Profileimage by Frank Keussen Qualitätsmanager/Six Sigma Black Belt Elektronik from Bocholt

Frank Keussen

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Last update: 14.03.2024

Quality Manager, Six Sigma Black Belt

Company: Keussen Management
Graduation: • Graduate Electronic Engineer (communications engineering)
Hourly-/Daily rates: show
Languages: German (Native or Bilingual) | English (Full Professional)

Attachments

Keussen CV DE 20210608.pdf
Kurzprofil Keussen DE 20201212.pdf

Skills

  • Graduate Electronic Engineer (communications engineering)
  • Six Sigma Black Belt
  • Industries: Automotive Industry, Railway Industry, Telecommunications Industry,
    Plant Engineering
  • Focus: Head of Q-Department, Escalation Management, Quality Management, (development-accompanying) Quality Assurance, Project Management, Supplier Development
  • Leadership experience
  • Strengths: assertive, goal-oriented, resilient, very good analytical and conceptual skills
  • Methods: MS-Project, JIRA, A-SPICE, APQP, PPAP, Minitab, APIS

Project history

11/2019 - 11/2019
Head of Quality Assurance
Pieron GmbH, Bocholt (Automotive and vehicle construction, 50-250 employees)

  • Head of Quality Assurance
  • Moderation, reflection and optimization of the quality culture in cooperation with executive board and department managers
  • Identification of problems and risks in ongoing projects
  • Definition and introduction of corrective actions in cooperation with customers
  • Definition and implementation of internal and external processes
  • Moderating of FMEAs
  • Optimisation of 8D-Reporting
  • Customer audits

11/2019 - 11/2019
Quality Manager Electronic
HÜTTINGER Elektronik (TRUMPF Group), Freiburg (Industry and mechanical engineering, 500-1000 employees)

  • Quality planning for High Power MF and RF –generators
    (APQP, PPAP, 8D, Monte-Carlo-Simulation, etc.)        
  • Quality support of development projects
  • Support and coordination in the fields of project management, development, test equipment construction and industrialization
  • Supplier Management
  • Moderation of FMEA projects according to VDA standards
  • Training of Six Sigma tools
  • Coaching of Six Sigma projects 
  • Design and optimization of product development processes (SYNCRO projects)

 

 

Used technologies:          Minitab, APIS, SAP, JIRA

 

Used methods:                 PPAP, 8D, FMEA, Monte-Carlo-Simulation, DOE, SPC, Six-Sigma

 

 

 



02/2019 - 10/2019
Supplier Quality Semiconductors
Magna, Tel Aviv (Automotive and vehicle construction, >10.000 employees)

Tier 1, Magna, has commissioned the development and production of a LIDAR at the
start-up Innoviz in Israel. A LIDAR (Laser Detection and Ranging) is a high-complexity sensor needed for autonomous driving. This sensor is to be used in vehicles of the OEM BMW.
Innoviz had no experience with the development and production of optoelectrical products for the automotive sector. Therefore many components, test concept and design did not meet the automotive requirements. In addition the EMS (Electronic Manufacturing Services) was unable to meet the automotive requirements. Massive problems in the development and production of MEMS (Micro-Electro-Mechanical Systems) and Application-Specific Integrated Circuit (ASIC) also led to delays and design changes. The status of industrialization was far below the expectations of a C-pattern. The schedule for the bring-up of the C samples was very critical.

 

 

Field of responsibilities

 

  • Monitoring of milestones, deadlines and goal achievements
  • Determination of countermeasures for occurring project risks
  • Reporting of project status (electronics) to Magna and BMW management
  • Ensuring compliance with all BMW Group standards for the design and production of PCBAs
  • Review, comparison and correction of the BMW Risk Assessment for Critical Components (SBL)
  • Verification and validation of APQP and PPAP processes for all electronic subassemblies and electronic components
  • Review of test procedures / work instructions / traceability
  • Regular supplier visits to the EMS service providers
  • Development of DoEs (Design of Experiments) for the optimization of manufacturing processes of MEMS in cooperation with BMW
  • Design for testability (DFT)
    • Ensuring test coverage in assembly production
  • Design readiness reviews (PCBAs)
  • Availability
    • Monitoring of system availability (test equipment)
    • Component availability monitoring (electronic components)
    • Ensure compliance with the C-Sample Built-in plan for PCBAs

06/2013 - 01/2019
Quality Manager R&D Electronics / Project Management
Knorr-Bremse, Munich (Automotive and vehicle construction, >10.000 employees)

Group-wide harmonization of processes for specification, development and qualification of test- and manufacturing processes of electronic control units.

