In this role, in addition to being the Director of Robofacturing, the team of engineers dedicated to designing the end-to-end robotic thermoplastic composites factory, I headed the Materials Development team dedicated to development, testing, A-class thermoplastic composites, in-mould interior finishes, adhesives, polymers, metals, and other related matters.The post required a full restructuring and realignment of the Composites and Materials team of 60 engineers handling the revised portfolio of 57 projects.

In this role, I finished the Composites Microfactory Design & Launch turn-around, with peak commissioning work intensity in July and August.In parallel, I established a two-year Strategic Technology Development Roadmap and started its execution to drive composite components cost down with a significant reduction in CAPEX and OPEX KPIs of a Factory.I created a fully digital thermoplastic Composites Microfactory Blueprint with all required documentation to deploy a new microfactory within a much shorter time and transitioned the majority of R&D technologies from early TRL to Production Ready state.

In 2022, as ARRIVAL transitioned into a mission-critical delivery phase, my teams’ scope widened to include launch of the Company’s first Composites Microfactory with full integration of the in-house materiatls with its end-to-end, robotic production technologies.I “hand-picked” many talented engineers and grew the team to 22, within nine months turning the warehouse-like and largely empty space into a full-scale production facility kitting, moulding, trimming, and bonding 102 unique polypropylene glass fibre body panels.This truly notable project unified all proprietary materials and solutions under one factory roof.

In the late 2021, as ARRIVAL advanced toward the 2022 SOP milestone (both VAN and BUS programs), my background in composites, the Company-specific software experience, and the past projects paved the way to the position of Lead of RBF. Started with a team of three Robotic Process- and two Robotic Tooling Design engineers, this role covered all Design and Development of the first Composite Microfactory in Bicester, UK. My team was to transition from R&D to industrialization (TRL to MRL) while adhering to the Design for Manufacturing standards.To advance from the in-progress gamma phase, under the auspices of the office of CEO, I established a task force of Product, Materials, RBF, Programme and other relevant teams. The task force enabled cross-functional team collaboration and established a unified project plan (with proper tracking, analysis, and reporting functionalities) to attain the KPIs for product and technology maturity.In addition, my team initiated the work on Composites bonding and surface activation cells.

Following my successful launch of the ply kitting cell (KCELL) within the Robotics Division, I advanced to the role of software Delivery Manager, who’s objective was the implementation of ARRIVAL’s proprietary Manufacturing Execution and Operations Control System. My responsibility was to model and implement the end-to-end production scenarios/processes within the Composites Microfactory. The system was to control the entire facility: from demand generation, through all manufacturing stages, and to EOL, packaging, and product delivery. In addition to creating the overall system design, this activity entailed task assignment and coordination of the backlogs of multiple software development teams, such as the Business, PLM, ERP, Production HMI, Traceability, release planning, and other related groups in connection with Composites Microfactory.Close collaboration with the internal customers, such as production operations, HSE, Procurement, Logistics, Quality, and Integration had been carried out in order to properly assess, systematise, and design the system befitting the multitude of vehicle-production requirements and ensuring flexibility and growth. The end product controlled a myriad of production scenarios in accordance with the panel fabrication process, including, but not limited to, the task allocation engine for the molding/forming cells (MCELL), robot machining cells (TCELL), system-to-machine interfaces/drivers communicating via enterprise-wide Ethernet/TCP/IP (incl. Allen Bradley and Modbus) and more. My contribution to the PLM system allowed us to parametrize control scripts of MCELL and TCELL for the fastest introduction of new products into manufacturing based on attributes and their values.I also led the creation of a piece-part mBOM structure with required attributes and stages describing each ply (layer) of a composite panel in Upchain and, later, in Team Centre. I also linked the mBOM with the Change Management loop.

Relocating from Berlin (Germany) to Bicester (UK)

Aggregation and integration of ARRIVAL’s in-house flexible-robotics software technologies into a production-ready solution under the Robotics Division umbrella was both challenging and exciting, a rare opportunity to couple the extensive experience in traditional polymeric composites with cutting-edge software technologies. Leading an agile team of two C++ programmers, a Python programmer, a QA and an integration engineer (later with the addition of several Robotics and Mechanical Design Engineers), I successfully launched one of the most advanced products within ARRIVAL’s microfactory called KCELL (ply kitting cell). The KCELL, using cutting machines, cuts fabric rolls into specifically shaped 2D plies, subsequently picked by a robot, and stacked to create a functional moulding kit. The cell is fully adaptable to any changes in product or production schedule; it does not require engineering or maintenance support for reprogramming. KCELL’s key USPs are:- Dynamic in-situ nesting engine with gripper resolution adjustment- Dynamic in-situ trajectory planning for 6+1+1 axis KUKA robot arm with a full collision map and a 3D digital twin- Cutting programs generation based on input geometry of a part for various ply-cutting systems- Matrix gripper with 250+ individually actuated gripping points and 150*150 mm resolution (overall size 2000 mm x 3000 mm)- Matrix gripper configurator that generates arrays of grippers to switch on/offThe Agile methodologies I implemented governing this project proved effective (including KANBAN/SCRUM boards, sprint planning, Objectives and Key Results (OKRs), release planning, one-pagers describing each feature, requirements, user stories, epics, etc.) GIT was the version control system.Within two years from development, we advanced from POC to MVP and a production-ready solution compliant with all specified features and tested at rate. In summary: KCELL is currently working at the current Composite Factory in Bicester, UK.

