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Injection Molding Engineer

Simpsonville, South Carolina, United States
November 06, 2018

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Stefan Thiele

** ********* **

Simpsonville SC **681



Dedicated team play with 20 + years’ experience in Project Management, Manufacturing, Sourcing and Quality. (Injection Molding, Automotive, Power Generation)

Detail oriented, fast learner and I am pretty proficient to find the necessary compromises to achieve my goals.


Yanfeng Automotive

02/2018 to present

Lead Process Engineer Lamination and Assembly

Build and managed team of 6 Process Engineers (Direct Reports) and 30 Process Technicians thru matrix organization.

Established and maintained KPI driven Target for Process Engineers above.

Supported the Launch of BMW GO5 Instrument Panel, Center Console and VOLVO Floor Console. This included APAP actives (PFMEA, Control Plan and Poke Yoke Validation)

Improved BMW GO1 Door Panel Production. Which allowed us to maintain and OEE of > 85% and scrap of less than 2%.

Implemented and maintained a computer aided PM system (INFOR) to track maintenance activities for Foaming, Laminating, Welding and Assembly.

GE Power

01/2017 to 02/2018

Senior Manufacturing Projects & Initiatives Manger (SAP QM)

Owned the Non-Conforming Reporting Business Process (NCR).

Provided input to the IT team covering Layout and Logic of the new SAP NCR Notification

Developed event based (NCR based) Cost of Failure collection process.

Mapped and implemented SAP processes to scrap, rework and return material.

Key Contact to ARIBA to design a customized Non-Conforming Material Reporting.

GE Power and Water

10/2011 to 12/2016

Senior Supplier Quality Engineer

Created and maintained Standardized Audit check list covering casting and processes for investment castings. (casting, CNC, EDM, Waterjet, Laser, Heat-treat)

Implemented standard Manufacturing Process Plan covering both the standard and rework processes.

Simplified Super Alloy Machining PPAP process to qualify several machines utilizing a reduced process validation plan. (Lead Time reduction of 80%)

Supported all Greenville based SQE training activities as instructor covering the Non-Conforming Material and Surveillance audit process.

Led several continuous improvement projects using 8D, Apollo and Six Sigma methods.

Supported cost reduction projects with a total saving of more than 1.5 mio dollar.

GE Energy

06/2008 to 10/2011

Lead Supplier Quality Engineer

Key User during the implementation of Supplier Collaboration Portal. Herby, I proposed and implemented several changes to make the system more effective.

Reduced the Non-Conforming Material processing time from an average of 10 days to 3 days.

Performed numerous internal and external ISO surveillance audits.

Performed numerous technical product and process audits.

Roechling Automotive (Injection Molding for Automotive)

02/2007 to 06/2008

Continues Improvement & Production System Planning Manager

Planned and Implemented Bonus System based on performance indicators

Introduced Kaizen Process and performed several Hoshin workshops with a total savings in excess of $ 600,000

Introduced a system of standard task times to better evaluate the true labor content of the different jobs.

Responsible for Problem Solving Process using PCDA/ 8 D and many other methods

Introduced and maintained Improvement Idea Program.

Performed layout studies to introduce ergonomic Standard Work Cells, which support an MTM system

Introduction of 5 S and performed several workshops

Responsible for SAP Material Master Administration

Intier Automotive (Injection Molding for Automotive)

07/2006 to 02/2007

Senior Plant/ Tooling Engineer

Lead several problem-solving teams involving the customer and suppliers to overcome customer complains.

TS Process Owner concerning all documentation incl. FMEA, MSA, Control Plan and Standards operation procedures.

Established process oriented specification with raw material suppliers and participated in the qualification of those suppliers.

Takt time calculation and Capacity Analysis

Manpower Requirement

Established Tool Maintenance Program with local tool source

Management of Engineering Changes with US tooling source

Member of acquisition team for several new projects.

Knowledge transfer of LMP (In mold decoration with textiles) process from Europe to the US including receiving inspection procedures and lot qualification.

Faurecia Interior Systems (Injection Molding for Automotive)

04/2004 – 07/2006

E 70 Project Plant Industrial Engineer

Estimated cycle time and machine requirements for all plastic parts

Performed Tact Time and JIT Window Analysis

Creation of material flow and Thru put Time Analysis

Helped to design Flexible Work Cells

Batch size and Shop stock calculation

Work Content Analysis

APQP team member in charge of injection molding and vacuum forming process

PFMEA Injection Molding and Back press

Created Tooling Specifications for all Injection, Backpress, Foaming and Vacuum Forming Tools

Created Machine Specifications for HE, US and VIB Welding Equipment

Performed several Capacity Studies for Injection Molding

Design Review of all new machinery and ergonomic analysis

Various feasibility studies and design reviews

Faurecia Interior Systems

05/2003– 04/2004

Plant Engineer Injection Molding

Implementation of Tei Tei Concept in the “Backpress” department

Implementation of process development procedure.

Implementation of Standardized Mold Start Up

Creation of mold books incl. QS Documents for Injection and Backpress process

Lead several cycle time improvement workshops

Faurecia Interior Systems


Production Manager Injection/ Backpress

Implemented reporting system to follow up production output.

Developed new production schedule based on optimum batch size.

Introduced “worker self control” and common quality tools such as First Piece Approval and Statistical Process Control.

Established and trained Team Leaders of the injection molding department

Faurecia Interior Systems


Plant/ Tooling Engineer

Technical contact for all custom molders (suppliers, where Faurecia provided the productions means)

Successfully launched all injection and Vacuum Forming tools for the BMW Roadster (Facelift), BMW Sports Utility Vehicle and Saturn (incl. customer PPAP)

Planned and implemented Preventive Maintenance Procedure for all Injection Molding and Vacuum Forming Tools above.

Planned and Started Injection Molding and Low Pressure Compression Molding Equipment from Krauss Maffei and Engel

Created specifications for all Injection, Vacuum Forming tools and measurement tools for upcoming BMW and GM projects

Performed Feasibility Studies and recommendations based on CAD data received from the customer or product development

Responsible for CAD data management with toolmakers

Sommer Allibert Lignotoc GmbH

1997- 1998

Sales Assistant (Engineering Changes and Tooling)

Responsible for Quoting of Engineering Changes

Making Recommendations based on above

Responsible for cost tracking after order placement

Determining and implementing cost savings and incentives on existing projects

Overseeing Tooling and Product Engineering Change Requests

Responsible for the negotiation of costs and Cost Management with customer

Misslbeck Model & Formenbau


Program Engineer Manufacturing

Developed and Implemented Tracking System to follow status of injection molds and prototypes for the automotive industry

Member of the implementation team for QS 9001 standard.

Internal Estimation and budgeting of projects (build of injection tools) with all major automotive European automotive manufactures

Project Manager for major expansion of production facilities

Additional Training

Six Sigma Greenbelt Certification

Individual Contributor Auditor Training

Liquid Penetrant Training Level I &II (ASNT SNT-TC-1A),

GE Crotonville ~ Leadership Development Course

GE Crotonville ~ Change Acceleration Process

GE Crotonville ~ Effective Coaching Skills,

GE Crotonville ~ Building Essential Leadership Skills

GE Crotonville ~ Hiring the right people

GE Crotonville ~ Influencing Skills

GE Crotonville ~ Project Management Fundamentals

Apollo Root Cause Analysis Methodology

Language Skills

English (fluent)

German (fluent)

Spanish (basic)


University Regensburg (Germany)

Diplom Manufacturing Engineering


Upon request

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