History of Projects Jörg Schacht

Functional Safety for a 500 kWh Methanol-Fuel-Cell

ASIl C / SIL 3

95 % offline 

Job within project:

FSM - Functional Safety Manager / external FuSa support

Tasks:

Funktional Safety / Functional Safety Management / AFSE

• Integration of functional safety into product development process
• Coordination with the certification body (ABS: American Bureau of Shipping)
• Communication with Freudenberg project management
• FuSa coordination with internal departments at Freudenberg

Functional Safety for a HV DCDC converter (800 V technology)

ASIl D

95 % offline

Job within project:

FSM - Functional Safety Manager / external FuSa support

Tasks:

Funktional Safety / Functional Safety Management / AFSE

• Integration of functional safety into product development process
• Coordination with the customer (Mercedes)
• Communication with Hella / Forvia project management
• FuSa coordination with internal departments at Hella / Forvia

Functional Safety for a Keyless Go system inclusive mobile control (Supervised Remote Parking)

ASIL B

100 % offline (Corona pandemic)

Job within project:

PSM - Project Safety Manager

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Integration of functional safety into product development process
• Coordination with international departments (USA, Germany, India, China, Australia)
• Communication with Bosch project management
• FuSa coordination with internal departments at Bosch

Functional Safety for an electrical drive system (powertrain) for roboter taxis

ASIL C

80 % presence on site at Nuremberg

2021: 25 % presence (reduction because of Corona pandemic)

Job within project:

FSQM - Functional Safety Quality Manager

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Integration of functional safety into product development process
• Coordination with internal departments
• Communication with hofer project management
• FuSa coordination with OEM (Zoox, Amazon)

Functional Safety for a control unit for positioning the vehicle within the ADAS activities (VMPS)

ASIL B(C)

80 % presence on site at Abstatt, Korntal and Weilimdorf

Job within project:

FSM - Functional Safety Manager

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Coordination with internal departments
• Training of the team members
• Communication with Bosch project management and the central FuSa organisation
• FuSa coordination with OEM (Daimler)

Reviews of documents for functional safety for a laser light system at different OEMs

ASIL C

10 % work at home office

Job within project:

FSQM - Functional Safety Quality Manager

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Creation of review checklists
• Document reviews

Functional Safety for electrical drives for pedelecs

ASIL B

10 % presence on-site at Fürth

Job within project:

Consultant for FuSa-activities, electrical drives for pedelecs

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Coordination with the internal departments (HW / SW)

Functional Safety for front camera, which will be implemented at VW world-wide for all platt forms and vehicles

ASIL A(B)

50 % presence on-site at Bietigheim-Bissingen and Wemding 

Job within project:

FSQM - Functional Safety Quality Manager

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Coordination with internal meetiers
• Communication with Valeo project management
• FuSa coordination with OEM (VW company-quality)

Functional Safety for an Instrument Cluster with Display

ASIL B

6 days/month presence on-site in Abstatt

Job within project:

FSM - Functional Safety Manager

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Define development process from the view of an OEM
  • Describe development phases
  • Describe swimlanes / responsibilities
  • Describe work products within the different quadrants of the development process
  • Generate templates / check lists / review lists
• Transferring an Audi base project to different applications at Bentley
  • Rework safety concept
  • Develop Impact Analysis
  • Modify Safety Goals
  • Modify safety documentation

Functional Safety for light applications – implementation of ISO 26262:2011

ASIL B

1 day/week presence on-site in Herbrechtingen, Regensburg, Garching

Job within project:

FSM - Functional Safety Manager

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Positioning of a product for the aftermarket (SmartCarConnect)
  • Write Item Definition
  • Make HARA
  • Define Safety Goals and reaction times
• Checking and upgrading of safety documentation
  • Laser applications for projects with Audi and BMW
• Supporting for offer negotiations with Daimler
  • Customer visits

Seminars and workshops with the topics: cause analysis (CA) / problem solving techniques for spinning machines;

Moderation of different CA-workshops

2 days/month presence on-site in Ingolstadt / Süßen / Winterthur

Functional Safety for the Electrical Steering Column Lock (ESCL) – Implementation of ISO 26262:2011 amongst others for the department mechanics

ASIL D

40 h/week presence on-site in Erdweg

Job within project:

FSM - Functional Safety Manager

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Transfer of the development according ISO 26262:2011 to mechanics development
• Analysis of current projects for continuous improvement

