Marcin Lachner
IT Project Manager | Consultant
Experience
Senior IT Project Manager
VF Corporation
Achievements: Focusing on shaping the Agile mindset and a mature approach to technology. Managing cross-functional teams, with a huge impact not only on the project itself, but also on people involved and the product being delivered.
- Delivering value to the Client through software development aiming at unifying all of its eCommerce platforms
- Leading the process of creating a common master template of the UI and design approach
- Facilitating flawless communication and teaching effective problem solving and root cause analysis to teams
- Taking part in the whole process from presales and sales until the implementation
- Taking full ownership of the budget and risk management
- Planning project schedule and estimating time needed to complete tasks- going down to the task level in the backlog to define project scope
- Helping the Client along the way and proposing solutions and improvements
- Understanding Client's custom needs from a technical perspective and leading teams in the right direction
- Conducting creative workshops with the client and building sharing knowledge & mentoring programs for team members
Client pain points:
- Legacy eCommerce 1.0
- Not so agile processes
- Many IBM WebSphere instances
- Lack of flexibility in releasing new versions
- Very long software release cycles/ lead times
- Expensive maintenance of the existing infrastructure
- Current organizational structure splits teams between EMEA and US by competencies
IT Project Manager
Johnson & Johnson Medical Devices
Achievements: Remediation of pick, pack, ship, repackaging and relabeling operations in J&J third party logistics providers (3PLs) across EMEA infrastructure with some involvement in North America and APAC. This role was a project assignment to ensure Deliver operations and IT systems in Johnson & Johnson Vision (JJV) are compliant to MDR and Johnson & Johnson Standards (J&J) through addressing an outstanding population of CAPAs and audit observations and bringing 3PLs (Third Party Logistics providers) to compliance with applicable J&J Standards. The role brought multiple paper based/digital as well as internal and external QMSs into alignment and required significant leadership skills.
- Partnering with JJV 3PLs to execute gap assessments to J&J Standards
- Shaping corrective action plans- leading implementation of defined remediation activities
- Supporting 3PLs in defining processes and documenting processes, where necessary
- Managing project timelines, deploying Quality Agreements, ensuring readiness for Supplier Audits
- Redefining and redesigning an NCR (Non-Conformance Reporting) process
- Digitizing the entire information flow- moving from paper-based reporting to digital data collection
- Sending real-time updates to suppliers about current production issues
- Supplier auditing and development: assigning 8Ds and verifying RC, CA and PA
- Assigning specific actions for suppliers to complete- management using project management tools
- Designing and implementing a custom form for data collection with acceptance criteria logic built-in
- Closing gaps in the NCR process
IT Project Manager
Bühler UK Ltd
Achievements: Moved on from a paper based management system to a digital QMS. Reduced the number of NCRs from 265 to below 40 NCRs per month. Reduced an average blocked stock value from 25K to below 1K. Streamlined the internal and external containment processes. Increased the % of 8D closures from 5% to 20% of the total number of NCRs. Reduced operational- mainly scrap, shipping and internal processing- costs by defining acceptance criteria (in cooperation with Engineering and R&D) and automating the NCR process using real-time data collection tools (tablet and email notifications based on predefined and agreed on process logic). Reduced supplier and client NCR costs and the number of disputes by providing real-time evidence to the relevant stakeholders.
- Responsible for redefining and redesigning an NCR (Non-Conformance Reporting) process
- Digitizing the entire information flow- moving from paper-based reporting to digital data collection
- Sending real-time updates to suppliers about current production issues
- Supplier auditing and development: assigning 8Ds and verifying RC, CA and PA
- Assigning specific actions for suppliers to complete- management using project management tools
- Designing and implementing a custom form for data collection with acceptance criteria logic built-in
- Closing gaps in the NCR process
QSB/QMT Engineering Consultant
BMW Group
Achievements: Eliminating issues with sealing systems and lights by performing the process/ design FMEAs and implementing complex permanent corrective actions internally and at suppliers'. Accumulating the inside knowledge on how suppliers are assessed and measured. Accumulating knowledge of the criteria for 8D assessments as well as the BMW scoring systems.