 

  • Feasibility study "Redundant System Architectures for Electronic Brake Controls"
  • Achievement of fail operational failure behaviour
  • Increase in availability
  • Cost reduction through the use of smart redundancies
  • Qualification of conformal coating materials and technologies (2k, UV, polyurethane, fluoropolymer)
  • Implementation of "Robustness Validation" for new developments (mission profile, requirements, lessons learned, knowledge matrix, FMEA)
  • Lifetime analyzes (analyzes of censored data)
  • Implementation of accelerated lifetime tests (HALT) for the preventive assurance of the reliability of electronic assemblies
  • Optimization and harmonization of test concept for electronic assemblies within KB group (Automated Optical Inspection (AOI + AXI), In-Circuit-Test (ICT), Boundary Scan, High Potential Test (HIPOT), Functional Testing (FT), Burn -in-test (BI))
  • Creation of design guidelines to improve the testability in production
    (Design for Testability)
  • Definition and rollout of a harmonized burn-in test in the KB Group
 
  • Optimization and harmonization of Underfill process
  • Definition of design rules for Underfill
  • Achieve RoHS compliance of new and ongoing projects
  • Recording the RoHS status of currently produced products in cooperation with EMS suppliers
  • Clustering of ongoing projects
  • Decision in dealing with non-compliant products
  • RoHS-compliant design of new products
  • Generic qualification of a lead-free soldering process
  • Qualification and specification of PCBs (lead-free)
  • Establishment of Obsolescence Management for electronic components
  • Group-wide definition of the processes
  • PCN (Product Change Notification)
  • ZVEI PCN-delta Qualification
  • Alignment of the AEC-Q qualification with requirements out of projects
  • Long-term storage of electronic components and assemblies
  • Definition of storage conditions and measures
  • Definition and harmonization of measures for technical cleanliness of electronic assemblies (no-clean processes, corrosion, dendritic growth, ionic contamination ...)
  • Introduction of a series-accompanying monitoring of ionic contamination for PCBAs
  • Introduction of a harmonized procedure for setting specific limit values in the type test (SMT, wave, selective soldering process)
  • Quality support for various projects in USA and India
  • Supplier development of EMS
  • Supplier audits


01/2017 - 06/2017
Quality Manager R&D Electronic
Merak (KB-Group), Madrid (Automotive and vehicle construction, 250-500 employees)

  • Quality Support in the development of a climate control system
  • Design for Testability
  • Supplier Development of EMS

 


10/2016 - 11/2016
Project Manager Electronics Division Textile Machinery
Spaleck GmbH & Co. KG, Bocholt

Technical transfer of the product group "Textile machinery” to the technical division of the buyer.

 

  • Hardware Electronic
  • Documentation
  • Schematics
  • Software
  • PLC control
  • Visualization
  • Digital gearing
  • Documentation   

 


05/2011 - 06/2012
Head of QM global
Hengst GmbH & Co. KG, Münster (Automotive and vehicle construction, 1000-5000 employees)

Personal responsibility

 

  • Disciplinary responsibility: 68 employees
  • Technical responsibility: 151 employees (Germany, China, Brazil, USA)

 

 

Field of responsibilities

 

  • Head of global Quality Assurance
  • Implementation of quality- and cost targets
  • Reporting to Senior Management
  • Moderation, reflection and optimization of the quality culture in cooperation with executive board and department managers
  • Conducting of best practise workshops
  • Launches of projects to optimize and secure process and product quality
  • Development and implementation of internal and external processes
  • Development of supplier and material strategies

 

 

 

 

 

 


05/2009 - 04/2011
• Head of R&D-Electronics
Spaleck GmbH & Co. KG, Bocholt (Industry and mechanical engineering, 50-250 employees)

Personal responsibility

 

  • 4 employees

 

 

Field of responsibilities

 

