Process Optimization

Project planning of an agrivoltaic system on 1 ha of farmland with 2.2 MW capacity.

• Concept and planning of an agrivoltaic system / creation of a business plan for full financing.
• Selection and procurement of components as well as cooperation partners for installation.
• Energy storage in large batteries (BESS) or in H₂ via electrolysis; local vehicle charging.
• Including necessary formalities and applications; especially building permit inquiries.

Development management of an LFP battery module including integration into three existing systems.

• Technical management and overall responsibility for TCQ + development/production process + planning.
• Battery module development including cell geometry (pouch + cylindrical), interconnection, bonding, integration of temperature and power taps.
• Support in drafting contractual documents (LOI, pre-development, series delivery).
• Technical primary contact with the supplier from East Asia.
• Execution of ongoing documentation and communication of project progress.

Typical tasks associated with the role:

• Steering project activities including interest management / stakeholder communication.
• Management of internal and external areas (cell technology + electrical + firmware development).
• Coordination of battery-related requirements of the system architecture with suppliers and internal departments.
• Consideration of module use in large battery storage / BESS.

Independent development in collaboration with other freelance engineers.

• System development of an autonomous power supply based on renewable energies & ESS.
• Direct use of generated energy and surplus storage in LFP-based storage.
• Own battery module development considering all cell geometries, interconnection, bonding, integration of temperature and power taps as well as usage analysis.
• Goal: Enable 100% self-sufficiency for single and multi-family homes.

Independent development in collaboration with other freelance engineers.

• System development of an autonomous power supply based on renewable energies.
• Use of renewable energies for hydrogen production and storage.
• Use of stored hydrogen for heat and electricity.
• Goal: Enable 100% self-sufficiency for single and multi-family homes.

Interim consultant for product files for RA/MDR / FDA compliant revision of ophthalmic DHF for re-certification. Interim consultant product files / DHF according to RA/MDR/FDA in ophthalmology.

• Advice on RA/MDR/FDA compliant revision of DHF for all affected products.
• Review of DHF documents including development of process improvements to maintain sterility of invasively used products.
• Project management and preparation of MDR + FDA audits.

Independent development in collaboration with other freelance engineers.

• Concept development of a modular propulsion system for pleasure boats using hydrogen as energy carrier.

Interim senior management for a global test system for X-ray system components.

• Task force lead as senior manager to develop a cost-effective solution for a project with savings potential of €6,000/system @6,000 systems/year ≥ €36 M/year.
• Technical and operational overall management of the development of an EOL test bench for X-ray systems.
• Risk management according to ISO 14971 at system and component level.
• Integration of 60 test systems into ongoing productions.
• Leading interface communication with international internal departments and external suppliers.
• Establishment of binding project planning and milestone tracking.
• Reporting to board level + representation of project interests at international corporate meetings.
• Consolidation of various design concepts for variant and cost reduction.

Freelance consulting on launch management / series ramp-up of bumper production.

• Quality improvement regarding cubing deadlines.
• Process optimization for handling pre-series parts.
• Planning of final series production including parts supply and call-off system integration.

Interim program manager for product development of the blower filter device X-plore 8500 and 8700 of DRÄGER® Safety AG, Lübeck.

• Original project assignment: relocation of a medical technology production facility.
• Sub-task: restructuring and process optimization during recommissioning.
• Parallel project: development of a PAPR (powered air-purifying respirator) in IP and EX variant.
• Overall project management including TCQ responsibility.
• Taking over design responsibility including prototype manufacturing (3D printing).
• Development coordinator and project contact for the customer.
• Requirements specification analysis; alignment with standards (ISO 13485), directives and legislation; definition of functional specifications.
• Risk management according to ISO 14971 throughout the development process.
• Definition & selection of all required components regarding EX protection and applicable standards.
• Supplier management / responsible selection of project-specific injection molding, purchased parts and production equipment suppliers / definition of supplier quality criteria.
• Evaluation of delivery quality of received EMPB; if necessary, definition of corrective actions.
• Organizing and evaluating D-/P-FMEA, FTA, safety and risk analyses.
• Tracking and alignment of OPL (open item lists) at regular meetings with the customer.
• Coordination with the series supplier in plastic injection molding.
• Start and support of series production (GMP) including production process monitoring & optimization.
• Capacity planning in coordination with the customer for quantities of 3–10,000 systems/year.
• Ensuring part and product traceability (serialization) and series manufacturing costs.