- Following defined processes to raise the Initial Complaint Report and 8D request ensuring the responsibilities of BMW are met
- Accountability for management, resolution, and prevention of quality issues using DFMEA, PFMEA and Control Plans
- Ensuring the problem landscape is clearly communicated to the appropriate suppliers and internal stakeholders
- Engaging with QMT's and supplier representatives at all levels to steer the problem resolution process at the supplier and to challenge proposed solutions using product knowledge and awareness of quality tools
- Progressing the Supplier 8D landscape to closure in a timely manner ensuring the quality of the content is satisfactory
- Ensuring the Red Rack is reviewed and suspect components are progressed as necessary
- Ensuring the PQM Landscape is progressed to closure in line with defined processes and supported by the Supplier 8D
- Ensuring Third Party Sorting actions onsite are dealt with efficiently and effectively and containment activity is transferred to suppliers as quickly as possible
- Escalate problems and suppliers as per the GS95015, defect elimination
- Provide cross-functional support to process partners with respect to problem analysis, module meetings etc
- Ensuring clear communication of Quality topics with the M-KIFA organization
- When required support supplier visits to verify 8D problem resolution where required
- Stand-in for QSB lead/manager on specific meetings and lead projects as required
- Any other reasonable duties as requested by QSB Lead/Manager
- Managing a number of suppliers /components and being the contact for supplier caused quality issues leading the initial analysis of root cause and responsibility allocation
- Ensuring Third Party Sorting actions onsite are dealt with efficiently and effectively and containment activity is transferred to suppliers as quickly as possible
- Engaging with multiple process partners and suppliers at all levels to drive the problem resolution and to challenge proposed solutions using product knowledge and awareness of green belt 6 Sigma quality tools
- Ensuring the cost recovery of disruption to the BMW business
- Escalating problems and suppliers when required
- Ensuring clear communication of Quality topics internally and to the supplier
- When required conducting supplier visits to verify 8D problem resolution
Project Manager
General Electric Power Conversion
Achievements: 35% reduction of the number of supplier NCR's for Rotor, Press and Machine sections. Keeping the quarterly supplier and internal production NCR cost below $200K for two quarters in a row. Facilitating the closure of over 68 historical suppliers and engineering NCR's. Taking immediate containment actions for non-conforming products, advising on preventive and corrective actions internally and externally.
- Managing the company NCR system (SAP) and providing reporting and driving actions with the required stakeholders to drive/own closure
- Using RCA/8D/5why to manage and investigate quality issues
- Designing & introducing new manufacturing processes as required by NPI plans
- Working with internal and external stakeholders to resolve quality issues that arise as quickly and efficiently as possible to prevent compromising quality and safety
- Carrying out product (APQP) and process (PFMEA) auditing
- Ensuring that control plans and associated documentation are implemented effectively and are maintained
- Monitoring and reporting quality-related KPI's including Scrap/Rework levels/First-time yields
- Promoting zero defect and stop the line culture
- Ensuring compliance and assisting with the QMS (ISO9001)
- Undertaking special projects as required
- Participating in cross-functional teams to aid development and identification of risk on new projects/processes inclusive of using an FMEA approach
- Contributing to continuous improvement projects and activities
- Meeting with customers during project meetings and final inspections and providing preparing reports and presentations to support those meetings
- Being flexible in approach and time management to allow tasks to be completed to support the project timelines
Project Manager
SPX International T/A SPX Rail Systems
Achievements: Implementing an online based reporting system for production, suppliers, and customers which feeds into the company infrastructure and training all three. 20% reduction in the number of rejects and 28% reduction in scrap costs. Facilitating and aiding in the ERP implementation (move from a legacy system SysPro to SAP) by creating Business Process Management documents detailing how the company processes flow across functions. Securing alternate supply sources for critical components by conducting assessments of suppliers, performing audits and process PFMECAs.
