Johannes Pfleger
Interim Director Operations
Experience
Interim Director Operations
ZKW Elektronik GmbH
- Performed crisis management
- Ensured delivery capability
- Built stabilization base
Founder, Interim Manager & Project Manager
OPEX Resulting
- Leads global projects in operations management
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)
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
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
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
Production and Project Manager Lean Factory
ZF Friedrichshafen AG
- Ensured daily operations
- Led factory planning and execution
- Secured product launches
Global Production System Roll-Out Coordinator
ZF Friedrichshafen AG
- Implemented operational anchoring of the global production system
- Conducted methodological adaptation to local requirements worldwide
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
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
Production & Project Manager
Philips Composants BU Magnetic Products
- Implemented cultural change in production
- Optimized KPI results
- Supported due diligence projects with the buyer
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
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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