Michael Thomas

Managing new vehicle programs from the early strategic planning phase through feasibility studies, simultaneous engineering, prototype validation, and full product launch. Responsible for both technical and financial aspects of vehicle programs at the assembly plant level, overseeing all phases from program initiation to “Job One” and final delivery to the customer. Expertise spans stamping, body construction, paint, final assembly, and logistics operations. Proven track record in driving complex programs to successful completion while maintaining high standards of quality, cost, and schedule.

Leading all body construction initiatives across Ford’s European assembly plants respectively body shops, taking programs from early strategic planning through product definition, simultaneous engineering, facility design, and full implementation. My role spans facility try-outs, production readiness, and seamless integration into assembly operations, ensuring each program delivers on time, on budget, and at top quality standards. With a focus on cross-functional leadership and operational excellence, I turn complex engineering and manufacturing challenges into successful, high-impact automotive programs across Europe.

Based in Pretoria, leading all manufacturing planning activities for future vehicle models across main assembly plants and KD operations throughout the Middle East and Africa. I spearheaded the new Ranger model launch and major capacity upgrades at the South African assembly plant, overseeing stamping, body, paint, and final assembly operations with a relentless focus on delivery, quality, and cost excellence. Passionate about turning strategic plans into operational reality, I drive cross-functional teams across multiple countries to deliver complex programs on time, on budget, and at the highest quality, ensuring every launch exceeds expectations while supporting sustainable growth.

Based in Pretoria, leading all manufacturing planning activities for future vehicle models across main assembly plants and KD operations throughout the Middle East and Africa. I spearheaded the new Ranger model launch and major capacity upgrades at the South African assembly plant, overseeing body operations with a relentless focus on delivery, quality, and cost excellence. Passionate about turning strategic plans into operational reality, I drive cross-functional teams across multiple countries to deliver complex programs on time, on budget, and at the highest quality, ensuring every launch exceeds expectations while supporting sustainable growth.

I led all paint material development and release processes across the European region, taking programs from initial development and validation, through prototype testing and assembly planning, to market launch and new product introduction. I ensure every product meets technical, quality, and operational standards, delivering excellence for customers while supporting on-time launches, cost efficiency, and program success. Known for turning complex development programs into smooth production reality, I coordinate cross-functional teams across Europe to achieve high-impact results in automotive paint systems.

Leading all manufacturing planning activities and Quality Workstreams for future vehicle models across assembly plant paint shops throughout Europe, Russia and Romania. I spearheaded new Passenger Car model launches and major capacity upgrades across those paint shops at Europe, Russia and Romani, overseeing paint operations with a relentless focus on delivery, quality, and cost excellence. Passionate about turning strategic plans into operational reality, I drive cross-functional teams across multiple countries to deliver complex programs on time, on budget, and at the highest quality, ensuring every launch exceeds expectations while supporting sustainable growth.

Presentation of study results for all interfacing BC sub-departments. Planning of BC Processes and Facilities while considering global architecture process at minimum cost, maximum flexibility, highest quality standards as well as material flow and layout. Execution of studies regarding modernization, optimization, capacity changes as well as relocation of facilities to increase Quality, productivity and completeness. Verification and validation of studies for content and completeness. Close loop to interfacing departments, especially to Manufacturing Business Office, Manufacturing Engineering, Clearing House, Product Development, Program Office, Finance and stamping. Support global alignment between FoE, FNA, FAPA and FSAO. Coordinate regular Meetings with all interfacing areas internally and supplier externally. Ensure flexible, robust processes and facilities at lowest possible investment and maximum re-use level. Support any benchmarking exercises of process and facilities. Develop cost- and capacity studies as well as cost benchmark of in-house vs. outsourcing. Develop new future process strategies. Judge any proposals for improvement from the internal proposal process. Support ans Senior Level Special Studie. Manage cost control vs. targets. Cost estimation to control investments and to establish negotiation targets,

Project: Black Belt Training plus assignments aside the duties of the Manufacturing Engineering role support new model progam activities. Role: Black Belt & EU Manufactruing Taskforce Leader Scope: Training & Technical project execution - Closure of >10 BB projects and one being a Mega project on corrosion. Section: Cross functional Technical issue resolution (Soft- and Hardvings > EURO 100 Mils)

Roles & Responsibilities -> Respond to Study requests. Review Study documents vs. Bill of Process. Identify facility, tooling, and labor issues and provide resolutions. Correspondence with Manufacturing Business Office. Process feasibility reviews for new model introduction. Review CAD data, assess feasibility. Plan, conduct and document line trials as required. Co-ordinate Virtual Manufacturing activities. Complete all body VM assessments. Liaise with Product Engineering. Join Program related Meetings. Manage Virtual assessment activities for new model programs. Update all respective IT systems. Manage and operate Issue tracking systems on new model program issues as well as drive and support resolutions. Manage process setup in respective electronic systems. Development of new processes and update of existing. Support new model launch phases. Review and signoff prototype builds, identify, track and resolve build / process / labor / facility / tooling issues. Co-ordinate ergonomic assessments. Communicate / liaise with Plant all Paint Manufacturing issues. Support 6 Sigma. Completion of Black Belt projects and support department Green Belts. Support body shop facilities projects including Project preparation bid reviews/recaps and order placement. Project management during full period of launch. Update existing, and create new feasibility specs as required. Document Lessons Learned for new model programs.

Roles & Responsibilities (only substantial ones) • Lead team of various disciplines thought out design and installation phase • Complete process feasibility reviews for new model processes and facilities • Manage Automated Issue Management System • Manage GSPAS system • Support new model launch phases • Co-ordinate ergonomic assessments • Communicate / liaise with Plant on all Manufacturing issues • 6 Sigma, complete Black Belt projects and support department Green Belt projects • Support general EU facilities projects • Update existing and create new feasibility specification as required

GVA mbH - Project planning of plastic granulate manufacturing facilities and development of technical equipment database for existing facilities at Bayer Dormagen, Germany

Project planning of plastic granulate manufacturing facilities for Bayer Dromagen, Germany