• ISO 26262 (module 01 to 05)
• Process-FMEA
• Design-FMEA 

Moderation of several FMEA-workshops

Functional Safety for the Vehicle Electronic Control Unit (VECU) within a truck (DAF) – implementation of ISO 26262:2011

ASIL B(C)

35 h/week presence on-site in Villingen-Schwenningen

Job within project:

FSC - Functional Safety Consultant

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Specialist for the implementation of ISO 26262:2011
• Analysis of the Functional Safety Concept of the customer
• Creation of Technical Safety Concepts for the functions of the instrument clusters
• Participation in reviews of the existing customer documents
• Coordination of internal activities concerning Functional Safety with the experts of the departments system / architecture, hardware, software and test
• Consulting of specialist divisions
• Creation of TSC for a platform project as SEooC (Safety Concept out of Context)

Functional Safety for the Power Distribution Unit (PDU) of a fuel cell – Implementation of ISO 26262:2011

ASIL C

30 h/week presence on site in Harrislee nearby Flensburg

Job within project:

FSM - Functional Safety Manager

Tasks:

Functional Safety / Functional Safety Management

• Specialist for implementation of ISO 26262:2011
• Training of internal employees concerning functional safety
• Training of project members with the topics functional safety / ASIL / decomposition / system / hardware / software
• Creation of an overview of necessary work products for ISO 26262:2011
• Development of the complete FuSy documentation for the project "Panther"
• Integration of FuSy activities into established development process of Kristronics (Automotive Division)
• Coordinating the internal activities of Functional Safety with the specialists of the departments system, hardware, software and test
• Creating templates and checking lists for the planned reviews of the work products
• Generating project specific documents which are mandatory for the standard – amongst others creation of the safety plan
• Storing concept for requirements and work products within Polarion and Subversion (SVN)
• Ensure traceability of requirements (development of own macros)
• Cooperation with customer NuCellSys (system fuel cell) and Daimler (original equipment manufacturer)
• Coordination of reviews for documents concerning Functional Safety
• Developing a skill-matrix together with the departments concerned

Functional Safety for engine control units – use in mobile cranes / construction machines / generator-sets – Implementation of ISO 26262:2011

ASIL B

30 h/week presence on-site in Lindau

Job within project:

FSM - Functional Safety Manager

Tasks:

Functional Safety / Functional Safety Management / AFSE

• Specialist for implementation of ISO 26262:2011
• Support of the internal specialist for Functional Safety
• Overviewing the issue of necessary work products for ISO 26262:2011
• Creation of the complete FuSy documentation for the project „Panther“
• Integration of FuSy activities into the new created development process of LEG for the area industry
• Matching the activities with the external partner TÜV Süd
• Coordinating the internal activities of Functional Safety with the specialists of the departments system, hardware, software and test
• Creating templates and checking lists for the planned reviews of the work products
• Generating the project specific documents which are mandatory for the standard – amongst others creation of the safety plan
• Cooperation with the customer LMB (Liebherr Machines Bulle, CH)
• Coordinating reviews for Functional Safety documents
• Ensure traceability of requirements (development of own macros)
• Creating a skill-matrix with the departments concerned
• Training the corresponding staff, following topics were covered:
  • ISO 26262:2011
  • ASIL and Decomposition

Optimization of development process within development and production

Development of an offensive for quality (strategie for the year 2017)

3 - 4 days/month presence on-site in Ronsberg (Allgäu)

Job within project:

QM consultant

Tasks:

QM consulting

• Analysis of development processes
• Analysis of production processes
• Analysis of quality processes
• Concept: From quality check to quality control
• Agreements with all departments concerned
• Presentation of results to executive board
• Development and implementation of specific problem solving
• Generating quality strategy for the year 2017

Optimization of realization of FMEA (product and process)

3 - 4 days/month presence on-site in Bad Neustadt

Job within project:

FMEA consultant

QM consultant

Tasks:

FMEA and QM consulting

• Revision of FMEA guideline
• Revision of ranking scales
• Optimization of integration of FMEA within development process
• New arrangement of responsibilities within the organization
• Integration of „Special Characteristics“ into development process
• Training the corresponding staff, following topics were covered:
  • APQP
  • PPAP

Functional Safety for power electronics in hybrid- and electric vehicles

FMEA moderation (mechanics, hardware)

ASIL C

30 h/week presence on-site in Nuremberg / Erlangen

Job within project:

FSM - Functional Safety Manager

SMiP – Safety Manager in Project

FMEA Expert

Tasks:

