Berater Funktionale Sicherheit – Maschinensteuerungen (ISO 13849 / IEC 61508)

Objectives: Facilitate the alignment of embedded development processes with ISO 26262 requirements.
Supervise the safety development of engine control management (ECM) system and transmission
control management (TCM) system in compliance with ISO26262.
Provide support for the implementation of ASPICE Level 3.

Tasks: Modelling the development environment.
Creating models of vehicle's function and infrastructure systems.
Conducting impact analysis and preparing safety plans and safety cases for various development
scopes.
Generating status reports and providing progress updates to the steering committee.
Planning all project-related activities related to functional safety for four functional software
components, hardware-related software, and the integration of two control units.
Providing guidance in creating Item Definitions, Functional and Technical Safety Concepts, Project
Plans, and Configuration Plans.
Leading the gap analysis of the development environment for safety-critical control units.
Leading the gap analysis of the testing environment for integrating safety-critical software and
its interaction with hardware.
Coaching teams in implementing functional safety practices in an Agile development environment.
Assisting process managers in developing product development processes and support processes while
considering Functional Safety standards like ISO 26262 and Automotive SPICE.
Documenting Organization Safety Plans within the department.
Facilitating verification reviews.

Tools: Serena Dimensions, Enterprise Architect


Functional Safety Lead Eng. (China Euro Vehicle Technology AB - CEVT, Gothenburg)

Objectives: Conduct training sessions and provide ongoing support for the development of brakes,
steering, steering column, active and passive driver assistance in accordance with
ISO26262.
Create functional safety concepts for brake system functions.

Tasks: Conducting training sessions for Safety Engineers and Function-, Software-, and
Hardware-Developers on functional safety in accordance with ISO 26262.
Establishing a systematic approach for functional analysis of brake systems.
Creating functional flow diagrams.
Performing qualitative fault tree analysis (FTA).
Developing functional safety concepts.
Implementing a systematic method to monitor project progress against the plan.
Conducting confirmation reviews of functional safety documents, including safety plans, risk and
hazard analyses, functional and technical safety concepts, test plans, and test
specifications.
Conducting impact analysis for changes required for production and service of the Steering Column
Lock.
Maintaining the Risk and Hazard Analysis and Safety Concept for the Steering Column Lock.
Providing training to users on organization-specific tools for requirements and test management.

Objectives: Lead System- and Design-Failure Modes and Effects Analysis (FMEA) for various gear
systems.
Conduct Quantitative Fault Tree Analysis (FTA) and Failure Mode, Effects, and Diagnostic Analysis
(FMEDA) for a microcontroller.

Tasks: Planning and monitoring analysis activities.
Creating function and failure trees.
Assisting in identifying effective actions to prevent system and design failures.
Assisting in identifying appropriate actions for failure detection through verification and
validation.
Documenting Failure Modes and Effects Analysis (FMEA), including supporting documentation,
participant involvement, action plans, and Key Performance Indicator (KPI) reports.
Conducting Failure Mode, Effects, and Diagnostic Analysis (FMEDA) and quantitative failure tree
analysis for a microcontroller (µC)

Tools: Reliability Workbench, Apis IQ-RM

Objectives: Manage cost, timing, and complexity during the development of steering system variants
for a vehicle platform.
Coordinate activities across development, controlling, industrialization, production, quality,
sales, purchasing, logistics, and aftermarket.
Coordinate development teams located in China, India, Europe, and the USA.
Implement technical adaptations to localize product production in China.

Tasks: Developing and timing plans and overseeing their progress.
Managing communication with customers.
Leading change, problem, and claim management processes.
Coordinating activities across development, controlling, industrialization, production, quality,
sales, purchasing, logistics, and aftermarket departments.
Providing regular reports to management.
Coordinating development teams across China, Europe, and the USA.
Monitoring simultaneous engineering (SE) activities with local suppliers.
Coordinating changes in hardware and software components throughout various system development and
product lifecycle phases.
Tools: MS-Project, PKIT, SAP, Axalant
Technical Project Manager and System Development Electronic Programable Steering Systems (ZF /
Bosch, Schwäb. Gmünd)

Objectives: Manage the technical project for developing electronic programmable steering gears,
adhering to ISO 26262 and IEC61508 standards for embedded software.
Coordinate multidisciplinary development teams responsible for electronic steering gear
development, including software, hardware, safety, quality, requirements, mechanical,
test, vehicle testing, and acoustics engineering.

