Frank Stephan Weigelt

• In General: Support companies in the automotive and mechanical engineering business in all areas of production and quality to Introduce TPM strategies to minimize machine downtimes and increase OEE
• Evaluated emerging technologies for potential integration into existing systems or future projects.
• Application of online training lectures on Industry 4.0, Project Management, KPI, 5S,Lean with integration of AI (AIaaS)
• Processes Technical training and support in all areas of digitization, automation, innovation capacities, and development potential in MES and ERP
• Supporting Chinese SMEs in putting International Standards into practice
• Establish connections between companies and cooperate in projects to support start-ups with our Platform Innoloft Aachen
• 01/2022- 07/2023 Support ZF Shenyang Plant 1 as an GM(Interim)/ Senior Consultant to prepare Leadership for the new Plant HEAT1/ EV with BMW
• Introduced TPM strategies to minimize machine downtimes, resulting in a reduction in downtime by 22% and increase the OEE during launch phase to 65%
• implement strategies for predictive maintenance with the german team as a global tool, include specific TPM and TQM tools or methods, such as OEE (Overall Equipment Effectiveness), 5S, Kaizen, and FMEA (Failure Mode and Effects Analysis). that led to a 92% increase in error-free production include training

• Spearheaded TPM and quality standards implementation, resulting in a 68% improvement in supply chain efficiency.
• Training and lectures for automation and Industry 4.0 students built up our engineering talents
• Certification as a Teacher in our Universities and technical colleges
• Planning the JV with GRG -Global-Retool-Group- Germany
• Leadership TPM and TQM for aprox 500 employees
• Technology implementation and improvement (AI,MES,ERP)
• Internal quality audits and development according to VDA 6.3 and IATF 16949, using quality process tools FMEA, PPAP, APQP, 8D reports
• Industry 4.0, lean management, process and project management
• Support with experience in all Departments like intelligent manufacturing, automatic parking, sales, and HR with TPM and QA-QS
• Supplier quality management (SQM) include first supplier visits(FSV), supplier development and follow-up organization, and support, especially for welding quality ISO standard processes
• Organization with purchasing and quality team for Supplier Audits, Supplier Development, 5S and 6S implementation
• Safety inspection at welding for operation and production areas, Safety Training
• Internal Management training and KPI implementation

Professional Experience Highlights:

• TPM/TQM Systems Implementation: Successfully developed and implemented a follow-up system to strengthen Supplier Quality Management (SQM) processes, leading to a 15% improvement in overall product quality.
• Shop Floor & Warehouse Optimization: Enhanced shop floor management for streamlined project supply chain handling, significantly improving operational efficiency. Achieved a 5% per-project cost reduction through standardized practices in warehouse management.
• Project Leadership at BBDC Beijing: Drove four follow-up projects tied to Top Kuka Performance, contributing to an increase in order volume and client retention.
• FAW-VW Audi T99 Project (Changchun):Reinstated the project schedule after a four-week delay through close coordination with Audi and FAW-VW planning teams, in collaboration with Kuka Augsburg.
  Directed site, assembly, personnel, and orientation planning to maintain project timelines and standards.
  
• Training & Development Oversight:Led staff education programs for 83 employees, focusing on machining tools, hand tools, professional conduct, and construction site timing to ensure high performance and productivity on construction sites and workshops.
  Oversaw comprehensive training and financial planning for diverse automotive assembly processes, including fixture and geo-framing operations.
  
• Production & Resource Planning: Managed production volumes and SQM in workshop operations, with an emphasis on resource allocation and efficient supply chain planning. Executed planning for piping, water, air pressure, and welding power systems for the development of a second workshop in Shanghai (17,000 sqm) to meet Ford Australia’s project needs. Delivered pre-assembly and shipment operations on time and within budget to the Thailand site.
• Supplier Support and R&D Coordination: Provided technical support across R&D, manufacturing, and assembly for multiple projects, strengthening supplier partnerships and process reliability.
• Quality Control Expertise: Directed quality control processes in welding and manufacturing, with hands-on management in Shanghai and Changchun facilities to ensure adherence to stringent quality standards.
• Key Manager for Audi T99 Project (Changchun FAW-VW): Responsible for managing sub-suppliers, tools & dies, and quality assurance volumes. Acted as the primary liaison with the VSC for Quality and Audi Planning Department to ensure timely and accurate project execution.

• Responsible for Kuka Projects, a new installation at FAW-VW- Model- X New-Bora Project and Audi A6/C6 Changchun, PR-China
• For BIW assembly Lines 1+2, closures, and finish Line implementing TPM methods to reduces downtime
• Responsible for CRM with FAW-VW/ adjustment and quality work after the measurement reports/ SQM-Supplier quality management/ responsible for 45 employees
• TPM Training for Operators at FAW-VW and Audi

• Takeover BU with minus 25% to a successful case with 85%OEE using TQM methodes
• implementing/Development of TPM and TQM of specialist welding BU automotive technology
• Hofmann GmbH, Staff leasing Nuremberg and Dresden Branch/ leading 225 employees
• Leading the BU for OEM like AMD, VW, BMW, Infineon, DREWAG, and Employee Education Training

• Conducted confidential training and expert consultations for private and corporate clients, focusing on precise financial advisement to maximize customer satisfaction and outcomes.

• Assembly for all Modules at the High Power Engine Plants from 40 MW to 1200 MW
• Build and weld heavy steel Structure at 150 m high, mechanical engineering
• Welder with new technologies- with eight special welding Certificates at the high-pressure level
• Unique welder at the mirror for materials in the W02 and W11, Welder classes EN 287-1, and welding Procedure tests 111 and 141 also include the combination/ welding of unique materials like C22 for acid-resistant equipment and structures
• Qualification to Safety officer for construction sites for the North German Metal BG

Core Competencies

• Build a new department in Audi Beijing (ATC) with the target and responsibility of localization on the Chinese market to implement a new financial structure and save project costs
• TPM & TQM Implementation: Preventive and predictive maintenance, quality control, downtime reduction, and OEE improvement
• Supply Chain Quality Management (SQM): Supplier evaluation, audits, and improvement aligned with IATF 16949 standards
• AI & Industry 4.0 Integration: Real-time monitoring, HMI systems, network structures for predictive analytics
• Leadership & Training: Development of training modules on TPM/TQM, Industry 4.0, and safety protocols
• Project & Operations Management: Assembly supervision, technical purchasing, shop floor management, and cross-functional team collaboration
• localization of suppliers and production for projects: up to 10 weeks of time-saving SCM process
• Implementing 3D measurement technology: up to 4 weeks of time-saving in the BIW quality work, and reduced costs for businesses traveling from Germany
• Develop measurement programs - based on CAD data
• Qualification and training for CMM measuring systems such as Faro Flexible Arm System and Polyworks software with Sigma 3D for 15 team members of our Chinese quality team
• Responsible for measurement and part, ZSB, and subassembly quality for new projects FAW-VW in Changchun and Foshan plants