Andreas Kälber-Project Manager
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Experience
Project Manager
Winkelmann Building+Industry / Reflex Winkelmann
- As part of a greenfield project in Slovakia, overseeing the construction of a new production plant that manufactures industrial media storage for OEMs and distributors after completion.
- Procurement and industrialization of production equipment for the prefabrication stage.
- Design, procurement, installation and integration of full production lines based on stamping, forming and welding technologies with labor-reducing, integrated processes.
- Setting up a production environment under strategic aspects using the latest state-of-the-art technologies.
- Overall and ongoing communication with the entire greenfield team, adjacent departments, plant management and executive management.
- Developing concepts together with key suppliers and identifying ratio potentials along the production process chains using value stream analyses.
- Gathering, evaluating and applying process data such as lead times, production times, setup times, waiting and idle times using time and multimoment studies and surveys.
- Forward-looking design of production systems and processes with the goal of implementing automated and competitive process solutions within a comprehensive supply chain management approach.
- Planning production workflows, defining manufacturing methods, designing the overall layout and workstations.
- Determining and recording process cost rates, allocation rates, cost evaluation of production processes, machine hourly rates, depreciation and expected share of warranty and rework costs to optimize production costs.
- Ongoing optimization of product designs for their adaptation to automation-focused production environments up to the plant's SOP.
- Multi-project management for engineering, design, procurement, installation and process integration of all relevant trades regarding plant technology, lifting equipment, production equipment and quality management setups.
- Continuous establishment of an overall concept in terms of design, plant technology, logistics, IT and quality management.
Project Manager
Infineon Technologies
- Management of a project to transfer multiple end-product production steps and related equipment from one production site to another.
- Conducting key product qualifications rolled out to the total relocation volume.
- Coordinating and agreeing on milestone decisions with approval committees, as well as planning and evaluating work packages, deliverables, timelines, resources, risks and risk mitigations.
- Communicating project plans, reports, milestone documents and release packages.
- Project planning and resource acquisition in line with business processes and identifying critical tasks to meet objectives.
- Coordinating required change management processes with product divisions and sites.
- Managing production launches at international, mainly Asian, production sites and, if necessary, at subcontractors.
- Final handover of equipment and its optimizations to production sites, including documentation.
- Collaborating with stakeholders and project team members from various disciplines such as technical experts, site staff, production planners, logistics, finance and project owners.
- Regularly informing all project participants, the project leadership team and the steering committee, including escalation management.
Interim Project Manager
Aumund Group
- Handling plant technology for the construction and dismantling of bulk material storage and blending beds for the bulk material industry, especially coal storage yards.
- Central coordination of customers and suppliers in an international setting as the main contact for the global project landscape.
- Responsible for cost, profit and contract controlling as well as claim and change management.
- Leading the project team and ensuring milestone achievement.
- Organizing and moderating meetings with EPC service providers, engineering firms and key suppliers in Asia.
- Conducting time zone-based video conferences with global escalation authority.
- Independently managing orders on time, within budget and meeting quality standards.
- Acting as the active link between customers and suppliers and internally coordinating responsible team members.
- Improving the communication structure and increasing transparency through straightforward management and adherence to deadlines.
Interim Manager SMT
Carl Zeiss
- Leading a focus team in the SMT (Semiconductor Manufacturing Technology) business unit for semiconductor technology and mirror optics following a quality incident.
- Managing an 8D process and leading a team to implement measures from the analysis results.
- Project management in the machine loading and Unimount modules (mirror loading unit for lithography mirrors).
- Overcoming challenges in micro-scale mass movements.
- Preparing content for weekly steering committees and presenting decision-ready issues.
- Initiating escalations, discussing content and implementing resulting decisions.
- Facilitating and coordinating weekly module- and topic-based web meetings.
- Tracking tasks and implementations in the long term.
- Establishing a roadmap thread, sharpening strategic goals and boosting team motivation through transparency and open communication.
Program Manager / Overall Project Manager
NTN Antriebstechnik
- Global orientation and coordination of project management for production plants including customers Daimler and AMG.
- Main contact for the customer and globally responsible for cost, profit, contract controlling and change management.
- Leading the program team (quality, sales, engineering) and project teams in Europe, USA and China.
- Supporting, guiding and coaching plant project managers to improve management.
- Internal planning, alignment, support and standardization of interface communication between central engineering and production plants.
- Responsible for achieving milestones and individual quality gates.