Tasks: Negotiating technical specifications with customers and internal departments.
Creating project plans and overseeing technical development activities.
Conducting internal commissioning and customer reviews of system simulation models.
Coordinating analysis documents during development: SFMEA, KFMEA, FMEDA, FTA, and System-CA.
Moderating SFMEA sessions.
Developing and managing safety plans.
Creating and obtaining approval for safety concepts.
Approving safety road releases.
Reviewing hardware resource requirements by software.
Facilitating regular meetings for the entire technical development team.
Organizing regular meetings for hardware, software, requirements, mechanical design, and bench
testing teams.
Implementing systematic release planning and configuration management.
Managing and coordinating technical change and problem management.
Coordinating and overseeing subsystem releases.
Coordinating system validation activities: EMC, system performance, environmental, durability,
misuse, acoustic, controllability, and steering feel.
Coordinating and releasing system releases, including development releases, road releases, and
safety cases.
Developing and releasing End-of-Life (EOL) test specifications.
Implementing systematic status reporting on project progress for Senior Management in the USA and
Europe.
Providing periodic reports to customer project management.
Providing periodic reports to customer Senior Management (Vice-President Level).
Participating in safety assessments.
Participating in process releases.
Participating in problem-solving related to interfaces between EPS systems and testing
environments.
Providing technical assessments for long-term service and remanufacturing.

Tools: MS-Project, Doors, Clear Case, PKIT, SAP, Apis IQ-RM, Axalant

Objective: Planning and management of supplier quality activities during the development of an
electronic display cluster

Tasks: Introducing a release-oriented approach for the development of purchased components.
Managing coordination efforts with Supplier Advanced Quality Engineers.
Overseeing quality and timing management for all technical supplier activities.
Implementing dynamic progress reporting for Senior Management based on key performance indicators.
Establishing a reporting system for release control managed by Program Management.
Approving processes at suppliers.
Conducting initial sample approvals for components with mechanical, electronic, and optical
characteristics.
Coordinating process approvals across America, Europe, and Asia.
Serving as the primary customer contact for audits at subcontractors.
Managing internal interfaces across four continents.
Quality Planer Lighting Electronics and Xenon Modules (Hella, Lippstadt)

Objective: Planning and management of quality activities in the development of xenon-modules
(bi-xenon and masked xenon-high beam) and LED-components

Tasks: Creating timing plans to track progress and provide regular reporting on various projects.
Facilitating Design and Process Failure Mode and Effects Analyses (D-FMEA and P-FMEA).
Developing design validation plans.
Securing approval for validation plans from internal and external stakeholders.
Generating control plans.
Writing requirements specifications and releasing offline inspection equipment.
Conducting measurement system analysis evaluations.
Reviewing and approving prototype samples based on documented criteria.
Evaluating documentation for initial samples.
Designing and outlining a seminar to explain technical lighting requirements' impact on components
and production floor measurement systems.
Managing and co-facilitating the seminar.
Creating and evaluating an alternative concept for measurement during serial production, including
commercial assessment.
Implementing key performance indicators to track adherence to project deadlines in various forums.
Establishing a systematic reporting system based on key performance indicators for reporting to
Top Management.
Serving as a member of the support team for the "masked xenon-high beam" application.

Tools: MS-Project, SAP, Apis IQ-RM

Objective: Manage the coordination of quality-related task scheduling for relocating production
operations to facilities abroad.

Tasks: Creating training plans for quality engineers' development.
Technically preparing electronic documents for translation with minimal effort.
Coordinating and overseeing quality engineer training sessions.
Analyzing Process Failure Mode and Effects Analyses (PFMEA) for new facilities.
Supervising quality activities at new facilities.
Providing regular progress reports.