Functional Safety / Functional Safety Management

• Cooperating in a platform project as FSM
• Matching activities with external partner TÜV Nord
• Coordinating the internal activities of Functional Safety
• Overviewing the issue of necessary work products for ISO 26262:2011
• Creating templates and supporting creation of incoming documents for determination of critical scopes:
  • Item Definition
  • Hazard and Risk Analysis
  • System Architecture (hardware and software)
  • Functional Safety Concept / Technical Safety Concept
• Composing all necessary procedures and tests for these scopes:
  • development on system level
  • development on hardware level
  • development on software level
• Coordinating reviews for Functional Safety documents
• Training the corresponding staff, following topics were covered
  • ISO 26262
  • ASIL and Decomposition
• Creating the Skills Matrix for scope FSM (with optional enlargement on all topics) and deriving demand of further education

FMEA-Moderation

• Internal coordination of different contact partners
• Clearing system FMEA with Requirements Engineering
• Evaluating various OEM specifications
• Comparing the government requirements / standards
• Supporting the creation of technical hardware requirements for equivalent FMEAs
• Creating of all FMEAs with expert contact partners
• Conforming the APIS^® software to company specific requirements
• Determining special characteristics (SC) together with the mechanics experts

QM support, FMEA moderation (mechanics, hardware) and Functional Safety for power electronics in hybrid- and electric vehicles

ASIL C

30 h/week presence on-site in Nuremberg

Job within project:

QM consultant

FMEA expert

FSM - Functional Safety Manager

Tasks:

QM support

• Supporting department in implementation automotive industry processes
• Training the corresponding staff with regard to different QM topics such as
  • FMEA
  • APQP
  • PPAP
  • Special characteristics
• Creating internal templates of documents such as:
  • APQP Overview (8 single Excel sheets)
  • Run@Rate approval at suppliers (7 spreadsheets)
  • 8D-Report for suppliers
  • Office templates (Word / Excel / PowerPoint / Visio)
• Moderating workshops, topics covered:
  • decision analysis
  • cause analysis
• 3D + 2D drawing reviews together with mechanics team
• Sorting and labelling necessary international and OEM specific standards and specifications (central storing at intranet)
• Cooperating in creation and review the monthly quality report
• Revising the central glossary
• Creating templates of delivery instructions together with parent company

FMEA moderation

• Internal coordination of different contact partners
• Clearing system FMEA with Requirements Engineering
• Evaluating various OEM specifications
• Clearing specification with Polarion^®
• Comparing the government requirements / standards
• Breaking down information from the existing system requirements (ENG2) to technical mechanics requirements (ENG4)
• Supporting the creation of technical hardware requirements for equivalent FMEAs
• Creating company non-generic ranking scales
• Gathering a severity matrix to determine topic progression for FMEAs
• Creating of all FMEAs with expert contact partners
• Conforming the APIS^® Software software to company specific requirements
• Determining special characteristics (SC) together with the mechanics experts

• Matching activities with external partner exida
• Coordinating the internal activities of Functional Safety
• Creating templates and supporting creation of incoming documents for determination of critical scopes:
  • Item Definition
  • Hazard and Risk Analysis
  • System Architecture (hardware and software)
  • Functional Safety Concept / Technical Safety Concept
• Overviewing the issue of necessary work products for ISO 26262:2011
• Training the corresponding staff, topics covered:
  • ISO 26262
  • ASIL and Decomposition
• Creating the Skills Matrix for scope FSM (with optional enlargement on all topics) and deriving demand of further education
• Further training to become an AFSP (Automotive Functional Safety Professional), certified by SGS-TÜV Saar

Design-FMEAs (field: mechanics) for hybrid control systems

ASIL B

35 h/week presence on-site in Nuremberg

Job within project:

FMEA expert

Functional Safety Engineer

Tasks:

FMEA moderation and Functional Safety

• Internal coordination of different contact partners
• Clearing system FMEA with Requirements Engineering
• Clearing specification with DOORS^®
• Change management with MKS^®
• Comparing the government requirements / standards
• Creating of all FMEAs with expert contact partners
• Determining special characteristics (SC) together with equivalent OEMs
• Documenting and pursuing open questions
• FSM (Functional Safety Management) / FuSy (Functional Safety) and ISO 26262
• Cooperating with scope hardware (electronic components) and software
• Integration of the SN29500 - Birolini / ConCERT^® Tool owned by Conti for determination of error probability of default at electronic components
• Coordinating with departments in Europe / Process FMEA
• Arrangements and reviews with various customers / OEMs
• Training the corresponding staff with regard to different QM topics such as:
  • APQP
  • PPAP
  • Run@Rate
  • FMEA
  • SPC
  • MSA
  • PokaYoke, …

