Roger B.

Consultant, Interim Management, Project Manager; New Development, Ramp-Up; Series Support, Process Optimization; Relocations

Neulußheim, Germany

Experience

Mar 2023 - Dec 2024
1 year 10 months
Backnang, Germany

Project Manager, PMO Department Ramp-Up, Series Support; Relocation to Sister Plants (Romania/South Africa)

Hays; SMA-Metalltechnik GmbH

  • Project management in the automotive environment
  • Analysis of the current state and definition of necessary measures
  • Project planning, coordination & controlling
  • Communication in English and German with various departments, interface management, and reporting
  • Documentation of results
  • Relocation of series projects to sister plants for customers like Porsche, Bentley, Audi, etc.
  • Coordination of required tasks and adjustment of all necessary processes
  • Preparation of project plans, process flow charts, and schedules for smooth implementation of projects
  • Regular alignment of all implementation topics with the client
Jul 2022 - Mar 2023
9 months

Interim Management/Project Management/Logistics/SCM/Process Optimization

Netzwerkpartner

  • Support in various projects in logistics concept implementation/process optimization/supply chain management, etc.
Jan 2022 - Jul 2022
7 months

External Consultant Cutover Manager; Logistics Process

Red Comerce; Huegli Lebensmittel GmbH

Cutover Management in the SAP S4Hana implementation process:

  • Support during the introduction of new enterprise software on the shop floor during testing, cut-over, and go-live
  • Analysis of potential disruptions in required process changes in production and initiation of preventive measures
  • Function as communication and organization interface between production, external warehouses, and the IT project team
  • Collection and coordination of any necessary training measures for production staff
Apr 2021 - Dec 2021
9 months
Germany

External Consultant Logistics Process, Central Warehouse Area

CplusM Consulting plus Management; IMA-Schelling Group Germany

Optimization of warehouse processes:

  • Identify process bottlenecks in the new logistics center and initiate corrective actions (workflow analyses)
  • Analyze existing processes
  • Sketch/document processes (Visio)
  • Develop new logistics concepts (lean manufacturing)
  • Involve employees in process flows including process support and training (guidance)
  • Active shop floor management
  • Define storage areas, determine bulk storage locations
  • Develop new logistics procedures in the central warehouse and infrastructure to departments
  • Set up tow trains; create logistics stations in departments
  • Install scanner system for system booking
  • Create manual for automatic pallet storage system (APL Viastore)
  • Train employees on the scanner station guidance system
  • Instruction training for picking workstations
  • Connect small parts lift system to Viastore APL control system
  • Revise feedback processes from APL system to ERP system

Process support for the introduction of new ERP and warehouse software (AS/400 to Infor and Viastore):

  • Implement new hardware/software on site with service technicians/programmers in the 'live process'
  • Train employees on new software and processes
  • Document the newly implemented process sequences in a manual to support employees in case of disruptions
  • Identify and consolidate errors and potential failure points
  • Close cooperation with internal IT and the ERP and warehouse software suppliers to develop solutions
  • Plan scheduled corrective actions and track progress of new developments including planning 'updates'
  • Evaluate and approve performance stress tests
Aug 2020 - Jan 2021
6 months
Germany

External Consultant/Project Manager; Industrial Area, Plant Closure Project Manager (CZ), Product Relocation (DE/RO)

Roechling Precision Components

  • Takeover of all activities and coordination of the plant closure for the Czech Republic plant (CZ)
  • Preparation of current state analysis
  • Development of concept and optimization potential, project plan, resources for relocation projects as well as plant closure and decommissioning, etc.
  • Collection of cost data and preparation of project budget for plant closure and relocation projects
  • Conduct risk assessment and create contingency plan
  • Prepare Romanian plant for basic site qualification, process audits, process approvals, etc.
  • Manage building decommissioning, etc., and handover to the owner
  • Relocate products in compliance with quality requirements from the Czech plant to the Romanian plant
  • Coordinate with customers, secure lead time according to customer requirements while meeting quality standards (requirement management)
  • Transfer production lines with pre-planned optimization opportunities (KVP)
  • Regular reporting to management on status, schedule, costs, and timing (board meeting)
  • Collect and plan resource deployment to achieve lead time requirements with increased staffing
Nov 2019 - Mar 2020
5 months
Germany

