Roger B.

Consultant, interim management, project manager; new development, new start-up; series support, process optimization;

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Neulußheim, Germany

Experience

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

Project manager, PMO department for new start-up and 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 different areas, interface management and reporting
  • Documentation of results
  • Relocation of series projects to sister plants for clients Porsche/ Bentley/ Audi, etc.
  • Coordination of required tasks and adjustment of all necessary processes
  • Creation of project plans, process flows and timelines for smooth implementation of the initiatives
  • 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 during SAP S/4HANA implementation:

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

External consultant for logistics process, central warehouse area

CplusM Consulting plus Management; IMA- Schelling Group Deutschland

Optimization of warehouse processes:

  • Identify process weaknesses in the new logistics center and initiate corrective measures (workflow analyses)
  • Analyze existing processes
  • Map/document processes (Visio)
  • Create new logistics concepts (Lean Manufacturing)
  • Involve employees in process flows including process guidance and training
  • Active shop floor management
  • Define storage areas, determine collective storage locations
  • Develop new logistics procedures in the central warehouse and infrastructure for departments
  • Install tow tractor system; create logistics stations in departments
  • Install scanning system for system booking
  • Create manual for automatic pallet storage system (APL Viastore)
  • Train employees on scanning station control system
  • Provide instruction and training at picking workstations
  • Connect small parts lift system to Viastore APL control system
  • Revise APL system feedback processes into the ERP system

Process support for the introduction of new ERP and warehouse software (AS400 to Infor and Viastore):

  • Implement new hardware/software with service technicians/programmers on site 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 disturbances
  • Identify and consolidate errors and potential faults
  • Work closely with internal IT and suppliers for ERP and warehouse software to develop solutions
  • Define planned corrective measures with timelines 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 in industrial area; project leader for plant closure (CZ), product relocation (DE / RO)

Roechling Precision Components

  • Take over all activities and coordination of the plant closure of the Czech plant (CZ)
  • Prepare current state analysis
  • Develop concept and optimization potential, project plan, resources for relocation projects as well as plant closure and decommissioning
  • Record costs and prepare project budget for plant closure and relocation projects
  • Create risk assessment and emergency plan
  • Prepare the Romanian plant for basic site qualification, process audits, process approvals, etc.
  • Handle building decommissioning and handover to owner
  • Relocate products in compliance with quality specifications from the Czech plant to the Romanian plant
  • Coordinate with customers, secure lead times according to customer requirements while meeting quality specifications (requirement management)
  • Transfer production lines with pre-planned optimization opportunities (KVP)
  • Regular reporting to management on status, deadlines, costs and timing (board meeting)
  • Plan and schedule resources to achieve lead time requirements with increased staffing needs
Nov 2019 - Mar 2020
5 months
Germany

Launch Manager, Project Kick-Off Rear Hatch Hinge BMW G21

Prinz-Kinematics

  • Consulting project management with a defined scope
  • Analysis of serial processes and control loops for optimization opportunities (KVP)
  • Accompanying and implementing agreed optimization measures (QVP, APQP)
  • Creating Q-Gate firewalls for quality inspection
  • Handling customer complaints internally and with the customer according to industry standard (8D report, customer portal)
  • Maintaining the relevant customer portals (B2B BMW)
  • Regular communication and management of customers/suppliers (international: China, England, Italy)
  • Accelerating fault analysis and corrective actions for complaints
  • Coordination of involved departments and suppliers
  • Monitoring delivery performance
  • Internal audits for process stabilization (IATF 16949)
  • Creating continuous output monitoring
  • Regular reporting to the executive management
  • Maintaining and further developing quality management systems
  • Adhering to the Product Development Process (PEP) as specified by the client
  • Reporting to the involved departments
  • Participation in K-FMEA and PFMEA
  • Monitoring change management (ECR)
  • Communication and knowledge exchange among all project team 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
  • Consulting 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
  • Acquiring 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
  • Implementing ISO 26262 for a new business division
Jan 2018 - Sep 2018
9 months

Project Manager/Project Leader for Plastic Extrusion Parts/Injection Molding Parts Multi-Component Exterior Parts for

SMIA

  • Managing 12 individual projects for a global OEM, producing roof trim strips for various vehicle types and variants by extrusion and insert-bending lines, painted in different colors and assembled on series finishing lines (BMW)
  • Managing two projects for a global luxury OEM (Rolls-Royce) for window frames and covers produced by 2K injection molding and painted, for windshield water management
  • Tasks include coordinating projects internally and with the customer regarding schedule, cost, and quality
  • Coordinating project teams
  • Coordinating requirements management, including aligning the specification, customer's requirement matrix, and creating requirement documents for implementation by technical departments 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 follow-up to achieve milestones
Mar 2017 - Dec 2017
10 months
Germany
Hybrid

Project Manager/Project Leader for AWC 3.6 kW Automotive Wireless Charging (Inductive Charging) of Passenger Cars for Company

Primove

  • Leading a project team of about 100 employees for an inductive charging system for a hybrid or electric vehicle via an onboard unit and a charging pad (floor plate) for a global company
  • Guiding the development project to achieve production readiness for the 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 objectives such as production line approvals; sampling of tools and equipment; quality releases (BMG, B-release, Note 3, Note 1); and relocations to production sites nationally and internationally
  • Coordinating product validation following the internal and external requirement catalog, and ensuring development compliance with ISO 26262 Functional Safety
  • Coordinating validation tests, ensuring test cases are followed as described internally and externally
  • Coordinating Industrial Engineering (Operations)
  • Creating prototypes
  • Documenting in DOORS, as well as monitoring according to Automotive SPICE processes
  • Reporting to internal management as well as to the OEM
  • Serving as the escalation level for the project team in case of deviations from the project plan, cost, or quality
  • Coordinating with the Technical Project Manager
  • Responsible for project budgets, schedules, and part quality, and reporting to management in regular meetings
Nov 2016 - Feb 2017
4 months
Germany