  • Head of R&D-Electronics
  • Interface to customers and suppliers with regards to electronic topics
  • Project management
  • Project definition in cooperation with customer and sales department
  • Estimation of costs, requirements analysis
  • Project coordination and monitoring
  • Planning and implementation of structural actions
  • Outsourcing of R&D electrical engineering
  • Supplier selection
  • Price and contract negotiations
  • Programming of CPUs (SIMATIC)
  • Programming of visualisation

 

 

 

 

 

 

 

 


02/2007 - 03/2009
Head of Quality Management
Digital Imaging Systems GmbH, Kirchheim unter Teck, (Telecommunications, 50-250 employees)

  • 8 employees (Germany, China, Thailand)

 

 

Field of responsibilities

 

  • Development and implementation of processes for supplier and material qualification as well as for product development 
  • Elaboration and implementation of internal and external processes
  • Development of supplier and material strategies
  • Supplier selection / Supplier rating
  • Supplier qualification
  • Global Supplier audits (System audit, Process audit)
  • Qualification of camera components according PPAP (Production Part Approval Process – QS9000 TS16949) and APQP (Advanced Product Quality Planning)
  • Interface to customers
  • Negotiations of specifications
  • Contact for quality, product and development issues
  • Realisation of audits with suppliers in cooperation with customers
  • Development and control of solutions in teamwork with customers
  • Project management
  • Implementation and moderation of Process- and Design FMEAs
  • Design and documentation of KPIs (Key Process Indicators)
  • Tolerance analysis
  • Execution of DOEs
  • Qualification of measurement equipment
  • Qualification of clean rooms according DIN EN ISO14644-1 and Fed.Std.209D/E at supplier
  • Certification of Digital Imaging Systems GmbH according ISO 9001:2008
  • Frequent local contact with suppliers and customers in Asia (China, Thailand, Taiwan, Korea, Japan)


06/2001 - 12/2006
Quality Manager / Six Sigma Black Belt / SAP Key-User
Siemens AG (Telecommunications, >10.000 employees)

  • Qualification of acoustic components, optical components, vibration motors and flexible printed boards according to PPAP (Production Part Approval Process – QS9000 TS16949) and APQP (Advanced Product Quality Planning)
  • Supplier- and material strategy
  • Suppliers development
  • Design and improvement of technical specifications in close cooperation with R&D
  • Specification and qualification of test concept for acoustics and optics
  • Moderation of Process- and Design-FMEAs at supplier
  • Auditing of suppliers in Asia and Europe
  • Realisation of Black-Belt-Projects
  • Negotiation and signing of QAAs (Quality Assurance Agreement) with suppliers
  • Team member of Carve-Out-SAP project Siemens/BenQ       
  • Project leader of O3-Project (One number, One system, One BOM process) scope material qualification

 

 

 

Training

 

  • Six Sigma Black Belt
  • Project Management
  • FMEA (Failure Mode and Effects Analysis)
  • ISO 9001:2000 to ISO/TS 16949:2002
  • (Interne und 2nd Party Auditors)
  • Moderation
  • Quality Assurance Agreements
  • Auditing of suppliers
  • Adhesive technology
  • Siemens -Quality Management
  • Process oriented, focused quality management according ISO 9000:2000

 

 

Black Belt Projects

 

  • Reducing failure rate of L55 microphones in production and field
    Benefit:     1.026.290 €   
  • Decreasing failure rate of acoustic module at the custom tester from 0.4% to 0,1%
    Benefit:     228.000 €      
  • Reducing lifetime requirement of vibration motors
    Benefit:     981.000 €      
  • Implementing of SMT- processible microphones in mass-production
    Benefit:     10.800.000 €

 



02/1996 - 06/2001
Project leader hard- and software / R&D hard- and software
Spaleck Oberflächentechnik, Bocholt (Industry and mechanical engineering, 500-1000 employees)

  • Design of specifications for system controls
  • Hardware construction (CAE-System EPLAN)
  • Programming of control units and visualisations 
  • Start-up of machines into operation at customer

03/1994 - 02/1996
R&D Hardware and Software
MSK Verpackungs-Systeme GmbH, Kleve (Industry and mechanical engineering, 50-250 employees)

  • Design of specifications for system controls
  • Hardware construction (CAE-System EPLAN)
  • Programming of control units and visualisations
  • Start-up of machines into operation at customer

 


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Profileimage by Frank Keussen Qualitätsmanager/Six Sigma Black Belt Elektronik from Bocholt Quality Manager, Six Sigma Black Belt
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