Eugen Pilarski-Interim Project Manager / Program Management / Operational Excellence
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Experience
Interim Project Manager / Program Management / Operational Excellence
Interim Project Manager / Program Management
Collins Aerospace / RTX Deutschland
- Responsible for development, industrialization, and production of military helicopter seats (Helicopter Seating, Part 21 / Part 145)
- Responsible for an innovative seating system weighing < 15 kg and 100% crash safety according to EASA (side facing), from concept to SOP
- Complete recovery of a project that was two years late with only 15% progress, frequent project manager changes, and massive loss of customer trust
- Implementation of a recovery plan with concept approval and prototype testing in 4 weeks, and certification testing in 8 weeks to achieve 100% EASA certification
- Managed global BCC development resources in Poland and India (>60% share) and optimized development cycles including FEA, as well as streamlined the supply chain
- Ensured on-time EASA and series release, compliance with the NRE budget, and timely delivery including FAI, restoring customer satisfaction
Interim Head of Process Engineering Electronics Production
ZKW Automotive Österreich
- Responsible for process development of electronics production (SMT, control unit assembly, LED prints, and PCB assembly) with 40 employees
- Introduced multi-project management based on a Stage-Gate process
- Restructured industrialization processes and organization along the value chain
- Synchronized industrialization with global development processes in the electronics segment
- Established and upgraded production and industrialization processes to automotive standards
- Carried out cost-down projects increasing production by 65% year over year by focusing on OEE, capacity, plant inventory, scrap, employee training, and procurement
- Designed the production footprint for SMT manufacturing in Dalian (China) and Mexico
- Defined pre-design processes in operations for the S4/Hana end-to-end transformation
- Used Lean Six Sigma, value stream analysis, and Stage-Gate process to optimize the production site
Interim Manager
Hoffmann Group - Garant Productions Deutschland
- Restructured industrialization and production processes with organizational changes along the value chain
- Conducted cost-down projects focusing on output increase (HK/AwH), backlog reduction (revenue), and inventory reduction (WIP, cash flow)
- Applied a brownfield approach to increase capacity in fine sheet metal processing, welding, and final assembly, achieving a 40% output increase
- Outsourced a high-runner product group from sourcing to the assembly line
- Served as interim head of final assembly with 40 employees and realigned manufacturing and assembly processes, achieving a 35% output increase
Interim Manager
Smart-Interim Management GmbH
- Restructuring, relocation, cost-down, and turnaround management in production
- Factory planning for greenfield and brownfield plants, and agile project management
- Designing and optimizing the production footprint, digitization, and process mining
- Implementing lean management, change management, and S4/Hana transformation
- In-house consulting for operations, supply chain, manufacturing engineering, and special machine building
Plant Manager (Aerospace)
Kaman Aerospace - Specialty Bearings & Engineered Products
- Plant management at a sister company of RWG Höchstadt an der Aisch
- Implementation of the One Piece Flow production system
- Managed 135 employees and 5 department heads, sales of EUR 28 million per year
- Project lead on a brownfield approach in forming technology for rod end bearing production
- Achieved a 135% increase in rod end output in four months
- Reduced headcount in the production cell by 25% as part of a cost-down project
- Created transparency and operational impact in operations by implementing shopfloor management (S-Q-C-D-P)
Global Head of Manufacturing Engineering
Schlemmer Group
- Established the global manufacturing engineering and supply chain group in the company, focusing on extrusion, plastic injection molding and assembly technology in multi-project development processes
- Integrated production plants worldwide into a production network as part of the production footprint, focusing on efficiency, manufacturing costs and supply chain, especially in Eastern Europe, Africa and the USA/Mexico
- Integrated and realigned the internal custom machinery unit into the Schlemmer Group
- Expanded the service portfolio in the automation and software segment
- Sourced and industrialized a 2K foam application with integrated 2K plastic injection molding machine in a fully automated one-piece flow concept for e-mobility
- Reduced procurement costs by EUR 600k and cut project duration by 10 weeks ahead of the planned SOP date for an OEM automotive customer
- Successfully expanded the plant in Romania with 2K injection molding technology and built the Mexico plant as a greenfield project
Plant Manager for Component Manufacturing and Assembly
GRW
- Managed component manufacturing and assembly of high-precision miniature ball bearings for the automotive and aerospace sectors
- Digitized production processes and increased production flexibility
- Introduced industrial automation in one-piece flow
- Realigned manufacturing strategy and organization along the supply chain
- Responsible for process development at the main plant and the assembly plant in the Czech Republic
- Led 300 employees and 8 department heads, with annual sales of EUR 55 million
- Successfully implemented the cost-down and lean project “Fertigungsinsel” to significantly advance production at the Rimpar plant
- Further professionalized manufacturing processes and the end-to-end supply chain while improving quality to aerospace and automotive standards
- Adjusted the production footprint of European plants in terms of efficiency, manufacturing costs and time-to-market
- Relocated the tapered roller bearing product group to Prachatice, Czech Republic
Plant Manager
Sinterwerke Grenchen AG
- Led and reorganized the Grenchen plant with a focus on flow-oriented production as a value stream unit in the automotive sector
- Increased output of operational units by 35% through operational excellence programs on the shopfloor and cut lead times from 34 to 6 days including supply chain