The main objective at BME was to develop a high-volume Thermoplastic Resin Transfer Moulding (T-RTM) production line for the Automotive Sector. I worked alongside Professor Jozsef Karger-Kocsis, Professor Jozsef Kovacs-Gabor, and Dr. Peter Molnar on this innovative technology. T-RTM allows the production of structural composites with thermoplastic matrix by impregnating glass or carbon fiber preform with a water-like viscosity monomer and a subsequent (after the wet-out stage) chemical reaction Anionic Ring-Opening Polymerization (AROP) in the presence of heat, the activator, and initiator.My primary responsibilities included materials development and production line construction. Working with professor Karger-Kocsis and Kovacs-Gábor on a state-of-art definition for epsilon- and lauryl-lactam AROP to obtain Nylon-6 and Nylon-12 thermoplastic matrices, I published several papers on modelling and tooling design.In collaboration with prof. Kovacs-Gábor and Dr. Molnar, I helped design an automated production line of two caprolactam dosing systems, a mould carrier, a performing cell, and a ply cutter. This system, coupled with a mould carrier from Krauss Maffei, rendered structure creation and in-mold coating with caprolactam-based material (similar to the IMC process). The negotiation efforts I conducted helped secure a significant equipment discount budget and, hence, fit the budget of EUR 1.6 million.I also developed composite competencies and established composite production for a former customer EvoPro.All of the aforementioned activities helped Dr. Molnar successfully secure a EUR 3.5 mln investment and establish a new start-up HD Composite (https://hd-composite.com), recognized via JEC yearly award for achievements in T-RTM technology development.

During the critical delivery phase for the MODULO project, I spearheaded the vacuum infusion to eliminate two bottlenecks in the bus body’s front and rear modules (overall team size of 21).Managing the team of 12 people, originally yielding a 6-day cycle time to complete the rear module, I reduced it to four days, repeatable quality, and the headcount of eight people. I achieved comparable performance improvements in connection with the front module, as a result, substantially improving this project’s economics.I also led work on licensing packages for MODULO composites and, together with two Process Engineers, created a set of detailed working instructions (1000+ pages) to enable EvoPro’s manufacturing worldwide.Resolution of the said bottlenecks led to EvoPro and NCC extending their collaboration via a new joint venture for CIS countries; this project received the JEC award in Paris, the most prestigious award in composites worldwide.In addition to MODULO, I was heavily involved in pultrusion, ply kitting, tool making, SMC, LFI, and machining, leading all assembly operations for pultruded hand rails and producing hundreds of metres handrails (subsequently successfully installed).As a member of a cross-functional team involved in IATF 16 949 accreditation, I was responsible for the compliance of the assembly and post-processing sectors. NCC had successfully passed the first and all the subsequent audits.

Мy main objective within the Production Technology Department was leading all the assembly activities within the MODULO bus program. Initially providing Engineering Support to the front module production team, my team grew to the headcount of seven technicians, taking on the additional activities in manual trimming and post-processing. I created multiple visual instructions, designed production workshops, selected equipment, developed assembly fixtures and templates, completing twelve part sets.Upon completion of the first set of bus body parts in May of 2015, I provided engineering/production support in Budapest helping bond the 9.5-meter bus body.

Joining an international team in one of the most prospective Composites and Nano-technologies Moscow start-ups NCC Russia (funded by Rusnano, DowAksa, and HCC), I utilised my Mechanical Engineering background (also acquiring a great deal of knowledge in Composites) to create, manufacture, and commission various 3D templates and jigs to enable metallic insert positioning and bonding on a composite bus body.

As a website content creator for a Russian subsidiary of a British Mechanical Seals manufacturer AESSEAL, I developed a locale-specific product catalogue. Creating a detailed requirements list, I worked with an external web development agency and launched the website within six months, resulting in the increase in local sales and improvements in service quality.

Successfully completed a one-month Coiled Tubing service internship and participated in 15 cleanouts and nitrogen kick-off (lift) operations. I was offered a job but had to decline as I wanted to work abroad where more advanced methods like directional drilling were used.