Karl-heinz Mayer - Managing Director

Recommended expert

Oberried, Germany

Experience

Jan 2018 - Present

8 years 1 month

Freiburg im Breisgau, Germany

Managing Director

Mayer Asset Management (MAM)

Review of the existing technical organization and processes
Optimization and implementation of efficient Engineering organization with definition of roles and areas of responsibility
Significant reduction of Deviation and CAPAs caused by asset failure
Plant shutdown, planning, scheduling and monitoring of all activities
Implementation of Asset Lifecycle Reliability processes
Achieving sustainability in Asset Lifecycle Management processes
Implementation of early Asset Management in projects
Definition of Asset Lifecycle Documentation
Development basic Engineering Guidance documents like asset management program and strategy
Development of site Asset Lifecycle Management SOPs
Implementation of Reliability Engineering processes
Implementation of GxP Processes in Asset Management
Development & Implementation of Spare Part Management processes
Implementation of Asset Management Improvement Processes
Implementation of Condition Based Maintenance
Implementation of CMMS, definition of efficient & compliant usage processes e.g. for, SAP-PM & Blue Mountain
Conduct compliance and efficiency assessments of Asset Lifecycle Management

Jan 2013 - Dec 2018

6 years

Basel, Switzerland

Global Business Owner SAP-PM

Novartis Pharma AG

Implementation of SAP-PM business processes (e.g., Corrective Maintenance, Preventive Maintenance, Planning and Scheduling and Calibration) in all pharma manufacturing sites
Review and optimization of all maintenance business processes for SAP-PM
Development of an SAP-PM best practice guide to harmonize and improve the usage of SAP-PM across the Novartis manufacturing sites
Leading and guide the SAP-PM super user community of Novartis Pharma
Review all SAP-PM service requests and collaborate with ERP-IT to achieve the annual IT budget
Standardized usage of SAP-PM across Novartis Pharma production units
Standardization of Asset Lifecycle Management KPI’s in EAM
Maintenance Cost transparency in Novartis Pharma production units
Reduction of maintenance cost and compliance observations

Jan 2010 - Dec 2018

9 years

Basel, Switzerland

TPM Champion / Principal Asset Maintenance Engineer

Novartis Pharma AG

Implementation of TPM and Asset Life Cycle Management (ALCM) in Novartis Pharma, 20 manufacturing sites in Asia, Europe and USA
Definition and execution of 17 basic work streams to achieve the TPM and ALCM requirements
Development of basic maintenance processes
Development of an ALCM Assessment tool according to ISO 55000
Execution of ALCM Assessments
Increase of the asset availability and reliability over 20 production sites
Significant reduction of break downs
Significant reduction of maintenance overdue work order
Significant maintenance cost reduction

Jan 2009 - Dec 2010

2 years

Marburg, Germany

Lead Maintenance Engineer

Novartis Vaccines and Diagnostic

Development of a Maintenance Program for the new manufacturing site
Defining an equipment (Floc) structure for production and utility equipment
Development of a SOP for the Asset Life Cycle Documentation

Jan 2007 - Dec 2008

2 years

Shanghai, China

Project Lead Engineer

Novartis Pharma AG

Execution of process equipment designs review for 3 new chemical production buildings
Leading the Project Engineers of the CN design engineering contractor (SSEC) to achieve the design requirements of the project URS
Release and control of all asset material specification
Auditing OEMs and advice the project purchasing organization to select the right equipment manufacturer

Jan 1996 - Dec 2007

12 years

Stein, Switzerland

Plant Engineer and Senior Plant Engineer Milling & Blending Center

Novartis Pharma AG

Management of site engineering’s of a production unit (5 Engineers, 2 direct reports and 3 external reports)
Responsible for a repair and maintenance budget, appr. 3 MCHF.
Creating of annual and 3years investment plan, project execution
Responsible for project schedule and costs in compliance with the internal and external cgmp guidelines
Execution of process optimization and changes of production and infrastructure equipment
Explanation of the site maintenance organization, processes and results in audits of pharmaceutical authorities (e.g. FDA, EMA, Swissmedic) and to internal quality organizations

Jan 1992 - Dec 1996

5 years

Basel, Switzerland

On-site

Project Manager

Ciba-Geigy AG

Planning and realization of environmental engineering projects within the Ciba-Geigy production sites
Design and execution a new WWT plant for a chemical production site in France, investment cost, 10 M€
Consultant for external companies around environmental engineering processes and in definition of user requirements

Jan 1988 - Dec 1992

5 years

Basel, Switzerland

Cost Engineer

Ciba-Geigy AG

Development and standardize a cost code structure for all investment projects of the central and site engineering in SAP-PS
Roll-out the standardized cost code in the central engineering and in all site engineering’s
Achieve a standardized cost structure for large investment projects by collaboration with the central project engineers
Calculation, creation and publishing engineering key indicators for investment projects within the engineering community

Jan 1987 - Dec 1988

2 years

Lörrach, Germany

Engineer for Production Improvements

Jacobs-Suchard Manufacturing GmbH & Co. KG

Support the startup process of new packaging equipment to achieve the expected asset performance (OEE) before hand over to production
Carrying out weak point analysis on process and packaging assets to improve OEE
Reduction of corrective maintenance by improving preventive maintenance
Increase of the production Output (1M€, year)
Reduction of maintenance costs (15%)