- Organizing business unit meetings and program steering committees with escalation authority to automotive management in Japan and the EU business unit in France.
- Moderating conference calls, coordinating and tracking tasks and providing in-depth training to participants.
- Managing Engineering Change Requests (ECR) in collaboration with sales and plants.
- Handling technical and commercial discussions with Daimler to close gaps toward nomination status.
- Accompanying process audits according to VDA 6.3 by Daimler and AMG in various production plants.
- Successfully completing process audits and integrating the implementation concept into standards.
- Achieving significant increases in transparency, on-time delivery and open communication with the customer Daimler.
Project Manager
IWM Automation
Planning and execution of complete, fully automated production and assembly systems for automotive OEMs.
Leading various projects and subprojects, particularly for Volkswagen.
Directing and coordinating project team members and engaging key suppliers.
Conducting commercial and technical negotiations and finalizing contracts.
Performing result-oriented analysis and structuring of existing project information.
Managing ongoing and new projects, including action planning, change management, and claim management.
Ensuring deadlines and project budgets with clear reporting.
Applying extensive experience in quality, supplier, and project management, as well as in commissioning robot-assisted assembly systems.
Strict adherence to agreements and milestone dates after initial delays.
Significantly easing tensions with the Volkswagen customer through transparency and straightforward management.
Achieving a positively noticeable change in overall business.
Interim Head of Order Center
Isringhausen
Interim management of the order center during a pre-series phase up to the series launch of seating systems for trucks, vans, and buses.
Planning production schedules for individual seats, suspension seats, driver and passenger seats, and rear seat modules.
Supporting and overseeing the sourcing of special parts for pre-series production.
Managing requirements via a FileMaker database due to ongoing SAP integration work.
Conducting technical alignments with sales, QA, prototyping, and lab for sourcing specific components.
Integrating pre-series requirements into the ramp-up series production program and distributing capacity.
Generating corrective actions through daily fine-tuning and reporting from picking, production, and shipping.
Leading daily status meetings and production rounds to coordinate the day's tasks.
Providing intensive training and support to the series team for task takeover.
Smooth coverage of requirements and efficient resource planning by implementing custom-built tools.
Establishing transparent daily reporting for finer alignment between customer and internal departments.
Project Manager and Site Manager
Actemium
- Interim project and site management for installing production equipment for aircraft fuselages at Airbus.
- Handling the 'Lands & Building' subproject within a major project.
- Central contact person for customers, suppliers, and project managers at the German site.
- Planning, organizing, monitoring, and controlling the site, as well as coordinating all processes and trades.
- Setting and managing schedules and organizing acceptance processes.
- Taking financial responsibility for site operations and leading claim management.
- Instructing contractors on safety and health protection guidelines.
- Initiating HSE processes and conducting risk assessments.
- Carrying out site scheduling, interim storage planning, progress reporting, and customer staff training.
- Managing subcontractors in mechanical engineering, robotics, control systems, and steel and concrete construction.
Project and Program Management
Yanfeng Europe
Project and program management for interior commodities such as doors, instrument panels, and center consoles.
Designing and preparing proposals for the Daimler S-Class BR223 in multiple loops according to the tender.
Technical and operational leadership of commodity teams through the offer loops.
Creating offer documentation while considering target goals and customer requests.
Holding daily Scrum meetings for team management and content adjustments.
Coordinating international activities across different plant locations.
Presenting and explaining loops to the customer, including preparing presentation materials.
Reducing production costs to meet target goals.
Delivering concept and proposal documentation on time.
Project Manager for Industrializations and Process Relocations
Heraeus Deutschland
- Managing the industrialization and relocation of around 500 products to optimize costs and capacity.
- Developing structural analyses as decision-making foundations for process relocations.
- Ensuring manufacturing and quality processes and conducting process approvals and ramp-ups.
- Reviewing and expanding complete process and procedure documentation.
- Involving relevant departments in workshops and regular meetings as responsible party.
- Planning conceptual solutions for conflicts between process equipment and relocation phases.
- Applying detailed knowledge in stamping, rolling, tooling, and plating technologies.
Interim Head of Project Management / Project Lead VW Touran
Boryszew Group
- Functional and disciplinary management of 15 project managers at the Gardelegen site.
- Supervision of day-to-day project execution in an escalation-prone environment.
- Conducting daily and weekly reviews to fine-tune projects in the pre-series stage.
- Ensuring the ramp-up and scale-up of the VW Touran for exterior and interior assemblies.
- Representing and approving build status generations in cubing at the customer's site.
