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 and cooperation partners for installation.
• Energy storage in large batteries (BESS) or in H₂ via electrolysis; local vehicle charging.
• Including necessary official procedures and applications; in particular building pre-approval requests.

Development lead for an LFP battery module including integration into three existing systems.

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

Typical tasks associated with the role:

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

Own development together with other freelance engineers.

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

Own development together with other freelance engineers.

• System development of an autonomous energy supply based on renewable energy.
• Use of renewable energy 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.

• Advising on RA/MDR/FDA-compliant revision of DHF for all affected products.
• Reviewing DHF documents including process improvements to maintain sterility of invasive products.
• Project lead and preparation of MDR + FDA audits.

Own development together with other freelance engineers.

• Concept development of a modular drive system for recreational boats using hydrogen as an energy carrier.

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

• Task-force lead as senior manager for an economical solution for a project with savings potential of €6 000/system @ 6 000 systems/a ≥ €36 M/a.
• Technical and operational overall management of EOL test bench development for X-ray systems.
• Risk management according to ISO 14971 at system and component level.
• Integration of 60 test systems into ongoing production lines.
• Leading interface communication with international internal departments and external suppliers.
• Building binding project planning and tracking milestones.
• Reporting at board level + representing project interests at international group meetings.
• Unifying various design concepts to reduce variants and costs.

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

• Quality improvements for cubing deadlines.
• Process optimization for handling pre-series parts.
• Planning 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 by DRÄGER® Safety AG, Lübeck.

• Original project assignment: relocation of a medical device production plant.
• Subtask: restructuring and process optimization during recommissioning.
• Parallel project: development of a PAPR (powered air-purifying respirator) in IP and EX variants.
• Overall project lead including TCQ responsibility.
• Taking over design responsibility including prototype manufacture (3D printing).
• Development coordinator and responsible project contact for the customer.
• Requirements analysis; compliance with norms (ISO 13485), directives and legislation; specification document definition.
• Risk management according to ISO 14971 throughout the development process.
• Defining & selecting all required components for EX protection and given regulations.
• Supplier management/responsible selection of project-specific injection molding, purchased parts and production equipment suppliers / defining supplier quality criteria.
• Evaluating supplier quality of received EMPB; defining corrective actions if needed.
• Organizing and evaluating D-/P-FMEA, FTA, safety and risk analyses.
• Tracking and reconciling open-item lists in regular meetings with the customer.
• Coordination with series supplier in plastic injection molding.
• Initiating and supporting series production (GMP) including monitoring & optimizing production processes.
• Capacity planning in coordination with the customer for 3 000–10 000 systems/year.
• Ensuring part and product traceability (serialization) and series manufacturing costs.

Interim management to develop an automotive-compliant battery solution.

• Varying roles between CTO, R&D lead and overall project lead in a pre-development for series development approval.
• Developing a company strategy based on the pre-development project (modular system).
• Developing a future product portfolio.
• Main responsible for the project and customer interface (C-level exchange).
• Managing requirements analysis; compliance with norms and legislation; specification document creation.
• Responsible for developing customer-specific battery concepts including IP69K housing, space analysis, total capacity, cell geometry, interconnection, connections (technologies), integration of temperature and power taps.
• Operational management of project purchasing and defining & selecting all required components.
• Responsible for cell analysis and test definition (BaSyTec devices + software).
• Coordinating FMEA, FTA, safety and risk analyses; testing functional safety per ISO 26262.
• Moderation and creation of design and process FMEA.
• Coordination of prototype assembly and checking 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 developing a platform solution for inductive charging of hybrid and electric cars (IPT):

• Aligning requirements with company capabilities.
• Creating a specification document and data reconciliation with interested parties/customers.
• Defining key parameters for a platform solution.
• Reviewing and defining system specifications and requirements.
• Coordinating development measures / concept and building prototype systems.
• Coordination meetings with customers at media conferences and in person.

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

• Analyzing requirements and aligning with internal implementation capabilities.
• Reviewing and defining new system specifications and requirements.
• Creating a specification document based on the above.
• Coordinating 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 timely and content updates by project leads.
• Maintaining the multi-project overview.
• Facilitating steering committee rounds.
• Recording meeting results.

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

• Concept creation for special machine solutions with subsequent development, design, production (contract awarding) and assembly (own work).
• 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 central research and pre-development 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.
• Gathering and processing relevant technical information for the overall project.
• Creating requirements and test specifications for e-drive components.
• Building necessary documentation and filing structure.
• Translating specification documents into English.
• Preparing and presenting work results.
• Moderating project meetings.

As project lead for (industrial) hybrid drives and electric machines, tasks include:

• Initial 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 (e-motor)
• Complete system design and development:
• Motor: custom design => radial-flux + single-tooth winding vs. axial-flux motor
• Inverter: design, definition and technology selection (e.g. MOSFET vs. IGBT)
• Control: standalone or integrated control => creating communication interface bridges if needed
• Energy storage: space analysis, total capacity, cell geometry, interconnection, connections (technologies), integration of temperature and power taps
• Project management / prototype development lead
• Defining project scopes with the customer and preparing offers based on them
• Sizing of custom prototype systems including components and supplier selection
• Time, resource and cost planning and control in the project
• Ensuring smooth project flow / resolving and removing obstacles
• Finding solutions for last-minute customer change requests
• Coordinating system tests on test benches / accompanying ISO tests
• Technical team leadership in hybrid and disc-rotor motor projects
• Cross-departmental overall development coordination (design, hardware & software development, system testing, procurement, manufacturing, sales, supplier management)
• Communication with suppliers and customers (customer-oriented project execution!)
• Quality management / project analysis (FMEA)
• Series development in consultation with the customer
• Weekly status meetings 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 car electric drive for delivery trucks (e-machine, gearbox adaptation, mechanical/electrical system integration).