- Managed 180 employees and 8 department heads, with annual sales of EUR 50 million
- Took the site into profit with an earnings improvement of EUR 7.0 million in 2016 based on numerous cost-down projects focused on cash flow and inventory (WIP and finished goods)
- Successfully industrialized the BMW cam carrier for variable valve timing and ramped up the production line using a value-stream approach
- Achieved material cost savings of 11% (technology and volume) and raw material savings of 9% (WIP and scrap) using Six Sigma methods
- Adjusted the production footprint with the German sister plant focusing on operational excellence
Director of Business Service, Head of Maintenance
ZF Friedrichshafen AG
- Operational management of maintenance for 7 production plants at the Schweinfurt site in the automotive sector
- Developed and implemented operational excellence programs on the shopfloor, reducing lead times by 18% (lean operations)
- Led 320 employees and 5 department heads, with a budget of EUR 55 million per year
- Reduced costs in my area by 16% while increasing site output by 24% (make-and-buy in an end-to-end context) as part of the e-powertrain development strategy
- Co-led a subproject in the European production footprint focusing on technology and relocation
Head of Maintenance at Schweinfurt and Elfershausen Plants
Schaeffler AG
- Operational management of maintenance at the Schweinfurt and Elfershausen sites in the automotive and aerospace sectors
- Reduced lead times of the operational units by 17% while increasing production output through lean management
- Established a planning and control department for overhauls at the site
- Sub-project management in the production footprint with focus on technology and relocation
- Managed 270 employees and 5 department heads with a budget of EUR 45 million per year
- Developed and built a lean management team at the Schweinfurt site to align the organization with the value stream
- Adapted the organization to the customer cycle through decentralized operational units in preparation for planned sales growth
- Led the maintenance planning and control team, implemented new service concepts and introduced a KPI system on the maintenance shop floor
- Sub-project management for setting up sites in Europe and Asia
- Conducted workshops in production (value stream design)
- SAP rollout in operations at the Schweinfurt and Elfershausen sites
Operations Engineer / Workshop Foreman Mechanics / Technical Assistant / Industrial Mechanic
Aurubis AG
- Industrial mechanic in a 5-shift system maintaining production equipment
- Technical assistant with project management for industrialization and cost-down projects as well as overhauls with internal and external partners
- Workshop foreman for mechanics with operational responsibility for mechanical maintenance at the site, managed 25 employees, including 5 shift leaders, budget approx. EUR 2.5 million per year
- Operations engineer with project management for investments and overhauls in the production environment
- Product and process development of copper collectors for electric machines and their industrialization (continuous forming process)
- SAP rollout in operations at the Stolberg site
Industrial Mechanic Final Assembly
Eltro GmbH
- Industrial mechanic in the final assembly of PVD/CVD systems in mechanical engineering
- Assembled, adjusted, and commissioned system components and equipment
Industry Experience
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Experienced in Automotive, Manufacturing, Metals and Mining, and Aerospace and Defense.
Business Area Experience
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Experienced in Operations, Project Management, Production, Supply Chain Management, Product Development, and Procurement.
Summary
Many years of leadership experience as plant manager for component manufacturing and assembly of rolling bearings, car and truck transmissions, shock absorbers, hybrid electric drives, and electronics production. Global responsibility for manufacturing engineering and special machine building. Focus areas: product development, production management, restructuring in international emerging markets, supply chain, engineering, multi-project management, change and lean management, and quality; broad practical experience in Industry 4.0 in production settings. Over 30 years in operations and engineering in automotive, industrial, and aerospace sectors. Expertise in primary and forming technology, powder metallurgy, hard and soft machining, heat treatment, sheet metal processing and coating, SMT electronics production and development, ICT and end-of-line test equipment, plastic extrusion/injection molding and assembly technology, production IT, with 25 years in automotive.
Skills
Soft Skills:
- Can-do Personality
- Strong Execution Skills
- Strong Technical Competence
- Clear Communication At All Levels
- Cooperative Leadership Style
Specific Technical Skills:
- Technical Reliability
- Product Development
- Shop Floor Management
- Asset Management
- Leadership Principles
- Supply Chain Management
- Quality Management
- Robust Development Processes For Synchronized Implementation
- Manufacturing Engineering
- Corporate Management And Controlling
- Change Management
- Lean Management
- Agile Project Management
- Digitization In Industrial Environments
- Industry 4.0 On The Shop Floor
- Isa-95 Model For Field Device Integration
- Human Factors In Aviation (Part145)
- Aviation Regulations Awareness
It Skills:
- Sap Fi/co, Mm, Pp, Pm (Sap Plant Trainer)
- Ms Office Applications (Very Good Knowledge)
- Celonis Data Engineer (Process Mining)
- 2d/3d Cad/cam Systems: Autocad Inventor 3d, Hsm Cam
Languages
Education
Rheinische Fachhochschule Köln - Faculty of Engineering
Diploma in Mechanical Engineering · Mechanical Engineering · Cologne, Germany
Chamber of Industry and Commerce Aachen
Industrial Foreman Metal · Industrial Foreman Metal · Aachen, Germany
William-Prym Works
Industrial Mechanic · Industrial Mechanic specialization in Machinery and Systems Technology · Stolberg (Rhineland), Germany
Certifications & licenses
EASA Certification
EASA
Statistics
Experience
Global Experience
Expertise
Qualifications
Profile
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