Tools: MS-Project, SAP

Objectives: Lead all quality-related efforts to restart series production of electronic control
units following the total loss of the original manufacturing facility.
Enhance the efficiency and effectiveness of the Production and Quality Management System.

Tasks: Coordinating quality activities to expedite the implementation of an interim production
solution.
Analyzing general requirements for an electronic control unit production facility.
Analyzing product-specific requirements for individual control units.
Establishing milestones for transitioning from interim to series production.
Participating in the Steering Committee for "Series Production Resumption."
Attending regular coordination meetings (Jour-Fix) to manage and assign tasks.
Coordinating quality department activities and collaboration with input-delivering departments to
resume series production.
Developing a timing plan for quality activities and integrating them into the overall project
timeline.
Monitoring progress of individual activities, including team member effectiveness and input from
collaborating departments.
Providing regular progress reports and comparing current status against the plan.
Creating a concept to streamline the organization and management of quality documentation for
issuance and maintenance.
Developing clear and concise production flowcharts.
Preparing Process Failure Mode and Effects Analysis (P-FMEA).
Deriving Control Plans content systematically from the P-FMEA.
Deriving Work Instructions content systematically from the Control Plans.
Developing Training Plans for technicians and operators based on Control Plans content, in
alignment with training requirements.
Implementing a Key Performance Indicator (KPI) system for managing production facility operations.

Tools: MS-Project, SAP, Apis IQ-RM

Objectives: Facilitate and document risk analysis sessions for production and logistic processes
utilizing the Failure Mode and Effects Analysis (FMEA) methodology.
Provide training on the FMEA methodology.

Tasks: Methodically documenting risks associated with production and logistics processes.
Facilitating risk analysis sessions, prioritizing cost-effective measures for failure prevention
and detection.
Identifying key risk factors for further mitigation and fostering awareness across interfacing
departments.
Organizing discussions with customers and linking Process Failure Mode and Effects Analysis
(P-FMEA) to Design Failure Mode and Effects Analysis (D-FMEA).
Conducting training sessions to enhance effective and efficient participation in FMEA meetings,
focusing on goals, benefits, and methods.

Tools: Apis IQ-RM

Objective: Identify functional safety requirements for the mechanical development of assisted
steering systems.

Tasks: Analyzing requirements according to ISO/TS16949, SPICE, and IEC61508 for documentation
during steering development, ensuring compliance with functional safety standards.
Developing a naming convention for all documents.
Creating a standard for organized document archiving.
Compiling a list of documents managed within the development department, including approval
requirements and evidence of development sequence.
Providing explanations on the minimum requirements by IEC61508 for a change management system.
Creating samples demonstrating various alternatives for organizing change documentation to ensure
efficient traceability with different software combinations (e.g., Excel+Word vs.
Access) and proposing suitable key performance indicators.

Tools: Excel, Word, Access, Powerpoint

Objective: Manage suppliers throughout the entire process from concept phase to serial production
approval, ensuring quality and timing alignment for a car module delivered
Just-In-Sequence (JIS).
Components include headlamps, painted and galvanized plastic injection exteriors, plastic blow
molding, metal stamping, and cooling systems.

Tasks: Assessing the quality of design concepts.
Evaluating the quality of logistic concepts for Just-in-Sequence (JIS) delivery of assembly
groups.
Assisting in defining reference systems for various assembly groups and components.
Developing a concept for a reference system for headlamps, considering lighting technical
requirements, available measurement systems, and assembly processes for headlamp,
frontend module, and vehicle.
Evaluating suppliers based on quality criteria and collaborating with Purchasing, Logistics, and
Development to select suppliers.
Analyzing and documenting the product and process maturity levels of suppliers for front end
module components.
Providing progress reports to customers on quality-related matters.
Releasing supplier processes and approving initial samples.
Transferring Lessons Learned to project teams in Spain and South Korea.
Tools: Excel, Word, Access, Powerpoint, Apis IQ-RM, SAP
Advanced Product Quality Planning Mechanical Components (PAC Project Advisors, Cologne)

Objective: Restoring of a trustful relationship between a company and its suppliers.

