, Kvp, 8d, A3, Vsa, Vsd, 5s, Jit, Jis, Smed, Line Balancing, Tpm/predictive/preventive Maintenance, Six Sigma, Zero Defects, Poka-yoke, Andon, Standardized Work, Ergonomics, Material Handling, Visual Management, Hse, Preventive Health Protection, Milk Run, Agv, Commissioning, Replenishing, Fulfillment, Mock-up, Kata, Lean Assessment, Train-the-trainer, 4mat, Utility Analysis

  • Product Development Projects / Project Management / Project Governance Frontloading, Dfma, Design-to-cost, Design For Six Sigma, Mab, Rapid Prototyping, Qfd, Doe, Fmea, Value Analysis, Feasibility Study, Apqp, Ppap, Rg, Run@rate, Lean Process Design, Factory Planning, Zero Emission, Creativity Tools, C8s, Project Management Tool, Risk Management, Guidelines For Location Setup & Product-process Allocation, Factory Scalability, Impactful Lessons Learned, Training Center, Problem Analysis And Solving, Supplier Selection, Operational Due Diligence, Engineering Change Management

  • Chassis Chassis Springs, Stabilizers, Torsion Bars, Control Arms, Shock Absorbers, Modules, Electromagnets Abs/eps

  • Powertrain Components E-drive, Torque Converters, Clutches, Dual Mass Flywheels, Automated Transmissions/electromechanical Actuators, Release Bearings, Master And Slave Cylinders

  • Interior & Engine Bay Headliner, Trunk Side Panels, Load Floor, Parcel Shelf, Carpet, Sun Visor, Door Seal, Hood Liner, Beauty Cover, Engine Encapsulation

  • Electronics Smd, Modules, Control Units

  • Process Engineering Assembly, Testing Processes (Function, Presence, Position, Orientation, Tightness, Material/product Properties, Dimensions, Imbalance, Color, Contours, Ultrasound, Image Processing, Cleanliness), 3d Plastic Printing, Metal Forming, Heat Treatment, Surface Treatment, Powder Coating, Cathodic Dip Coating/air-dry Coating, Cutting, Plastic Injection Molding, Vacuum Forming, Bonding, Wetting, Waterjet Cutting, Vapor Deposition, Welding Processes (Disk Laser, Mag, Friction, Ultrasonic), Riveting, Rolling, Machining, Winding, Pressing, Drawing, Bending, Shot Blasting, Robotics, Cnc, Image Processing, Handling Technology, Agv, Mechanization, Hydraulics, Electric Drives Manufacturing, Transport And Conveyor Technology, Test Engineering, Information And Communication Technology, Plc, Mes, Scada, Pps, Operator Guidance, Vr/ar, Traceability

Languages

German
Native
English
Advanced
Spanish
Advanced
French
Advanced

Education

University of Hanover

Dipl.-Ing. Mechanical Engineering, Production Engineering/Labor Sciences · Mechanical Engineering · Hanover, Germany

Certifications & licenses

Certified Occupational Safety Engineer

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