Launch Manager, BMW G21 Rear Hatch Hinge Project Launch

Prinz-Kinematics

  • Advisory project management with a defined assignment
  • Analysis of series processes and control loops for optimization potential (KVP)
  • Support and implementation of agreed optimization measures (QVP, APQP)
  • Creation of Q-Gate firewalls for quality checks
  • Handling customer complaints internally and with the customer according to industry standards (8D report, customer portal)
  • Maintenance of relevant customer portals (B2B BMW)
  • Regular communication and support of customers/suppliers (international: China, England, Italy)
  • Accelerating fault analysis and corrective actions for complaints
  • Coordination of involved departments and suppliers
  • Monitoring delivery reliability
  • Internal audits for process stabilization (IATF 16949)
  • Creation of continuous output monitoring
  • Regular reporting to management
  • Maintenance and further development of QM systems
  • Compliance with the product development process (PEP) according to client specifications
  • Reporting to the involved departments
  • Participation in K- and PFMEA
  • Tracking change management (ECR)
  • Communication and knowledge sharing among all project members
Nov 2018 - Jul 2019
9 months
Germany

Consultant/Project Manager/Product Manager for a pre-development project, automotive industry, inductive charging (WPT) of

Roechling Automotive

  • Securing prototype order from McLaren
  • Advising to secure the series order from McLaren
  • Setting up a pilot plant for inductive charging systems
  • Equipping the company car (BMW i3) with an inductive charging system
  • Acquisition of new orders for inductive charging systems (international: China, USA, Europe)
  • Involvement in the development of inductive charging systems
  • Support as product manager for inductive charging systems
  • ISO 26262 implementation for a new business division
Jan 2018 - Sep 2018
9 months

Project Leader/Project Manager for plastic extrusion parts/injection molded parts, multi-component exterior parts for

SMIA

  • Leading 12 separate projects for a global OEM on roof trim strips made by extrusion and bending processes, painted in various colors, and assembled on production lines for various vehicle models and variants (BMW)
  • Leading two projects for a global luxury OEM (Rolls-Royce) for window frames and covers, using 2K injection molding and painting, for windshield water management
  • Tasks include coordinating projects internally and with the customer regarding schedule, cost, and quality
  • Coordination of project teams
  • Requirement management coordination, aligning the specification sheet and customer requirement matrix, and preparing requirement documents for the technical teams and documentation
  • Aligning test requirements and descriptions to coordinate with external service providers
  • Project planning, structuring, and control
  • Internal reporting to the steering team
  • Reporting to the OEM
  • Creating action plans, monitoring, and tracking to achieve milestones.
Mar 2017 - Dec 2017
10 months
Germany
Hybrid

Project Leader/Project Manager for AWC 3.6 kW automotive wireless charging (inductive charging) of passenger cars for a company

Primove

  • Leading a project team of about 100 employees for a charging system for inductive charging of a hybrid vehicle or electric vehicle, via an onboard unit and a charging pad (floor plate) for a globally operating company
  • Guiding the development project to achieve production readiness for Audi A8 and e-tron
  • Internal coordination with various departments, as well as customer communication and on-site support to achieve production readiness
  • Coordinating project team leaders to meet targets such as production line approvals; sampling of tools, equipment; qualitative approvals (BMG, B-approval, Grade 3, Grade 1); relocations to series locations nationally and internationally
  • Coordinating product validation following the internal and external requirement catalog, and ensuring development complies with ISO 26262 functional safety
  • Coordinating validation tests, ensuring test cases are followed as described internally and externally
  • Coordinating industrial engineering (operations)
  • Creating prototypes
  • Documentation in DOORS, as well as monitoring according to Automotive SPICE processes
  • Reporting to internal management as well as to the OEM
  • Escalation level for the project team in case of deviations from the project plan, cost, or quality
  • Coordination with the technical project manager
  • Responsibility for project budgets, timelines, and part quality, and reporting to management in regular meetings
Nov 2016 - Feb 2017
4 months
Germany

Project Leader/Project Manager, automotive industry, for IMD plastic injection molded interior decorative trim strips for