Complete process-FMEA-workshops for the M20/32 drive at the production site Aspern (GM Austria) from 2003 to 2005 with the entire production process of internally manufactured components as well the installation of the complete drive (approx. 120 days)

Integration of re-built and new devices from 2005 to 2008 (approx. 20 days)

• Preparatory conversations with the persons responsible for the project
• Conducting the entire workshops
• Documentation of the results on the computer (partly bilingually) during the event
• Translating for the participants from different countries
• Revising the results and preparing risk lists

Complete process-FMEA-workshops for the Family 1 engines at the production site Szentgotthárd (GM Hungary) from 2004 to 2007 with the entire production process of internally manufactured components as well as the installation of the complete engine (approx. 80 days)

• Preparatory conversations with the persons responsible for the project
• Conducting the entire workshops
• Dokumentation der Ergebnisse auf dem Rechner (zum Teil zweisprachig) während der VeranstaltungDocumentation of the results on the computer (partly bilingually) during the event
• Translating for the participants from different countries
• Revising the results and preparing risk lists

Introduction to the Cost Management Process. During the development, this process contributes to a balance between quality, time and costs. Alongside the vehicle development process, it is the one that has turned into the central process of GM development process throughout the world

• Planning a process in order to develop a vehicle in a cost-effective manner
• Support in preparing the database with Access
• Preparing the entire training documents
• Consultations with international colleagues in USA, Korea, Australia, Brazil and China
• Training of all engineers who are involved in the project at the European development sites

• Preparing the entire training documents
• Consultations with international colleagues in USA, Korea, Australia, Brazil and China
• Training of all the engineers involved in the project at the European development sites
• Support in the continuous development of the process for new vehicle projects

Conducting approx. 250 workshops with about 550 training days in the development centre at the Adam Opel AG in Rüsselsheim from 1994 to 2007. The topics dealt with all the FMEA types:

• System FMEA,
• Design FMEA (Design),
• Process FMEA and
• Machine FMEA.
• The topics also covered special fields such as: metals, plastic materials, elastomers, single parts and components as well as modules and systems.

Over the last 6 years, the focus was especially put on carrying out FMEAs in the field of electrical and electronic engineering:

• control systems, CAN-bus and other applications (hereby working together with the majority of the leading automotive suppliers)
• Preparatory conversations with the persons responsible for the project
• Supporting them to invite the participants
• Conducting independently the entire workshops
• Documentation of the results on the computer (partly bilingually) during the event
• Translating for participants from different countries
• Revising the results and preparing risk lists

Development, training and implementation of KCDS (Key Characteristic Designation Process)

• Supporting the planning of internal procedures
• Developing training measures
• Training the staff involved that works at the development and the production sites

Training of about 1,200 managers of General Motors on how to accomplish the GM TQM-strategy „Quality Network“ from 1995 to 2005; approx. 300 training days

• Supporting the planning of the training material
• Supporting the development of case examples
• Supporting the testing of procedures in pilot meetings
• Training the staff

Complete process-FMEA-workshops for the F 40 drive at the production site Rüsselsheim (Adam Opel AG) from 2000 to 2003 with the entire production process of internally manufactured components as well the installation of the complete drive (approx. 95 days)

• Preparatory conversations with the persons responsible for the project
• Supporting them to invite the participants
• Conducting independently the entire workshops
• Documentation of the results on the computer (partly bilingually) during the event
• Translating for participants from different countries
• Revising the results and preparing risk lists

Project description:

Courses, workshops and introductory consultation for the corresponding specifications of the different OEMs.

The topics have included in particular Functional Safety, FMEAs and more QM-techniques such as APQP, PPAP / PPF / EMPB, Run@Rate, KCDS, SPC, MSA, PokaYoke, GVDP, CMP etc. at the automotive suppliers as well as the actual implementation in the existing business processes:

• Listing of each company would be too long at this place. On your request we would like to send you detailed information within a PDF file.

Introduction of FMEA at the development centre of Adam Opel AG in Rüsselsheim in 1994 / 1995; about 50 training days

• Preparing the training documents
• Supporting the development of case examples
• Testing the procedures in pilot meetings

Project description:

Seminars and Workshops with topics of the different OEMs

Topics were mainly FMEAs and other QM techniques as well as Functional Safety according ISO 26262:2011:

• Listing of each company would be too long at this place. On your request we would like to send you detailed information within a PDF file.