Norman J.
Managing Director
Experience
Oct 2023 - Present
1 year 11 monthsEllwangen, Germany
HybridData Analyst and Ramp-up Support
Varta Microbattery GmbH
- Implemented automated data visualization/analysis as a basis for further decision-making processes
- Analyzed production data to identify relevant quality issues and their technical causes using Six Sigma methodology
- Led task force for internal resistance (mechanical/electro-chemical)
- Led task force for AI-based X-ray image analysis to reduce scrap
- Solved acute issues and established a continuous improvement process in production
- Introduced performance metrics; planned resources and timelines; conducted risk assessments; and managed changes
- Developed and implemented corrective actions
- Ensured supply capability during pre-series process
- Coordinated between OEM and customer
Oct 2022 - Sep 2023
1 yearAuerbach, Germany
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EAO Automotive GmbH & Co. KG
- Project manager for tool redesign and creation in ongoing production
- Task force leader for project relocations after supplier insolvency
- Established pragmatic decision-making processes in change management
- Ensured supply capability during series production
- Coordinated between OEM and supplier
Apr 2022 - Jul 2022
4 monthsBerlin, Germany
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Berlin Millhouse GmbH
- Operational program manager for Bosch projects
- Restructured project/program management processes
- Operational purchasing of all required semi-finished materials
- Supported management in strategic new business decisions
- Conducted potential analyses and audits of new suppliers
Jan 2022 - Mar 2022
3 monthsMannheim, Germany
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tmax Germany GmbH
- Analyzed customer requirements, specifications, and schedules
- Determined resource requirements (personnel and machinery) with support from departments and plants
- Developed and implemented measures based on these analyses for efficient project control
- Coordinated equipment expansion through relocation and/or acquisition
- Prepared, managed, and implemented supplier change requests (SCR)
- Coordinated relocation activities between the Mannheim and Sibiu sites
- Project controlling to ensure financial goals and deadlines by coordinating with development teams, internal departments of the tmax Group, and customers and suppliers
- Analyzed deviations and initiated countermeasures for deviations that could jeopardize schedule, cost, or quality targets
- Conducted efficient and goal-oriented workshops for problem-solving, project meetings, and task package coordination with relevant teams
Jul 2019 - Dec 2021
2 years 6 months Lorem ipsum dolor sit amet
IHI Charging Systems International GmbH/ Automotive
- Program manager for Audi Evo5 development project
- Project procurement for Audi Evo5 development project
- Project quality manager for critical global customer projects (Audi & Porsche) focusing on supplier management and internal project quality
- Customer interface for "production readiness" and supplier management / APQP
- Qualitative and quantitative assurance of critical global suppliers
- Developed and implemented a sustainable internal change management system
- Planned and executed global relocation projects during pre-series
- Implemented appropriate tracking processes in supplier management
- Analyzed and assessed quality-related customer requirements
- Methodological support for FMEA workshops
- Prepared all IATF audit-relevant documents for annual certification
- Developed relevant quality processes for planning, controlling, and monitoring during pre-series
- Developed and standardized the internal sampling process
- Supported and involved members from quality, procurement, and the plant
- Industrialization, process stabilization, and process optimization
- Conducted Audi-specific gate reviews in the Audi LION system
Jan 2019 - May 2019
5 monthsCharleston, United States
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MahleBehr GmbH & Co. KG / Automotive
- Support global quality management at MahleBehr for all cooling modules of the BMW X5, X6, and Rolls-Royce projects at the Mahle locations Stuttgart, Dayton, Charleston
- Analyze and evaluate quality-related customer requirements
- Plan and carry out pilot production runs at the MahleBehr plant and at critical subcontractors in Europe and the USA together with BMW QMTs
- Handle level 1 escalations and track KPIs
- Support critical sampling issues in IPQ
- Result achieved: Secured global start-up support for BMW's main SUV model series
Sep 2017 - Jan 2019
1 year 5 months Lorem ipsum dolor sit amet
IHI Charging Systems International GmbH/ Automotive
- Project Quality Manager for critical Audi & Porsche customer projects focusing on supplier management / APQP
- Main contact for customers (monthly customer meetings on project status)
- Weekly management presentation on supplier status
- Analyze and evaluate quality-related customer requirements
- Provide methodological support in FMEA workshops
- Prepare all IATF audit relevant documents for annual certification
- Develop relevant quality processes for planning, control, and monitoring in the pre-series process
- Develop and standardize the internal sampling process
- Ensure qualitative and quantitative assurance of critical suppliers
- Support and involve members from quality, purchasing, and production
- Prepare all sampling relevant documents in coordination with the customer for full approval of ongoing projects
- Industrialization, process stabilization, and process optimization
- Conduct Audi-specific gate reviews in the Audi LION system
- Result achieved: IATF certification without deviations. Approval of all subcontractors according to schedule, industrialization of a critical customer project.