SMIA Automitive

  • Coordination of the project team for two VW projects and another project for a sealing valve
  • Internal coordination with various departments, as well as customer communication and on-site support
  • Achieving production readiness
  • Coordination of relocation and approvals; sampling of tools nationally and internationally
  • Coordinating product validation internally and externally
  • Coordinating industrial engineering
  • Reporting to the OEM
  • Coordination of internal and external audits
  • Coordination with the technical project manager (tool manager)
  • Responsibility for project budgets, schedules, and part quality; requirement documentation and coordination (Excel-based); and reporting to management in regular meetings
Oct 2015 - Sep 2016
1 year
Germany

Project Management / Project Engineer / Key Account for safety restraint systems/safety belts for various automotive OEMs

ITW

  • Project management/engineering for up to 35 simultaneous international projects of various components for one customer.
  • Independently managing projects/engineering change management and monitoring adherence to schedules, costs, and quality.
  • Leading various coordination meetings/technical reviews with customers and internal departments.
  • Conducting regular QVP meetings, manufacturability evaluations/feasibility analyses, coordinating PPAP internally and externally, and aligning on the customer platform (VIN system).
  • Creating project plans, determining project costs, preparing project budgets and carrying out various CAPEX processes, preparing quotes for new projects/changes/prototypes, reviewing and creating requirement and specification documents, coordinating requirements and ensuring documentation, processing and complying with legal requirements/regulations and internal guidelines/policies.
  • Coordinating alignment meetings to ensure supplier deadlines and qualifications meet the quality systems/requirements of various OEMs.
Feb 2015 - Sep 2015
8 months
Germany

Ramp-up management of door trims and instrument panel trims for BMW X1, output monitoring, KPIs, ZDF, production control

NBHX

  • Acting as the interface between logistics, quality, and assembly; serving as the contact person for customers and plant staff on project inquiries and problem-solving in series development projects.
  • Conducting feasibility analyses and monitoring project progress.
  • Responsible for meeting project goals, determining daily output targets, creating KPI overviews, and calculating department target values to meet volumes and secure ramp-up curves.
Jul 2014 - Sep 2014
3 months
Slovakia

Project management/support for the Audi Q7 roof-edge spoiler and Audi TT side skirts under project leadership

Rehau

  • Independently guiding and advancing the maturity level of the components, including industrialization measures at the Györ plant (Hungary).
  • Participating in and conducting internal and external product presentations, maturity reviews, and general project meetings (VW Bratislava (Slovakia) / Audi Györ plant (Hungary)).
  • General project coordination for the mentioned development scopes internally and externally.
Feb 2014 - Jun 2015
1 year 5 months
Mumbai, India

Consultant role

Bright Auto Plast PVT Ltd

  • Consulting in process optimization, lean manufacturing (LEAN), quality improvement (QVP, KVP), and output increase (output monitoring).
  • Development and development consulting for new developments (PEP, requirement management) for the automotive industry (fuel tank/AdBlue tank).
Oct 2013 - Present
11 years 11 months
Norway

Consultant role in the industrial area

Easy Roller

  • Advising on product quality issues of your supplier.
  • Developing solution proposals, KVP.
  • Searching for a new supplier.
  • Transferring products from current to new suppliers.
  • Training, onboarding, and establishing new quality standards with new suppliers.
  • Developing new standards for alternative solutions with new suppliers (accessories).
May 2013 - Feb 2014
10 months
Germany

Automotive Consultant, Project Manager

Promens (now Berry/RPC Plastics)

  • Manage new customer projects for plastic products as project manager in line with internal and external requirements with the customer.
  • Perform cost calculations and prepare proposals together with sales.
  • Review or create requirement and specification documents, prepare purchase inquiries for bought-in accessories according to customer requirements.
  • Select suppliers, coordinate tool design and procurement.
  • Create and track schedules and project budgets.
  • Execute projects according to internal decision gates and coordinate them independently.
  • Coordinate sampling and the creation of test reports.
  • Present products to customers, obtain approvals from customers and suppliers.
  • Bring products to series production readiness and provide ongoing support.
Oct 2012 - Present
12 years 11 months
Neulußheim, Germany

Owner, Freelance/Self-Employed Consultant

Boettcher Consulting

Consulting/ Project Management/ Product Development/ Interim Management

Oct 2012 - Feb 2014
1 year 5 months
Germany

Project Assignment for Product Development, Urea Tank for Trucks

Emitec

  • For Russian customers (YaMZ, MAZ, MMZ).
  • CAD design, tool design, definition of accessories, specification of quality features / system requirements / legal requirements, supplier selection, acting as link between customer and manufacturer (client).
Feb 2011 - Sep 2012
1 year 8 months
Hockenheim, Germany

