Project requests
Business Case:
OP-26-248
Sectors / Bereiche:
Produktion / Production
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Position / Position / Pozice:
Qualitäts-/Produktionsleitung & Lieferantensteuerung
Location / Einsatzort / Lokace projektu:
Europa - mehrere Standorte
Start:
ASAP
Project duration / Projektdauer / Délka projektu:
3 Monate +
Customer / Kunde / Zákazník:
Tasks / Aufgaben / Úkoly:
- Forging Process & Forged Blank Design: Route/preform strategy, presses vs. hammers, induction/lubrication/descaling; OEE & Cp/Cpk on main/rod journals, webs, counterweights. Define parting line/flash/machining allowances; analyze simulations, optimize forming sequence/number of blows; proactively prevent underfill/overfill.
- Heat Treatment & Surface Layer: Normalizing, Q+T/bainitic routes, straightening; induction hardening of journals, fillet rolling, and, if required, (nitro)carburizing. Manage microstructure and decarburization (e.g., 42CrMo4) in line with fatigue requirements.
- Machining & Dimension/Tolerance Concept: Datum/fixturing concept, process sequence; oil‑hole drilling & deburring, cleaning, corrosion protection. Secure runout/roundness/surface finish via SPC.
- Quality & NDT: Control plan with MPI/UT (and possibly eddy current), hardness profiles, decarburization depth, microstructure checks, fiber‑flow verification. Drive 8D/containment, PPAP/ISIR, process FMEA; address typical defects (laps/folds, cracks—thermal/forging, underfill, segregation).
- Supplier Management & Industrialization: APQP, run‑at‑rate/capacity demonstration, change management. Audits (pressing, heat treatment, induction, fillet rolling, grinding); make‑or‑buy; traceability (heat/batch/cavity) & poka‑yoke.
- Reporting & Committee Coordination: Decision papers, KPI reporting (quality, capacity, yield, scrap), lessons learned / knowledge
Conditions / Anforderungen / Požadavky:
- Former Quality or Production Manager in crankshaft manufacturing (automotive/heavy duty), 10+ years relevant experience.
- Deep expertise in forging, heat treatment, induction hardening, fillet rolling, finishing & metrology.
- Confident in assessing/challenging suppliers (equipment, process windows, simulation, inspection strategies).
- Experience with NDT and forging simulations.
- Materials expertise (e.g., 42CrMo4, micro‑alloyed steels); strong understanding of fatigue and surface‑layer effects.
- Strong quality mindset under time pressure; fluent in 8D/APQP/PPAP; excellent communication & negotiation skills.
- Proficient with MS Office (especially Excel, PowerPoint), ideally Minitab; high willingness to travel.
Languages / Sprachen / Jazyky:
German, English
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