Corporate Engagements
BMW Group (MINI)
Overview
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SQA MANAGER INTERIOR ELECTRONICS
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ELECTRONICS MANAGER (TASK FORCE)
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MANAGER OF CHASSIS & POWERTRAIN ELECTRONICS
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GROUP ENGINEERING QUALITY MANAGER (PV)
AWARDS
GOLDEN KEY AWARD: Business optimisation £4m
BUSINESS EXCELLENCE: Business Quality & Recovery
TECH SPECIALIST: Semiconductors & Electronics
TECH. SPECIALIST: Metallurgy & Manufacturing
Manager of Interior Electronics
BMW Mini's immediate success through the reintroduction of the 60's icon was a significant outcome.
The Rover plant at Cowley, was converted into Oxford MINI Development and Manufacturing facility through careful investment by owners BMW Group.
The Brand loved by the whole world had a new outlook and new ranges, each designed with the quality and care of any BMW equivalent.
Tasked with ownership of every electronic component in the vehicle linked to the driver system was a significant function, for current vehicles, but also development for the new ranges too, the R52 Mini Cabriolet, and all the ranges that followed.
Involved totally for each part supplied by a manufacturer, was an amalgamation of the products life cycle, procurement, development engineering and quality manufacturing in one single role.
The function entailed;
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Writing specification
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Supplier technology nomination
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Award of business
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Development of the technology
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Release for manufacturing by testing and results
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Manufacturing quality by process audits and approval
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Release of supplier funds
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Introduction into MINI plant
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Warranty performance
The extensive role was fitting for my background in business management, product development and manufacturing. With my knowledge in electronics and manufacturing, every technology manufacturer was only able to provide the best parts, processes and capability to support the MINI brand.
Of course where things did not go as intended by background in Physics was helpful to recover the situation with efforts to modify materials, processes to solve multiple issues and problems.
working predominantly on the microprocessors, silicon fabrication and PCB failures.
The role evolved to extend the mini range and features, introducing new interior package using Chrome, and new technologies, again developed under my supervision and management.
Manager of Electronics + Task Force
(Facelift 2006)
The success of the Mini brand required the evolution of the vehicle with a complete technology and product overhaul. The 2006 MINI facelift was the most radical change of any model range and really it was a new product of its own class.
Managed by Magna-Steyer the project was very technically ambitious. As a Product Manager my involvement was clear, in the recovery of suppliers, as an escalation point and the strength of BMW, where the the new developments were not capable of being introduced, not working or there were manufacturing delays or issues.
Assigned the role of 'Task Force' leader and interacting with the supplier board level directors, taking control of ANY/EVERY aspect deemed necessary, in a 'no-holds-barred' manner to recover the timing and prevent a delay or jeopardy of the launch.
Of the vehicle, 42 components were escalated and significantly modified, redesigned, or needing a new strategy, within a 6-month period to meet launch of the 'New MINI'.
For the effort, the BMW board and senior managers awarded recognition of the success, with invitation to meet HRH Prince Charles at the opening evening events to launch the 2006 MINI.
Manager of Chassis & Powertrain Electronics
Operating in the same mode previously with Interior electronics, this function was significantly more involved with the vehicle driver systems more usually associated with engine components, and the drive electronics of the vehicle. the components included Engine ECU's, all body and chassis electronics including 'micro-machined' sensors for safety crash detection.
The llustration above showing the outer buildings (offices) of Oxford MINI plant manufacturing 240,000 vehicles annually for the global automotive market.
Typical internals of Micro-Machined silicon component, like used in a crash or accelerometer -sensor array.
Usually machined or etched from a single crystal of silicon, the process is very precise.
The methods used are typical of the semiconductor industry.
The llustration above showing the MINI product range; Mini standard, Cabriolet, Cooper, CooperS, Coupe (Not shown) and the 5-Door extended Clubman
Typical internals of MicroChip, demonstrating the technology and complexity involved.
Typical cross section of a solder joint. this method is used to validate state-of-art production process and control of parameters.
Working closely together with certainly the most leading brands, Bosch, Valeo, Siemens, Ricardo, Aisin, Delphi, Marqurdt, Gabaur & Griller, TRW, etc. I was able to take control of the technology and the quality of the products.
The evolution of the BMW MINI included several model improvements to the Turbo Charger, and the introduction of the PRINCE II diesel engine, designed by BMW, but the engine ECU designed by BMW by a colleague and myself with Bosch GMBH and used also in the Joint Venture, (JV) with PSA Group.
Group Manager of Engineering Quality (PV)
Chassis & Powertrain, and Interior Electronics
Heading up the group technology, was the next progressive step.
Working daily with the Plant Directors at Oxford and the Group Technology Directors in Munich allowed me to control the future of MINI Products and the technology and quality drivers of all the suppliers.
With a group of 52 engineers the function to process the feasibility of the MINI products, the problems landscape, and the technical solutions driven by the engineers, with myself actioning board level supplier escalations where performance or solutions were insufficient.
Further, the warranty landscape, the cost and development of solutions to resolve matters including campaigns were in my remit.
I am proud to have worked alongside some of the greatest names in BMW. Weekly working with Oliver Zipse, the plant director of MINI then, now the chairman of BMW Group. Dr Herbert Diess, now chairman of Volkswagen, Audi Group, and so many other fantastic individuals that gave me the opportunity to excel and become a part of something special.