Carsten Nicklaußen-Production and Process Consultant | Interim Manager
Check rate
Experience
Production and Process Consultant
Self-employed
- Ramp-up management: Stabilizing launches - whether a new product, a new production line, or a series ramp-up - until the processes run reliably
- Production management and process optimization: Improve lead times, inventories, and delivery reliability in a lasting way with value stream analysis and continuous improvement
- Solve process and quality issues at the root cause instead of fighting symptoms
- Anchor lean and shopfloor management in daily work with the leadership team
- Change management and stakeholder management: Guide leaders and teams through change and involve the surrounding environment
Head of Vehicle Completion / Finish Assembly
VW Commercial Vehicles
- Overall responsibility for chassis adjustment, engine start-up, and electrical and mechanical finish.
- Leadership responsibility for around 700 employees
- Significant reduction of vehicle inventory through process transparency, targeted staffing, and building an interdisciplinary team to solve complex E/E and software issues.
- Control of market-specific delivery priorities with short lead times and country-specific regulations.
- Definition of strategic guidelines for controlling and planning the organizational unit.
Project Manager End of Production
Volkswagen Commercial Vehicles
Took over project management at short notice after an unexpected absence. Stabilized ongoing operations within a few days and coordinated all trades along the vehicle production process during a major plant conversion. Ramp-up after the conversion phase on time and within budget. Led a project group (works council, women's representative, production areas) to develop flexible working time models for employees outside the newly paced assembly line.
Head of New Products / Pilot Hall
VW Commercial Vehicles
- Production responsibility for product changes and tooling optimization in body shop and assembly.
- Built and led interdisciplinary teams to resolve complex product-related issues during the ramp-up phase of new vehicle models.
- Successful production ramp-up of two models – from the testing phase to stable series production.
- Responsibility for budget and personnel planning of the pilot hall, including long-term competency and qualification needs.
Production Manager Water Radiators
VW Components Hannover
- Managed an internal component area with around 300 employees in production and logistics.
- Quality and on-time supply for all brands of the group.
- Budget responsibility in direct competition with external suppliers – cost, delivery reliability, and quality as competitive factors, not just group obligations.
- Established stable production and logistics processes to secure supply capability.
Head of Process Design
VW Nutzfahrzeuge
Coordination and delivery of process optimization workshops along the production line. Establishment and further development of lean principles in vehicle production, including work organization. Design and delivery of lean training for managers and production employees. Building structures for continuous improvement (CIP) and for the lasting anchoring of lean on the shopfloor.
Resident for VW Nutzfahrzeuge
VW Nutzfahrzeuge
Representing VW as supplier of painted body shells for the Porsche Panamera during ramp-up. Recording customer complaints, organizing defect feedback, and rework directly on site. Responsibility for communicating corrective actions and quality improvements to Porsche.
Specialist Advisor in Project Management Porsche Panamera for VW
VW Nutzfahrzeuge
- Worked in project management for the start-up of the body shell delivery for the Porsche Panamera.
- Coordination of schedules for plant setup and pre-series parts
- Interface between development, body shop, and customer.
- Alignment of technical changes, quality requirements, and process adjustments in the pre-series and ramp-up environment.
Production Body Shop
VW Nutzfahrzeuge
- Started at VW Hannover in the body shop through an internship and diploma thesis, then held several roles from specialist advisor to head of a production area.
- Responsibility for body shop processes, quality, and productivity in series production, as well as involvement in process improvements and production planning.
- As deputy department head and later head of a production area in the body shop, built up and controlled lines during the ramp-up of the VW Multivan/Transporter T5.
- Led teams in shift work, worked closely with project management, maintenance, and quality assurance, and implemented measures to stabilize cycle times and defect rates.
- This gave me an early combination of shopfloor leadership, process optimization, and launch management.
Industry Experience
See where this freelancer has spent most of their professional time.
Experienced in Automotive and Manufacturing.
Business Area Experience
See which departments and functions this freelancer has contributed to most.
Experienced in Production, Project Management, Operations, Quality Assurance, Product Development, and Logistics.
Summary
When a launch does not run smoothly or an existing production gets out of hand, you need someone who knows the shop floor from the inside and gets hands-on.
I spent 30 years in series production at an international automotive group, most recently with responsibility for up to 700 employees. I led production launches from testing to stable series production, took over critical situations as an interim project manager after short-notice failures and stabilized them within days, and was responsible for a component production area in direct competition with external suppliers. I know both sides: the cost pressure from management and the reality on the line.
My focus areas:
Ramp-up management: Stabilizing launches — whether a new product, a new production line, or a series ramp-up — until the processes run reliably
Production management and process optimization: Improve lead times, inventories, and delivery reliability in a lasting way with value stream analysis and continuous improvement
Solve process and quality issues at the root cause instead of fighting symptoms
Anchor lean and shopfloor management in daily work with the leadership team
Change management and stakeholder management: Guide leaders and teams through change and involve the surrounding environment
I work directly on site, as a consultant for individual projects or as an interim manager who takes responsibility until the new processes and structures run reliably.
Methods: Lean management · Value stream analysis · Continuous improvement · 5S · Shopfloor management · Ramp-up management · Process optimization · Change management · Stakeholder management
Skills
Many Years Of Leadership Experience
Decision-Making Responsibility In Production
Budget Responsibility In A Challenging Environment
Ai Tools (Generative Ai, Analysis And Research Tools)
Data Analysis And Structured Evaluation
Process Optimization And Lean Management
Identifying Innovation And Digitalization Potential
Microsoft Office (Powerpoint, Word, Excel, Teams)
Image And Video Editing
Structured And Solution-Oriented Way Of Working
Preparing Complex Content For Different Target Groups
Strong Communication Skills And Confident Stakeholder Management
Concepting And Running Workshops, Training Sessions, And Networking Formats
High Personal Initiative, Strong Organization Skills, And Focus On Results
Languages
Education
University of Bremen
Diploma Engineer · Production Engineering · Bremen, Germany
Statistics
Experience
Global Experience
Expertise
Qualifications
Profile
Frequently asked questions
Have questions? Find more information here.
Average rates for similar positions
Rates are based on recent contracts and do not include FRATCH margin.
Similar Freelancers
Discover other experts with similar qualifications and experience
Roland Hovestadt
Andreas Kälber
Stefan Schotte
Philip Scott
Volker Schreiner
Klaus-dieter Bleuel
Franz Hornung
Robert Lebherz
Jörn Baumann
Stefan Hans
Experts recently working on similar projects
Freelancers with hands-on experience in comparable project as a Production and Process Consultant
Volker Schreiner
Philip Scott
Stefan Schotte
Jörn Baumann
Andreas Kälber
Andreas Kückelmann
Roland Hovestadt
Thomas Lüftl
Paul Weißhaar
Thomas Meyer-Dethlefs
Nearby freelancers
Professionals working in or nearby Hanover, Germany
Sandra Klinkenberg
Enrique Carrillo
Markus Peters
Houssem Ben Zid
Olfa Azzabi
Lisa Rodenberg
Mubashar Ali
Willi Ziegenhagel
Bastian Vasterling
Dennis Schuchardt
Most recent projects
FRATCH works with many companies and recruitment agencies. Here you will find our recently posted projects and opportunities.