- Creating special teams for invoicing orders according to customer specifications.
- Conducting training sessions for deeper integration of project managers into process structures (PEP, PPAP).
- Monitoring milestone content to ensure smooth processes.
Project Manager
Denso
Design, planning, and execution of retrofit, service, and maintenance projects for production and press systems for water coolers.
Selection and management of system suppliers based on specification requirements.
Organizing kick-off and regular meetings to support internal production.
Managing modernization projects in terms of budgeting and scheduling.
Claim management including calculation of change order documentation.
Spare parts management and developing solutions for unforeseen maintenance requirements.
Site management at the production facility including staff briefing.
Coordinating materials for start-ups and conducting machine capability studies.
Creating initial samples, eliminating residual defects, and handing over to full production readiness.
Implementing concepts on time and within budget.
Production increase between 5% and 20% and reduction of follow-up costs by around 30%.
Interim Manager
Broetje-Automation
Support and leadership in an escalation situation within a turnkey large-scale project for aviation production systems.
Developing a planning system with defined structures and an interface matrix.
Introducing tools for operational reviews to align overall and subproject plans.
Enabling cross-functional planning and feedback into project teams together with the customer.
Successful training of all team members and ensuring the sustainability of the implemented planning system.
Project Manager
TI Automotive
- Leading various upgrade and expansion projects for production line conversions to new product series.
- Preparing technical documents (drafting, costing) and developing concepts.
- Guiding project team members and coordinating key suppliers.
- Conducting technical negotiations and finalizing contracts.
- Analyzing existing production structures for result-oriented reorganization.
- Facilitating FMEAs in group workshops to derive specification content.
- Overseeing installations, start-ups, and process approvals, and obtaining customer sign-offs.
- Coordinated adjustment of already installed processes in collaboration with department heads.
- Implementing production optimizations and setting up new assembly and testing equipment.
- Managing projects in the field of plastic welding machines during continuous 3-shift operation.
Project Manager
Denso
Design and execution of retrofit and maintenance projects for water cooler production systems.
Managing system suppliers and coordinating based on specification requirements.
Monitoring specifications, budgets, and schedules.
Claim management and preparation of change order documentation.
Site management at the production facility including briefing up to 13 employees.
Coordinating materials for start-ups and machine capability studies.
Conducting start-ups and preparing internal acceptance reports.
Increased production by between 7% and 25%.
Reduced follow-up costs by over 30%.
Project Manager
Johnson Controls
Expanded production capacity for car and commercial vehicle batteries to meet volume increases.
Extended relevant production areas and built new buildings in multi-year phases.
Adjusted utility supply of the production plant while running operations (350 days/year, 3 shifts).
Developed concepts and prepared technical documentation with a total budget of about 15 million euros.
Procured fully automated packaging machines, testing equipment, and production lines.
Led technical negotiations and finalized supplier contracts.
Supported installations, commissioning, and secured customer approvals.
Coordinated and implemented process changes through workshops and regular meetings.
Improved productivity and efficiency in ramping up new areas by over 45% compared to the start period.
Lead Project Manager
BRÖTJE Automation
- Planned complete manufacturing facilities for a Russian aircraft consortium within a budgeted planning phase.
- Held planning responsibility for about 185 million euros.
- Converted design and material specifications into budget proposals.
- Fully planned and documented processes for producing parts and assembling commercial aircraft to European/US standards.
- Coordinated and led all meetings with design offices and suppliers.
- Presented concept details and prepared cost estimates and proposals.
Project Manager / Project Controller
Voith Industrial Services Ermo
- Managed project controlling and supported overall project management in building the new 'Poly 8' polysilicon production plant at Wacker Chemie AG.
- Responsible for meeting the budget (about 12 million euros) and strict timelines.
- Recorded actual costs and revenues and continuously tracked the project's expenses.
- Consolidated costs related to subcontractors for major trades and subprojects.
- Checked, reconciled, and verified all quotes against the actual costs incurred.
- Coordinated between trades on a cost level, including analysis and reporting.
Project Manager / Sales and Procurement Engineer
Zeppelin Silos & Systems Friedrichshafen
Led the relocation of a plastics plant and planned and designed operational facilities.
Designed and cost-calculated production equipment based on P&IDs, PFDs, and customer documentation.
Procured, accepted, and commissioned plant components.
Selected and managed system suppliers and coordinated based on specification requirements.
Prepared procurement cost calculations using value analyses and comparison results.