Tasks: Analyzing quality complaints from the production team.
Developing acceptable solution proposals.
Assessing measurement systems.
Formulating customer complaints.
Reviewing deviation approvals.
Collaborating on risk evaluation for deviation approvals.
Conducting process audits at subcontractors.
Facilitating workshops to resolve technical issues.
Leading workshops to analyze requirements and assess their fulfillment.
Providing interim management for the quality department of a subcontractor in South Africa.
Coaching the Quality Manager at a subcontractor.

Tools: Excel, Word, Access, Lotus Notes


Advanced Product Quality Planning Mechanical Components (PAC Project Advisors, Cologne)

Objectives: Assess the maturity level of suppliers throughout the development of homokinetic
shafts.
Act as the sole point of contact for quality matters within the development department.

Tasks: Assisting suppliers with Advanced Product Quality Planning (APQP) in accordance with QS9000
standards.
Assessing product maturity at suppliers.
Reporting deviations from the timing plan to management.
Approving initial samples.
Coordinating a team to enhance the change management process.
Leading a team to prepare for an ISO/TS16949 certification audit.
Coaching development engineers to align their working methods with ISO/TS16949 requirements.
Reviewing work instructions.
Implementing a cost reduction process through design changes.

Tools: Excel, Word, Access, Outlook

Objective: Manage all activities to fulfil customer orders.

Tasks: Conducting contract negotiations to establish payment terms, specifications, etc.
Ensuring customer expectations regarding quality and timing are met.
Managing project progress until final payment is received.
Controlling project budgets.
Coordinating teams comprising up to 5 freelancers.

Tools: Excel, Word, Access

Project samples

Functional Safety Eng. (BRP-Rotax, Gunskirchen)

Objective: Design and execute a procedural framework aligned with ASPICE and ISO26262 standards for
the development of electric drive systems and vehicle control systems.

Tasks: Defining the extent of the process framework scope.
Planning, creating, and implementing a process framework conducive to ASPICE and functional safety
for electric drive system development.
Managing process connections with other organizational units.
Creating a platform framework.
Outlining the design concept for control units.
Establishing procedures for reviewing work products, validating stakeholder requirements, safety
validation, managing documentation storage and retrieval and developing technical
safety concepts.
Conducting training on functional safety fundaments and safety development at the system level.
Conducting verification review of safety work products.

Tools: Medini, Windchill RV&S

Objectives: Increase turn-over and yield.
Manage all production activities.

Tasks: Coordinating supplier activities related to acquiring business opportunities with potential
customers (OEM's).
Managing and expanding the client base for consulting and inspection/rework services.
Negotiating the contract for an IT system and supervising its implementation.
Developing a business application to streamline operational activities.
Conducting regular performance analyses of individual employees.
Analyzing bills payable and chargeable services on a regular basis.
Supervising a team for inspection/rework services consisting of a team leader and up to 10
operators.
Providing training to operators in the analysis of casting.
Implementing inspection and rework services for original equipment components.
Assessing Development, Production, and Quality Engineers to align their products and processes
with customer or supplier interface requirements.

Tools: Excel, Word, Access, Outlook

Objectives: Enhance customer satisfaction levels.
Facilitate communication between customers and suppliers regarding quality and commercial matters.
Supply comprehensive data to suppliers to minimize customer complaints.

Tasks: Organizing and coordinating containment actions in response to customer complaints.
Initiating and overseeing the problem-solving process (8D-Report) until resolution.
Conducting audits of actions proposed by suppliers to address the issue.
Creating procedures for efficient communication of information from suppliers to the customer.
Developing procedures for analyzing components rejected by customers.
Establishing databases to document reject data.
Analyzing and evaluating rejects using traceability data.
Supporting suppliers in their communication with Purchasing departments.
Assisting suppliers in meetings and presentations aimed at acquiring new business opportunities.

Tools: Excel, Word, Access