Sep 2016 - Sep 2017
1 year 1 monthBremen, Germany
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Prae-Turbo GmbH / Automotive
- Industrialization, process stabilization, and process optimization
- Introduce standardized process monitoring
- Introduce suitable measuring equipment based on required resolution after thorough analysis
- Optimize cycle times of ongoing production processes
- Develop and standardize the internal sampling process
- Manage suppliers / secure critical suppliers
- Secure capacity for global Daimler and VW volumes
- Prepare all sampling relevant documents in coordination with the customer for full approval of ongoing projects
- Support and involve members from quality, purchasing, and production
- Result achieved: Secured internal supply and process capability
Nov 2015 - Jul 2016
9 months Lorem ipsum dolor sit amet
Bosch Mahle Turbo Systems GmbH & Co. KG / Automotive
- On-site support / global SQ assurance of critical suppliers (project management)
- Exhaust manifold modules
- Compressor wheels
- Pneumatic actuators
- Bearing housings
- Exhaust flap systems
- Secure capacity for global VW volumes
- Support weekly reviews at VW
- Track bottlenecks of critical suppliers
- Conduct supplier selection / potential analyses
- Industrialization and process optimization
- Introduce standardized process monitoring
- Support members from quality, purchasing, and production
- Provide parallel support for special projects, e.g. T/H Brakes India
- Result achieved: Secured delivery capability of critical suppliers
Jan 2015 - Nov 2015
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IHI Charging Systems International GmbH/ Automotive
- Support the Daimler task force within the Q-Help 3 classification
- Secure capacity for Daimler volumes
- Support weekly reviews at Daimler and all current sampling topics
- Main point of contact and communication liaison to Daimler
- Support global SQ assurance of critical suppliers
- Optimize cycle times of ongoing production processes
- Manage and carry out the Daimler sampling process in the Supplier Quality Management System (SQMS) of Daimler AG
- Develop and standardize the ICSI sampling process for Daimler
- Prepare all sampling relevant documents in coordination with the customer for full approval of ongoing projects
- Support members from quality, purchasing, and production
- Provide parallel support for special projects, e.g. T/H NWS in China, B/H Trompetter Foundry
- Result achieved: ICSI upgrade at Daimler to Q-Help 2
Jan 2014 - Present
11 years 8 monthsManaging Director
Joiko Consulting
Global management consultancy with a focus on Six Sigma (DMAIC, Lean Six Sigma)
- Quality and development support for global, complex product launches in the automotive industry
- Implementation of Six Sigma projects
- IATF 16949:2016 1st / 2nd party auditor
- Interface for customer communication
- Supplier management / project management
Jan 2012 - Dec 2014
3 yearsAssociate
Dr. Schäfer Consulting
- Support in Six Sigma projects (foundry technology, exhaust gas turbochargers, module division)
- Documentation of processes for product launches in the automotive industry
- Process optimization in the automotive industry
- Potential analyses
- Support / implementation of process monitoring
- Evaluation and processing of industrial data
- Development of standardized tools for process assurance within experimental planning and execution
- Creation of training materials for process standardization
- Support in process analysis of complex technical components such as EGR valve, electric actuator, ...
- Introduction to quality management systems according to VDA 6.3
- Support in global Six Sigma projects
- Creation of long-term management concepts in quality assurance
- Identification of ongoing series issues on final assembly lines
- Support for process optimization of electric actuator setup on final assembly lines
- Initiation of a poka-yoke solution for electric actuator final assembly
- Resolution of open material issues during the sampling process
- Support in electric actuator inspections at Audi AG in Ingolstadt
Summary
Professional focus areas:
- Ramp-up support
- Process development/optimization
- Supplier management
- Quality management
- Data analysis
- Strategic & operational procurement
- Supplier development / sourcing / auditing
- Relocation management
- Automotive industry
- Task force support in the automotive sector
Strong technical expertise:
- Manufacturing and testing processes of high-performance lithium-ion battery cells from electrode through winding to the final charged cell.
- Turbocharger technology for diesel and gasoline engines, as well as most required sub-supplier manufacturing processes.
- Product and process knowledge of electronic actuators for turbochargers (diesel and gasoline).
- Cooling modules, heat exchangers, charge-air coolers, oil coolers, water coolers, condensers.
- Manufacturing technologies: steel casting / aluminum casting (gravity and vacuum).
- Joining methods (MIG/TIG welding).
- Plastic injection molding.
- Technologies such as stamping, deep drawing, forming, turning, milling, sintering, and balancing.
Extensive hands-on project management experience:
- Project quality management for a Tier 1 system supplier of A-components.
- Global supplier management and change management within the VW Group.
- Daimler & VW Group specific process flows (especially Daimler "Special Terms" and VW "Formula Q").
- Quality management through all IATF/VDA gates from pre-series to SOP.
- Implementation of lessons learned, design reviews, and process audits.
- Six Sigma projects in process optimization and scrap reduction.
- Relocations of production sites and assembly lines.
Practical application of quality management systems: (VDA 6.3, QS 9000, IATF 16949)
- Daimler SQMS & VW, Audi BEON as well as LION sampling processes according to VDA standard/special terms.
- Excellent knowledge of common quality management system methods (TQM).
- Specific Six Sigma tools such as balanced scorecard, DOE, Ishikawa diagram, …
- Comprehensive potential analyses according to VDA 6.3 standard.
- Continuous improvement of preventive quality methods.
Languages
German
NativeEducation
Oct 2015 - Jun 2017
Technical University of Ilmenau
Master of Science, focus on Mechanical Engineering · Industrial Engineering and Management · Ilmenau, Germany
Oct 2011 - Jun 2014
Technical University of Ilmenau
Bachelor of Science, focus on Mechanical Engineering · Industrial Engineering and Management · Ilmenau, Germany
Oct 2001 - Jun 2009
Wilhelm von Humboldt Gymnasium
German Abitur · Nordhausen, Germany
...and 1 more
Certifications & licenses
IATF 16949:2016 1st / 2nd Party Auditor
DGQ- Quality Systems Manager Junior
DGQ
Lean Management & Kaizen Practitioner Certification
Six Sigma Black Belt Certification
Six Sigma Green Belt Certification
Six Sigma Yellow Belt Certification
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