Lead Engineer

ADJABENG SENANU

Location: Lübeck, Germany Email: ***************@*****.***

Phone: +49-152******** LinkedIn:www.linkedin.com/in/adjabengsenanu PROFESSIONAL SUMMARY

Accomplished Manufacturing Engineering Leader with over five years of experience delivering operational value exceeding €50M through new product introduction, global industrialization, and manufacturing transformation initiatives across Europe, Asia, and Africa. Demonstrated success in developing and implementing zero-defect launch strategies and scalable production systems for Tier-1 OEMs in the renewable energy and industrial sectors. Skilled at bridging R&D innovation with shop floor execution, with advanced knowledge of PFMEA, VDA 6.3 audits, Design for Manufacturing/Assembly (DfM/DfA), and Industry 4.0 integration. Recognized for achieving performance improvements of 25-70% while leading cross-functional, multi-regional teams through complex product launches and technology transfers.

CORE COMPETENCIES & STRATEGIC CAPABILITIES

• Manufacturing Strategy & Industrialization: Advanced Product Quality Planning (APQP) New Product Introduction (NPI) Production Part Approval Process (PPAP) Design for Manufacturing/Assembly (DfM/DfA)

Make vs. Buy Analysis Capacity Planning Global Footprint Strategy Technology Road mapping

• Operational Excellence & Quality Systems: PFMEA Process Flow Diagrams Control Plans VDA 6.3 Audits

IATF 16949 ISO 9001/14001/45001 8D Problem Solving Root Cause Analysis (5-Why, Fishbone) Statistical Process Control (SPC)

• Lean & Continuous Improvement: Lean Six Sigma Kaizen Events Value Stream Mapping (VSM) Single Minute Exchange of Dies (SMED) Overall Equipment Effectiveness (OEE) Total Productive Maintenance

(TPM) Poka-Yoke 5S

• Digital Manufacturing & Industry 4.0: Manufacturing Execution Systems (MES) Digital Twin IoT & Sensor Integration Predictive Maintenance Data Analytics & Visualization Digital Work Instructions Automated Process Monitoring

• Global Leadership & Change Management: Cross-Functional Team Leadership Stakeholder Management Engineering Change Management Global Technology Transfer Supplier Development Training & Capability Building Budget & Resource Management

TECHNICAL EXCELLENCE

• Manufacturing Engineering: PFMEA FMEA Control Plans Process Validation GD&T Tolerance Analysis Life Cycle Assessment Energy Modeling Assembly Process Design

• Digital & Analytics: Power BI Tableau Advanced Excel (Macros, VBA) MS Project Jira Asana Git

• Programming & Automation: Python R SQL JavaScript HTML/CSS

• CAD/PLM: Familiarity with SolidWorks, AutoCAD

PROFESSIONAL EXPERIENCE

Lead Production Engineer, Vestas Nacelles Germany GmbH, Travemünde, Germany

(February 2025 – Present)

• Delivered end-to-end ramp-up readiness for multiple NPI programs (offshore & onshore), enabling stable SOP and scalable global manufacturing.

• Industrialized new nacelle and generator designs, converting R&D concepts into robust, repeatable production processes deployed internationally.

• Optimized high-mix, multi-product manufacturing lines, improving throughput, flexibility, and changeover efficiency.

• Implemented advanced line balancing algorithms, achieving 95%+ workstation utilization and eliminating bottlenecks.

• Owned and standardized PFMEA, Process Flow Diagrams, Control Plans, and PWI/PII, aligned with VDA and OEM quality standards.

• Acted as process responsible and SME during internal and external VDA audits, ensuring compliance and zero critical findings.

• Led global technology transfer, coordinating equipment readiness, process validation, and operator training across regions ensuring +98% first-time capability (Cpk >1.67).

• Supported cost-out initiatives, reducing assembly time, material usage, and overall product cost through DfA and process optimization.

• Assessed and implemented engineering change requests, applying risk-based decision-making to protect production stability.

• Served as the primary interface between R&D, Quality, Supply Chain, and Manufacturing during critical launch phases.

Guest Researcher, Climate + Tech Thinktank + AI for Climate Risk, ESG and Adaptation, Berlin

(September 2023 – January 2025)

• Led ESG research and strategic advisory initiatives for energy-focused organizations, aligning them with international compliance and sustainability benchmarks.

• Built AI/ML forecasting tools to model energy demand and grid resilience, enhancing decision-making for public and private energy stakeholders.

• Contributed to global policy white papers focused on climate adaptation, workforce health, and sustainable economic development.

Solar Project Developer, Sustaining Dunbar, Dunbar, Scotland (September 2022 – February 2023)

• Delivered a comprehensive feasibility study for a 20 MW solar park, increasing projected yield by 15% through innovative layout and orientation strategies.

• Developed ROI, IRR, and risk models (P50-P90) to support investor due diligence and strategic funding acquisition.

• Reduced CAPEX by 10% through optimization of procurement and system design. Project Engineer, Roots Consults Limited, Madina, Ghana (August 2020 – August 2021)

• Supervised and executed large-scale industrial electrical installations, ensuring strict adherence to safety, quality, and budget timelines.

• Approved and optimized over 50 technical drawings, ensuring alignment with international construction codes and standards.

• Fostered collaboration across engineering, procurement, and construction teams in high-pressure environments. Production Engineer, Nexans Kabelmetal Ghana Limited, Tema, Ghana

(September 2017 – May 2020)

• Increased throughput by 25% (€2 + ) through Lean Manufacturing and process redesign across extrusion, stranding, and insulation lines.

• Reduced defect rates by 70%, saving €500K+annually€500K+ annually€500K+annually in scrap, rework, and warranty costs via PFMEA-driven improvements.

• Delivered 15% annual OPEX reduction through Value Stream Mapping, Kaizen events, and energy optimization.

• Supported market launch of 3 new cable product lines, achieving 98% first pass yield within 3 months of launch.

• Developed process specifications and quality control plans for new products, ensuring regulatory compliance.

• Achieved 863 consecutive days without Lost Time Injury (LTI), establishing facility safety record.

• Implemented behavioural-based safety program and daily Gemba walks, fostering culture of continuous improvement.

• Mentored 18 junior engineers and 15 technicians, improving team capability and reducing reliance on external support.

EDUCATION & ACADEMIC EXCELLENCE

Europa Universität Flensburg, Flensburg, Germany (September 2021 – September 2023) Master of Engineering, Energy and Environmental Management Award: Deutsche Akademische Austauschdienst (DAAD) Scholarship University of Mines and Technology, Ghana (November 2013 – July 2017) Bachelor of Science, Electrical and Electronics Engineering CERTIFICATES & PROFESSIONAL DEVELOPMENT

• Project Management Professional, Project Management Institute (PMP) - 2026

• Certified Renewable Energy Project Developer, RENAC (Focus on PV Systems) - 2024

• Google Project Management Professional Certificate - 2023

• Google Data Analytics Professional Certificate - 2023

• Spring School Hydrogen Technology 2023, Lauenburg – Germany - 2023

• Environmental Social Governance (ESG) Expert Training -2023 LEADERSHIP, IMPACT & COMMUNITY

• Mentored 20+ graduates into fully funded international graduate programs (DAAD, Chevening, Erasmus+), with 95% placement success rate.

• Delivered technical training programs on Lean Manufacturing, Six Sigma fundamentals, PFMEA, and HSE best practices to 100+ engineers globally.

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