Roger B.
Consultant, interim management, project manager; new development, new start-up; series support, process optimization;
Experience
Mar 2023 - Dec 2024
1 year 10 monthsBacknang, 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 monthsInterim 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 monthsExternal 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 monthsGermany
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 monthsGermany
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 monthsGermany
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 monthsGermany
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 monthsProject 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 monthsGermany
HybridProject 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 monthsGermany
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 yearGermany
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 monthsGermany
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 monthsSlovakia
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 monthsMumbai, 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 monthsNorway
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 monthsGermany
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 monthsNeulußheim, Germany
Owner, Freelance/Self-Employment
Boettcher Consulting
Consulting/ Project Management/ Product Development/ Interim Management
Oct 2012 - Feb 2014
1 year 5 monthsGermany
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 monthsHockenheim, 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 monthsPietermaritzburg, 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 monthsHockenheim, 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
NativeEnglish
AdvancedEducation
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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