Project Manager/Project Leader, Automotive Industry, for Plastic Injection Molding Interior Decorative IMD Trim for

SMIA Automitive

  • Coordinating the project team for two VW projects and an additional project for a sealing valve
  • Internal coordination with various departments, as well as customer communication and on-site support
  • Achieving production readiness
  • Coordinating relocations, approvals, and sampling of tools nationally and internationally
  • Coordinating product validation internally and externally
  • Coordinating Industrial Engineering
  • Reporting to the OEM
  • Coordinating internal and external audits
  • Coordinating with the Technical Project Manager (Tooling Manager)
  • Responsible 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 / seat belts for various automakers

ITW

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

Launch management of door trims, interior panel trims for BMW X1, output monitoring, KPI, ZDF, production control

NBHX

  • Interface between logistics, quality, and assembly; contact person for customers and plant staff on questions about project handling 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, calculating target values in the department to achieve volumes, and securing ramp-up curves.
Jul 2014 - Sep 2014
3 months
Slovakia

Project management/support for Audi Q7 roof edge spoiler and Audi TT side skirt projects

Rehau

  • Independently overseeing and advancing the maturity level of the parts, including industrialization measures at the Györ plant (Hungary).
  • Participating in or 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, both internally and externally.
Feb 2014 - Jun 2015
1 year 5 months
Mumbai, India

Consultant activities

Bright Auto Plast PVT Ltd

  • Advising on process optimization in lean manufacturing (LEAN), quality improvement (QVP, KVP), and output increase (output monitoring).
  • Development/development consulting for new projects (PEP, requirement management) in the automotive industry (fuel tank/AdBlue tank).
Oct 2013 - Present
12 years 3 months
Norway

Consultant activities in industrial area

Easy Roller

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

Automotive Consultant, Project Management

Promens (today Berry/RPC Plastics)

  • Handle new customer projects for plastic products as Project Manager, following internal and external specifications with the customer.
  • Perform cost calculations and prepare proposals together with Sales.
  • Review or create requirement and specification sheets, and prepare purchase requests for purchased accessories to meet customer requirements.
  • Select suppliers and coordinate tool design and procurement.
  • Create and track schedules and project budgets.
  • Execute and independently coordinate projects according to internal decision gates.
  • Coordinate sample production and the creation of test reports.
  • Present products to customers and obtain approvals from both customers and suppliers.
  • Bring products to series maturity and then support them in production.
Oct 2012 - Present
13 years 3 months
Neulußheim, Germany

Owner, Freelance/Self-Employment

Boettcher Consulting

Consulting/ Project Management/ Product Development/ Interim Management

Oct 2012 - Feb 2014
1 year 5 months
Germany

Project Assignment: Product Development of Urea Tank for Trucks

Emitec

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

Project Manager in Product Development and Deputy Development Manager

Promens Hockenheim GmbH

  • Identify customer requirements and implement them in a rotation project.
  • Plan and manage projects, resources, and costs.
  • Ensure production readiness and continuous improvement in series production.
  • Review requirement documents and create specification sheets for suppliers.
  • Present the company to new customers.
  • Identify and implement development potentials.
  • Provide technical support to Sales for new project implementation.
  • Provide technical support to existing customers and their products.
  • Additionally responsible for the department as Deputy Department Head.
  • Immediate 100% entry into daily operations, as customers and systems were already known.
  • Acquisition of new projects with major customers (Daimler, Evo Bus, 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 Product Development, Quality Assurance, and Maintenance/Toolmaking departments.
  • Acquire new projects from existing customers.
  • Acquire new customers.
  • Present the company to new customers, at trade fairs and ARM events.
  • Prepare budgets and take responsibility for individual departments.
  • Negotiate prices and contracts for new projects.
  • Lead projects for received assignments.
  • Reduce costs/Process Optimization.
  • Develop a plastic pallet for aluminum rollers with a load capacity of 15 tons.
  • Develop and implement machine standards to reduce prices and boost competitiveness.
  • Optimize machine downtime, document repairs and their causes, and introduce preventive maintenance.
Apr 2002 - Oct 2008
6 years 7 months
Hockenheim, Germany

Project Leader in Product Development

Promens Hockenheim GmbH (formerly Bonar-Plastics)

  • Gathering customer requirements and translating them into rotational molding projects.
  • Planning and managing projects, resources and costs
  • Ensuring production readiness and continuous improvement in 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
  • Technical support for existing customers and their products
  • Providing technical support to the sales team on implementing new projects
  • Developing plastic fuel tanks for Daimler NCV3 ladder frame
  • Developing plastic fuel tanks for Volkswagen Caddy 4Motion Diesel
  • Prototype development for Volkswagen Passat CNG test vehicles
  • Various other product developments, such as a cooler box for Claas combines, air ducts for MAN
  • Managing various projects for sister plants in Denmark and Poland

Summary

Assignment in one or more projects / project leadership / subproject leadership / project management / product development / start-up management / industrialization / quality planning / advanced quality planning in the automotive and other industries according to qualifications, at 100% capacity.

  • Several years of experience in the automotive industry (since 1996)
  • Several years of experience in various quality assurance systems/methods/warehouse logistics, cut-over management, SCM/product launches, relocation of production lines, start-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 like MS Project, Office (Windows) in general, 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 Plastics/Rubber IHK · Master Craftsman Plastics/Rubber · 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 Plastics/Rubber (IHK)

IHK Würzburg-Schweinfurt

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