Developed problem-solving solutions for pneumatic conveying systems.
Managed supply chain and claims, including preparing change order proposals.
Brought project budgets (about 30 million euros) in under budget by around 14%.
Ensured reliable execution conditions despite ongoing customer changes.
Project Manager / Sales Engineer
Heilbronn Maschinenbau
- Led projects for custom-designed high-tonnage press systems to manufacture customer-specific stamped parts.
- Considered orders, requirement specifications, and technical drawings.
- Selected, defined, and managed system suppliers.
- Awarded contracts based on specification requirements, using value analysis insights.
- Held budget responsibility for a total of about 4 million euros.
- Organized and led kick-off meetings.
Production Manager / Sales Manager
Rayer Group
- Managed production of automotive series parts according to ISO/TS 16949.
- Created and delivered assembly units for body attachments just in time.
- Production instructions for stamped and formed parts from steel and aluminum sheets.
- Developed process flows and rationalization solutions based on value and cost analyses.
- Managed claims for process changes and prepared additional offers.
- Quality management including staff training, creating work instructions, and using PDCA and Lesson Learned Cards (LLC).
- Defined measuring techniques and strategies and monitored their implementation in Q-DAS.
- Organized in-house logistics and customer deliveries according to ISO/TS standards.
Head of Sales, Project Manager, Purchasing, Service
Modine
Planning, design, and calculation of press systems for oil coolers to make cooler fins.
Detailed project definition, organization, and budgeting (approx. EUR 3 million).
Managed system suppliers through specification guidelines and bid calculations.
Claim management and preparation of additional offers.
Supported and optimized production, and developed problem solutions for assembly structures.
Site management at the production site, including staff training.
Coordination of materials for commissioning, first sample production, and machine capability tests.
Conducted final acceptance and handed over the operational-ready unit to the customer.
Presented a sound concept already in the sales phase.
Increased production output by around 48%.
Head of Sales, Project Manager, Purchasing, Service
Volkswagen
Planning, design, engineering, and calculation of press systems for water coolers.
Selection and management of system suppliers and budgeting (approx. EUR 5 million).
Developed solutions for plant technology to process aluminum and steel stamped sheets.
Site management at the production site in Hannover/Wolfsburg, including staff orientation.
Performed commissioning, final acceptance, and first sample production.
Complete, on-time execution within budget.
Concept-driven increase in production output by over 50%.
Head of Sales, Project Manager, Purchasing, Service
Volkswagen
Planning and calculation of cooler assembly lines for fully automatic production of ready-to-install passenger car radiators.
Managing system suppliers based on specifications and budgeting (approx. EUR 7 million).
Organizing pre-acceptance, defect correction, and shipping acceptance.
Calculated personnel resources and planned their deployment.
Conducted commissioning and handed over the operational-ready unit.
On-time transition to a lean, fully automatic radiator production.
Head of Sales, Project Manager, Purchasing, Service
Denso
Engineering and calculation of press systems for water coolers to produce cooler fins.
Budget responsibility for approx. EUR 11 million.
Managed system suppliers and coordinated according to specifications.
Site management at international production sites, including staff briefing.
Conducted machine capability tests and first sample production.
On-time and within budget concept implementation.
Increased production by around 44%.
Head of Sales, Project Manager, Purchasing, Service
Modine
Planning and costing of press systems for water coolers.
Budgeting and managing system suppliers.
Troubleshooting frame designs for processing aluminum and steel sheets.
Performing commissioning and handing over of ready-to-operate systems.
Successful execution of projects within a budget of around 2 million euros.
Owner / Interim Manager
Ingenieurbüro / Interim Management
- Managing an engineering office to acquire, plan, execute, deliver, and support custom production facilities.
- Activities as a freelancer and interim manager in sales management, project management, supplier management, project engineering, and production management.
- Specializing in process development, process cost management, change management, and supply chain management.
- Planning, designing, and costing of production automation systems and machine tools.
- Conducting supplier audits, metrology, quality inspection, and failure analysis.
- Cross-industry experience, especially in machinery and plant engineering, automotive, and aerospace.
- Personnel and disciplinary responsibility for up to 200 employees in leadership positions.
- Application of standards such as VDA 6.3, IATF 16949:2016, and DIN EN ISO 9001:2015.
- Proficiency with tools such as MS Project, SAP/R3, AutoCAD, and CoCreate OneSpace Designer.
Design and Sales Engineer
RWM Raster-Werkzeugmaschinen
- Working as a design and sales engineer.