Project Manager in Product Development and Deputy Head of Development

Promens Hockenheim GmbH

  • Identify customer requirements and translate them into rotational projects.
  • Plan and manage projects, resources, and costs.
  • Ensure production readiness and drive continuous improvement in series production.
  • Review requirement documents and create specifications for suppliers.
  • Present the company to new customers.
  • Identify and implement development opportunities.
  • Provide technical support to sales in realizing new projects.
  • Provide technical support for existing customers and their products.
  • Serve as deputy head of department.
  • Immediately integrate 100% into daily operations since customers and systems were already known.
  • Win new projects with major clients (Daimler, EvoBus, VW Commercial Vehicles).
Nov 2008 - Dec 2010
2 years 2 months
Pietermaritzburg, South Africa

Technical Service Manager (Operations Manager)

Kaymac Structural Foam PTY Ltd.

  • Responsible for the departments of product development, quality assurance, and maintenance/toolmaking.
  • Acquire new projects from existing customers.
  • Gain new clients.
  • Present the company to new customers at trade shows and ARM events.
  • Create budgets and take responsibility for each department.
  • Negotiate prices and contracts for new projects.
  • Lead projects from received orders.
  • Cost reduction and process optimization.
  • Develop a plastic pallet for aluminum rollers with a load capacity of 15 tons.
  • Develop and implement machine standards to reduce costs and increase competitiveness.
  • Optimize machine downtime by recording repairs and their causes to implement preventive maintenance.
Apr 2002 - Oct 2008
6 years 7 months
Hockenheim, Germany

Project Lead in Product Development

Promens Hockenheim GmbH (formerly Bonar-Plastics)

  • Identifying customer requirements and translating them into a rotational molding project.
  • Planning and managing projects, resources, and costs.
  • Ensuring series production readiness and continuous improvement during series production.
  • Reviewing requirement specifications and creating supplier specifications.
  • Presenting the company to new customers.
  • Identifying and implementing development opportunities.
  • Participating in price and contract negotiations.
  • Providing technical support to existing customers and their products.
  • Providing technical support to sales for the execution of new projects.
  • Developing plastic fuel tanks for the Daimler NCV3 low-frame chassis.
  • Developing plastic fuel tank for the Volkswagen Caddy 4Motion Diesel.
  • Prototype development for Volkswagen Passat CNG test vehicles.
  • Various other product developments, such as a cooler box for Claas combines and air ducts for MAN.
  • Managing various projects for sister plants in Denmark and Poland.

Summary

Assignment in one or several projects/project leadership/subproject management/project management/product development/ramp-up management/industrialization/quality planning/advanced quality planning/automotive or other industries according to qualification, for 100% utilization.

  • Many years of experience in the automotive industry (since 1996)
  • Many years of experience in various quality assurance systems/methods/warehouse logistics, cut over management, SCM/product launches, relocation of production lines, ramp-up of new production lines, product development processes (IATF 16949, TS 16949, ISO 9001, APQP, PPAP, QVP, KVP, PEP, FMEA, PFMEA, DFMEA, etc.)
  • Knowledge of Automotive SPICE, DOORS, ISO 26262 functional safety
  • Knowledge and experience in various project management methods like Agile, multi-management, Waterfall, etc.
  • Knowledge of common office tools such as MS Project, Office (Windows), SAP, etc.
  • Experience in international project management, international supplier selection, support and evaluation, etc.

Languages

German
Native
English
Advanced

Education

Aug 2000 - Jul 2002

IHK Mannheim

Technical Business Administrator IHK · Technical Business Administrator · Mannheim, Germany

Apr 1995 - Sep 1995

IHK Würzburg-Schweinfurt

Master Craftsman for Plastics/Rubber Industry · Master Craftsman for Plastics/Rubber Industry · Würzburg, Germany

Oct 1985 - Jun 1988

Polydress Plastics GmbH

Plastics Molder · Plastics Molder · Michelstadt, Germany

Certifications & licenses

Technical Business Administrator (IHK)

IHK Mannheim

Master Craftsman for Plastics/Rubber Industry (IHK)

IHK Würzburg-Schweinfurt

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