Johannes Pfleger
Interim Director Operations
Experience
Apr 2023 - Aug 2023
5 months Wiener Neustadt, Austria
Interim Director Operations
ZKW Elektronik GmbH
- Crisis management, ensured delivery capability & stabilization basis
Jan 2022 - Present
2 years 7 monthsFounder, Interim Manager & Project Manager
OPEX RESULTING
Jan 2020 - Dec 2022
2 years Emden, Germany
Head of Business Development
Dirks Industrial GmbH & Co.KG
- Established PMO, successful implementation of high-speed projects
- Multi-project industrializations & org setup for JIS location VW ID4&7 module assemblies, AKL cable harnesses, logistics (2021–2022)
- Coordination of TISAX and ISO 9001 certifications (2022)
- Implementation of Automotive Business Development (sales, project governance, PMO, technical planning) (2021)
Jan 2020 - Dec 2021
2 yearsDirector Manufacturing Engineering & Footprint Project China E-Drives
ZF Friedrichshafen AG
- Co-designed & implemented matrix organization, defined & executed production strategy, led E-drives China site setup & industrialization
- BMW HEAT China E-Drive site setup & industrialization: project initiation, process development, launch management, staffing and purchasing (Schweinfurt-Shenyang, 2020–2021)
- Powertrain Manufacturing Engineering projects in 5 plants (Schweinfurt, Germany, 2020)
- Know-how transfer project Center of Competence for 3D printing and robotics, setup of smart project database (Schweinfurt, Germany, 2020)
Jan 2014 - Dec 2020
7 years Germany
Director Operations Clutch Systems
ZF Friedrichshafen AG
- Made production units profitable, created & deployed global production network, managed projects/crises, global engineering & production system site responsibility
- Taskforce Audi E-Hybrid capacity requirement (Schweinfurt, Germany, 2019–2020)
- Turnaround ZMS: strategy definition, works council negotiations, automation, product launch, logistics, agility, reporting (Schweinfurt, Germany, 2017–2019)
- Transformation to matrix line: production, engineering, QA, logistics, global production network (Schweinfurt, Germany, 2019)
- Setup of clutch & ZMS production, supplier selection & development (Pune, India, 2018)
- Planning and construction of ZMS factory, phased industrializations of 3 automated production modules + intralogistics, org setup, training & coaching of leadership (Shanghai, China, 2015–2018)
- BCC relocation of passenger car clutch production from Germany to Eastern Europe, handling HR & works council in Germany (Schweinfurt, Germany, 2014)
- Brazil aftermarket productivity initiative – footprint review, roadmap actions, individual project implementation (Araraquara, Brazil, 2013–2015)
- Establishment & activation of global production network → experts exchange, accelerated project and OEE results (powertrain components worldwide, 2013–2014)
Jan 2010 - Dec 2014
3 years Mexico
Director Major Projects Active Drive Modules & Licensing
ZF Friedrichshafen AG
- Ensured R&D launches/industrializations, delivered high-productivity SOPs, achieved licensing manufacturing implementation legally & technically
- 9-speed converter full project R&D/industrialization brownfield (Saltillo, Mexico, 2012–2013)
- 8-speed converter manufacturing license & know-how transfer to Chrysler (Northville, MI, USA, 2012–2013)
- 8-speed converter full project R&D/industrialization brownfield (Saltillo, Mexico, 2010–2013)
- Electromechanical actuator efficiency project: layout, organization, SFM, automation, OEE push, intralogistics, process quality, TPM (Schweinfurt, Germany, 2013)
- Brazil aftermarket productivity initiative – footprint review, roadmap actions, individual project implementation (Araraquara, Brazil, 2013–2015) (2013 share)
- Establishment & activation of global production network → experts exchange, accelerated project and OEE results (powertrain components worldwide, 2013–2014) (2013 share)
Jan 2008 - Dec 2010
3 years Germany
Production & Project Manager Lean Factory
ZF Friedrichshafen AG
- Ensured day-to-day operations, factory planning & execution, secured launches
- Greenfield lean showcase factory for 8-speed torque converters (Schweinfurt, Germany, 2008–2010)
Jan 2005 - Dec 2008
2 yearsCoordinator Roll-Out Global Production System
ZF Friedrichshafen AG
- Implemented operational anchoring and methodological adaptation to local requirements worldwide
- Production system roll-out worldwide: lighthouse sites in each plant, on-the-job training, maturity measurement, action adjustments, trainer network, best-practice sharing (global, 2007)
- Setup of global production system: toolkit, methods, hands-on trainer training, academy, rollout planning, KPI development (Schweinfurt, Germany, 2006)
Jan 2002 - Dec 2005
4 years Howell, United States
Operations Manager
Carcoustics USA Inc.
- Optimized costs, acquisition capability, performance
- Operational due diligence for NAFTA M&A initiative (2005)
- Implemented and certified TS 16949, ISO 14001, SAP R/3 (2005)
- Turnaround profitability & feasibility of new orders: layout, product launches, modernizations, low-cost automation, waste reduction (2003–2004)
Jan 1998 - Dec 2003
4 years Mexico
Plant & Project Manager
ThyssenKrupp SASA
- Ensured customer supply in North America, executed plant relocations & redesign successfully, integrated organizational development
- Designed & implemented lean production system and HSE initiative including training center setup (San Luis Potosí, Mexico, 2002)
- Interim general management (4 months) at Hoesch Suspensions Inc.: maintained operations & delivery capability, day-to-day management (Hamilton, OH, USA, 2000)
- Greenfield factory: site selection, relocations, planning/integration of new technologies, ramp-ups, organizational setup (San Luis Potosí, Mexico, 1999–2001)
Jan 1997 - Dec 1998
2 years Évreux, France
Production & Project Manager
Philips Composants BU Magnetic Products
- Executed cultural change in production, optimized KPI results
- Contributed to due diligence with buyer (1998)
- Value enhancement project with cultural change: optimized production processes, qualifications, focus on SFM (1997)
Jan 1993 - Dec 1997
3 years Tlalnepantla de Baz, Mexico
Process Manager
ThyssenKrupp SASA
- Established work preparation, implemented investments, introduced CI, made production planning/control operational
- Setup and led process management department at Hoesch Suspensiones Automotrices S.A. de C.V.: IE, CI, setup and operation of KPI systems, SFM, productivity measures, MRP setup (1994)
Summary
- Projects: 31 successfully completed core projects
- Budgets: up to €100 M
- Revenues: up to €1000 M/year
- Productivity increase up to 200%, ROI 1–3 years
- PEP projects maturity: project completion > 90%, target-oriented QKT, OEE SOP +3 months = 75–82%
- Span of control: up to 12 direct, 5 matrix, 2500 workforce employees
Languages
German
Native
English
Advanced
French
Advanced
Spanish
Advanced
Education
University of Hanover
Dipl.-Ing., Production Engineering/Work Science · Mechanical Engineering · Hanover, Germany
Certifications & licenses
ISO 14001
ISO 9001
Q1
TISAX
TS 16949
Train-the-Trainer
Certified Safety Engineer
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