- Focusing on design and sales of machine tools.
Industry Experience
See where this freelancer has spent most of their professional time.
Experienced in Manufacturing, Automotive, Aerospace and Defense, and Chemical.
Business Area Experience
See which departments and functions this freelancer has contributed to most.
Experienced in Production, Project Management, Supply Chain Management, Procurement, Operations, and Sales.
Summary
With many years of project experience, a proven specialist with a hands-on mentality and experience in international settings (OEM, Tier-1, Tier-2). Strong communication and solution orientation with team and leadership skills. Thinking in terms of the "whole package", pragmatic and consistent in execution. Structured approach even in situations that demand solid personal maturity. Drawing on extensive experience including sales and commercial know-how. Skilled in planning, project engineering, sales, implementation, quality assurance, project design, approval, delivery, and long-term support for turnkey production plants and production systems. Also offers competence and experience in startups, process optimization, remediation, consolidation, and restructuring.
Skills
- Project And Program Management
- Supply Chain Management
- Process Development And Process Costing
- Change Management
- Quality Management
- Reorganization
- Restructuring
- Commodities
- Sales Management
- Claim Management
- Procurement And Purchasing
- Supplier Management
- Production Management
- Process Engineering
- Service Management
- Planning, Design, Takt Time Calculation, Engineering And Costing Of Production Automation Systems And Machine Tools With Integrated Production Automation
- Project Execution, Layout Design, Engineering, Planning, Coordination, Controlling, Reporting, Scheduling And Tracking
- Supplier Audits
- Measurement Technology, Quality Inspection And Quality Improvement
- Error Analysis And Troubleshooting
- Initial Sampling
- Requirements And Specification Sheets
- Software Applications, Development, Design, Testing
- Mechanical Engineering
- Plant Engineering
- Stamping And Forming Technology
- Stamping Tools
- Maintenance And Servicing
- Machine Tools
- Automotive
- Automation And Plant Engineering
- Gear Technology
- Plastic Machines And Plastic Technology
- Quality In Production And Processes
- Aerospace
- Precious Metals, Electroplating
- Chemical Plants
- Medical And Pharmaceutical Sector
- Consumer Products
- Cooling Technology
- Thin Strip And Aluminum Processing
- Personnel And Disciplinary Responsibility For Up To 200 Employees In Leadership Positions
- Vda 6.4, Vda 6.3, Process Audit 2016
- Qm Iatf 16949:2016
- Fmea Harmonization Vda / Aiag
- Din En Iso 9001:2015
- Din En Iso 13485:2016
- Machinery Directive 2006/42/ec, Ce Conformity
- Gmp
- Extensive Experience With Computer Hardware And Software And Their Setup In Networks Or Network Domains
- Proficiency In All Common Software Applications In Office, Cad, Image Editing, Document Management, Bus Systems
- Microsoft Office, Project, Visio, Publisher, Sharepoint, Web Office 365, Lotus Notes, Coreldraw
- Mathcad
- Cad/cae: Visi, Cocreate Onespace Designer (Me10), Autocad, Skills In Solidworks, Catia
- Plc Tools: Siemens Step
- Bus Systems: Ets For Eib
- Operating Systems / Lan: Ms Windows, Linux
- Plm/erp: Sap/r3, Unipps, Ams, Asseco, Abas, Proalpha, Microsoft Dynamics, Sage, Pro.file
- Databases: Openaccess 4, Ms-access, Dbase, Sql-based Databases
- Hgb, Financial Statements
- Six Sigma, Iso, Ts, Din
- Fmea, Pps
- Consignment, Kanban, Logistics Systems, Jit/jis
- Organization And Setup Of Trade Shows And Company Presentations
- Handling Of Circuit Documentation Of Machinery
- Systematic Isolation And Resolution Of Electrical Or Electronic Issues During Commissioning
- Cocreate Onespace Designer Me10
- Autocad Lt
- Mathcad
- Microsoft Office, Project, Visio, Publisher, Coreldraw
- Ets For Eib
- Openaccess 4 And Other Proprietary Tools
Languages
Education
Berufsakademie Karlsruhe
Diploma Engineer (BA) in Mechanical Engineering, specialization in Design · Mechanical Engineering, focus on Design · Karlsruhe, Germany
Technisches Gymnasium Pforzheim
Technical high school diploma · Pforzheim, Germany
Certifications & licenses
REFA basic certificate
Statistics
Experience
Global Experience
Expertise
Qualifications
Profile
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