Freelance · ConsultingOn-site
Senior Consultant, Injection Molding and Surface Finishing, Automotive Supplier (m/f/d)
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Key facts
- Start
- 07/2026
- Duration
- [Duration]
- Work mode
- On-site
- Location
- Nuremberg
- Workload
- 100 %
- Contract type
- Freelance · Consulting
Project description
An international industrial group specializing in the automotive and plastics processing sectors is seeking an experienced Interim Manager / senior consultant with proven expertise in injection molding and surface finishing (painted plastic visible parts).
Responsibilities
- Analysis and stabilization of existing injection molding processes for painted plastic components (visible parts), including parameter and material evaluation
- Systematic identification of quality defects (e.g., sink marks, warpage, weld lines, surface defects, paint adhesion issues), including root cause analysis
- Conducting process audits directly on the shop floor (injection molding, handling, pretreatment, painting, drying) and developing actionable improvement plans
- Optimization of process windows, setup and approval processes, and inspection criteria to achieve a sustainable reduction in scrap and rework
- Development, documentation, and rollout of standards/best practices for injection molding and painting processes (e.g., checklists, control plans, process parameter standards)
- Close coordination with production, quality, and development to ensure robust defect prevention (e.g., adjustments to molds, materials, part design, and paint systems)
- Support for series production launches, including troubleshooting, maturity level tracking, and assistance with initial sample inspection/approval (EMPB/PPAP)
- Training and coaching of team leaders and on-site employees (problem-solving methods, process discipline, standardized work)
Requirements
Must-have
These criteria are required for the project.
- Must-have: 5+ years of relevant experience in injection molding production, ideally with a focus on visible parts and painted plastic components
- Must-have: Very good knowledge of injection molding technology (understanding of molds and cavities, process parameters, temperature control, venting, material behavior)
- Must-have: Material expertise in common thermoplastics, especially PP, ABS, and PC (including blends, if applicable), as well as their impact on surface quality and paintability
- Must-have: Proven shop floor experience, including structured analysis of process deviations and rapid implementation of corrective actions
- Must-have: Experience with painting processes for plastics (pretreatment, adhesion promoters/primers, paint systems, environmental conditions) and surface requirements
- Methodological expertise: Proficient use of Lean/Six Sigma, FMEA, 8D, Ishikawa, SPC, as well as sustainable measure and effectiveness monitoring
- Desirable: Project experience in the automotive sector (OEM/Tier 1/Tier 2), including high quality and documentation requirements
- Desirable: Proficiency in PPAP/EMPB, support for production ramp-up, and liaison with customer/supplier quality
- Strong in communication and stakeholder management—from line personnel to plant/division management
Skills
- Spritzguss
- Kunststofflackierung
- Lean Six Sigma
- FMEA
- 8D
- SPC
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