Manager of Chassis Powertrain Electronics (Hybrid and Electric Vehicles) 

Hybrid Electric Vehicle; 5-Series

The new era of Green Energy Vehicle was upon us, BMW had been conducting research into the Hydrogen Power as a fuel alternative with an equally impressive drive train concept, but it remained and still remains in concept phase.

With immediate focus on the luxury Hybrid market BMW was fixed on the success of the 5-Series Hybrid vehicle as its entry into the market as the 'First Luxury class Hybrid to market' with the 3-Series and 1-Series Hybrids to follow.  

 

Coming from the UK division of MINI, the transition to working at the German headquarters, and with the 'home-team' was a privilege, particularly on a vehicle programme that was groundbreaking, and the first of its kind in BMW. 

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

​

My involvement in the programme a 'new concept' was a concept in itself, as a 'UK Manager' it was a new era of working and my introduction into the team of German engineers was enlightening and pleasing.

I later understood after our first assignment, my colleagues, mostly senior Board Directors and Professors were in deep shock for several days thereafter, but each wearing a satisfied grin of achievement.

 

The 5-Series Hybrid, was to be BMWs flagship entourage for the world of Luxury Hybrid.

I entered the project 60% through, the project reached 4-road-blocks, each deemed to delay the critical launch indefinitely, and my opportunity to achieve, where other had not.

As a specialist in Manufacturing and Semiconductor fabrication methods, now for 13-years the topic was well rehearsed, and now 'in the real time, at the real place' it proved to be challenge needing to be overcome.

 

One encounter.

Taking full responsibility, a suppliers manufacturing facility was completely in my control, Euro 4-Million of investment of a semiconductor fabrication and precision assembly plant line, was dismantled and reassembled with thanks to the supplier teams who designed and industrialised the product.

The manufacturing process of 423 steps with a precision down to 20microns was about to provide the first valuable lesson in 'value added KPI's', changing from a 2% yield to 22%, but the 1400 point KPI constructed and deployed with the team revealed exactly why. 

Progressive modifications and fine tuning created the yield from 22% to 60% to 99.235%

​

​

​

​

​

​

​

​

​

​

​

​

​

​

The launch of BMW 5-Series, completed on schedule, and introduced to the world as the first luxury Hybrid on market. The vehicle achieved 'Zero PPM' failure for the duration of 4years, ie no defects, and no breakdowns and was indeed a leading technical achievement in the automotive industry.

​

​

​

​

 

 

​

​

​

​

​

​

​

​

​

​

 

​

 

Hybrid Electric Vehicle; 1-Series and 3 Series

With now a growing reputation as a technical specialist in semiconductors, productions techniques and a significant capability managing, suppliers and technologies in design and quality, the whole product line up was offered for my attention with a team of engineers in Munich, and once again some very senior directors at BMW that had given me the opportunity to become a part of the 'Green Energy' Hybrid product range of the future.

​

Much like the efforts of the Hybrid 5 series, the actions included all significant parts of the vehicle;

• Drive train motor and gearbox

• Electric engine ECU 

• Regeneration electric systems

• DC -DC convertors

• Battery systems

• Body electronics 

• Safety systems

• Electronics cooling 

​

Involved totally for each part supplied by a manufacturer, it was an amalgamation of the products life cycle, procurement, development engineering and quality manufacturing in one single role.  

The function entailed;

• Specification negotiation

• Supplier technology review and nomination

• Award of business

• Development R&D of the technology

• Release approval for manufacturing

• Manufacturing quality by process audits and approval

• Release of supplier funds

• Introduction into MINI plant

• Warranty performance, and recovery for non-performance

  

The function conducted at a higher level, where the business delivery for the vehicle product line, was my care and attention to complete the BMW product range with an equivalent Hybrid technology alternative.