- Managing supplier and purchasing quality related activities including pre-approval, audit and performance reviews for excellence (supplier assessments, PFMEAs)
- Communicating effectively to R&D engineers, manufacturing policies and procedures relevant to product design
- Design, planning and commissioning production line layouts/cells in NPI activities, specifying & procuring production equipment for NPI, PFMEA's
- Acting as the lead for all quality related 3rd party audits and meetings. Managing and performing internal and external audits and random product quality inspection and goods inwards inspections as and when required. Managing and administering business product concession process
- Discovery, management, and planning of tasks to achieve agreed customer requirements, delivering to documented or new processes within agreed timescales
- Identifying training and development requirements, mentoring/coaching and undertaking performance management of teams internally and externally
- Managing engineering systems, integration, testing, guiding improvements, process development, and process automation/ testing
- Assisting in the resolution of systemic manufacturing related issues, and the reduction and elimination of process non-conformances
- Compiling and reporting production/quality metrics, identifying trends and proposing improvements
- Creating and managing internal and external inspections, test specs and product sample sign-offs
- Managing and administering internal and external corrective action and improvement processes
- Managing and administering all warranty, servicing and customer complaint related issues
- Acting as appointed Health, Safety and Environmental representative- investigation HSE incidents, creating and enforcing company policies and processes relating to HSE activities
- Ensuring quality processes are followed and eventually (where feasible) built into the ERP system (internally and externally) or automated- liaising with and educating ERP implementation consultants on process automation
- Automating the QMS (when I started the company was using a QMS system based on paper forms. Since I was unable to process all the data on my own and the business refused to hire additional staff I automated this part of the business with cloud applications and scripts which I then passed on to the new manager)
Quality Engineer
Koito Europe Limited
Achievements: Implementing Poke yoke for rear lamps, permanently fixing an issue with light bulbs falling out of their housing in Nissan Qashqai vehicles, reducing the number rejects and line stoppages.
- Contributing to early-phase concept work, supplying advice and direction to design engineers
- SQA activities within the simultaneous engineering teams and at suppliers as part of the industrialization process (NPI - APQP & PPAP)
- Series process and product approval
- Ensuring launch readiness at the component level for the introduction of new models
- Supplier nomination and problem resolution of parts quality issues
- Management of supplier quality performance and implementation of corrective actions
- Proactive & reactive Supplier Development activities, impacting on supplier process yield, continuity of supply and product quality. Hands-on experience of Lean Manufacturing
- Setting up objectives for department involving all disciplines within Quality Control
- Ensuring robust corrective actions to customers in a timely manner (QPR's, 8D's, PPS Documents)
- Effectively supporting problem resolution activities
- Attendance & implementation of any actions from scheduled meetings
- Effective management of Quality Engineering
- Communicating on a regular basis with all departments on Quality concerns and ensuring they are effectively dealt with
- Stopping shipment authority for control of non-conforming material
- Management & setting up of agreed department KPI's
Process Automation Engineer
Renhal Sp. z o.o. oddział w Polsce
Achievements: Implemented G-Suite and automated e-commerce processes by configuring and setting up sales, distribution, procurement, materials management, inventory, accounting, shipping, reporting and data collection systems using third party cloud applications and PHP. Created an API integration for transferring customers and orders data from an order aggregation application (providing native integration with marketplaces, shops, couriers, accounting systems and labeling and printing solutions) with an enterprise grade inventory and production management system used by manufacturers, wholesalers and distributors.
Supplier and Part Quality Assurance Engineer
MAN Truck & Bus AG
Achievements: Driving 8D activities for Turkish and German suppliers. Reducing the number of goods inwards rejects by working directly with the suppliers on proactive strategies e.g. asking for specific measurements of features know to be repeat issues in production.
- Managing supplier quality issues, problem resolution of parts quality
- Evaluating and selecting suppliers based on SQA criteria
- Involved with suppliers of engineering teams (from Poland and Germany)
- Participating in supplier development, using Lean Manufacturing techniques
- Tools used: check sheet, control chart, kaizen, FMEA, ppm, TQM, histogram, NPI, APQP, PPAP
- Series process and product approval
- Ensuring parts availability for production line launches
- Operations management and companywide quality system DIN/ISO 9001/ISO TS16949 implementation
Design Engineer
Diam International
- 3D CAD designs, creating prototypes, specification documents, patent applications, presentations
- Briefing production staff and data entry
- Failure mode and effects analysis (FMEA) operations. Software: Pro/Engineer (now CREO), SolidWorks, AutoCAD