Interim management for the development of an automotive-compliant battery solution.

• Alternating roles between CTO, R&D lead and overall project management within a pre-development to series development release.
• Development of a corporate strategy based on the pre-development project (modular system).
• Development of a future product portfolio.
• Main responsible for the project and interface for the customer (C-level exchange).
• Management of requirements specification analysis; alignment with standards and legislation; creation of functional specifications.
• Responsible for developing customer-specific battery concepts including IP69K housing, packaging analysis, total capacity, cell geometry, interconnection, bonding (technologies), integration of temperature and power taps.
• Operational management of project procurement as well as definition & selection of all required components.
• Responsibility for battery cell analysis and test definition (BaSyTec devices + software).
• Coordination of FMEA, FTA, safety and risk analyses; reviewing FuSi according to ISO 26262.
• Moderation and creation of design and process FMEA.
• Coordination of prototype assembly and review of manufacturing processes for up to 1,000 systems/year.
• Co-development of the Streetscooter battery based on BMW i3 batteries (prismatic SDI cells).

Interim project management for development of a platform solution for inductive charging of hybrid and electric passenger cars (IPT):

• Alignment of requirements specification with company's implementable options.
• Creation of functional specification and data alignment with prospects/customers.
• Definition of key parameters for a platform solution.
• Reviewing and defining system specifications and requirements.
• Coordination of development measures / conceptualization and construction of prototype systems.
• Alignment discussions with customers in media conferences and personal meetings.

Freelance project management for further development of an existing conductor rail system considering changed market and customer requirements (project manager for enclosed conductor rails):

• Analysis of requirements specification and alignment with internal implementation options.
• Reviewing and defining the new system specification and requirements.
• Creation of functional specification on the above basis.
• Coordination of design in close collaboration with product management.

Freelance support in building an internal multi-project management process for implementing a new project management process (multi-project coordinator for development projects):

• Preliminary work for decision-making by development management.
• Monitoring deadlines and content update obligations of project managers.
• Maintaining the multi-project overview.
• Moderation of steering and governance rounds.
• Documenting meeting results.

Customer-specific development including small series production in special machine engineering:

• Concept development of special machine solutions followed by development, design, manufacturing (contract award) and assembly (own performance).
• Development and assembly of a modular work system for an autonomous robot.
• Delivery of prototypes and an initial small series (10 pcs.).

Technical support in the central research and pre-development department for hybrid drives and electric drive technology for off-road vehicles (Dept. TEM-EP):

• System specification and requirements definition of e-drives.
• Managing interfaces to mechanics, electronics and control units.
• Collection and processing of relevant technical information in the overall project.
• Creation of requirements and test specifications for e-drive components.
• Creation of necessary document and filing structure.
• Translation of specification documents into English.
• Creation and presentation of deliverables.
• Moderation of project meetings.

As project manager for (industrial) hybrid drives and electric machines, activities can be summarized as follows:

• First point of contact for prospects regarding hybrid systems and axial flux disc rotor motors
• New customer acquisition
• Product presentations and technical lectures at trade fairs and conferences
• Prototype development from concept to finished prototype (hybrid), or series (electric motor)
• Overall system design and development:
• Motor: customer-specific design => radial flux + single-tooth winding vs. axial flux motor
• Inverter: design, definition and selection of technology (e.g. MOSFET vs. IGBT)
• Control: autonomous or integrated control => if necessary, creation of communication interface bridges
• Energy storage: packaging analysis, total capacity, cell geometry, interconnection, bonding (technologies), integration of temperature and power taps
• Project management / prototype development lead
• Definition of project scopes with the customer and corresponding quotation
• Design of individual prototype systems including component and supplier selection
• Time, resource and cost planning and control in the project
• Ensuring smooth project flow / resolving obstacles
• Finding solutions for last-minute customer change requests
• Coordinating system tests on test benches / accompaniment of ISO tests
• Technical staff leadership in hybrid and disc rotor motor projects
• Cross-departmental overall development coordination (design, hardware and software development, system test, procurement, logistics, sales, supplier management)
• Communication with suppliers and the customer (customer-oriented project flow!)
• Quality management / project analysis (FMEA)
• Series development in agreement with the customer
• Weekly status meeting with management.

Design and construction of an energy hybrid system based on CHP, water, PV and wind for a multi-family house.

Development of a passenger car electric drive for delivery trucks (electric machine, gearbox adaptation, mechanical/electrical system integration).