Schnitzer Group Newsletter
IN TIME 05/25 .

10 Years of Schnitzer Group USA –
Happy Birthday! 

15 Years of Robert Faeller at Schnitzer Group – Congratulations! 

Ten years ago, Schnitzer Group USA was founded in Charlotte, North Carolina – following Schnitzer Consulting Shanghai and Schnitzer International Swiss, it became the Group’s third international location. Since 2019, the company has been under the leadership of Robert Faeller. 

Interview with Peter Schnitzer and Robert Faeller 

Mr. Schnitzer, what motivated you to establish a company in the United States? 

Our customers' strategic decisions were a major driver, particularly the localization of vehicle platforms in China and the USA. Expanding into the U.S. was a logical step for Schnitzer Group. We are highly familiar with the requirements of German OEMs and have a long-standing reputation for delivering process-oriented, high-quality services. Producing the same product across three continents – each with different supply chains – while maintaining consistent quality is highly complex. To meet this challenge, a partner must not only understand intricate interdependencies but also be able to respond quickly to changing conditions on site. Our local presence also helps minimize currency risks for our clients. 

Why Charlotte? 

Charlotte offers a high quality of life with numerous recreational opportunities and a vibrant cultural scene. Over the past years, the city has experienced robust economic growth, supported by a diversified industrial base. It is a major business hub with thriving sectors such as banking, manufacturing, energy, and automotive. In 2025, Charlotte's population was estimated at around 935,017. Interestingly, Charlotte is home to the largest German community in North America – thanks in part to the direct flight connection to Munich and the presence of several German companies in the area. 

What were the initial challenges? 

We had no local network and limited experience in the U.S. market. However, due to strong demand from our international clients, we started with one motivated project manager and a modest assignment – which, frankly, didn’t cover our costs. For the first three years, we had to pre-finance rent, salaries, and travel expenses until the “seedling” took root. What we underestimated was the administrative burden. In Germany, we often talk about reducing bureaucracy – but let me tell you, there are even more complex systems out there. 

Do you offer the same services in the U.S. as in Germany? 

Germany, the U.S., and China work hand-in-hand on shared customer projects. A key challenge is often rooted in the U.S. business mindset. Our pragmatic, systemic approach can be unfamiliar in an American environment shaped by a “hire & fire” management culture. In Germany, there is stronger employee retention and a structured vocational training system. “Made in Germany” and German engineering are highly respected in the U.S. Our mission is to ensure consistent premium quality, no matter where a vehicle is manufactured. 

Mr. Faeller… 

You joined Schnitzer Group in 2010 and are celebrating your 15th anniversary this September. How does that feel? 

I’m proud to say that Schnitzer Group has shaped me into the person I am today. Over the past 15 years, I’ve worked in various roles across Germany, China, and now the U.S. The company truly feels like a second family. 

You’ve been leading the U.S. operations as CEO for nearly six years now. How do you manage that responsibility?  

I’ve been fortunate to be supported by great mentors who genuinely wanted me to succeed. I learned a lot from them and developed my own leadership style. I always immerse myself in the local culture, stay open-minded, and make it a point to be a trusted advisor to my team.  

Do Americans like working for German companies? 

Absolutely! Our company culture combines the best of both worlds: German structure, direct communication, and reliability – with the openness and innovation spirit so appreciated in the U.S. The stability and transparency of German companies are often perceived as strong positives. 

How do you see the future of global companies in the U.S. given the current geopolitical climate? 

Our deep technical expertise and specialization in the industrialization of complex engineering projects give our clients a competitive edge. In uncertain markets, we operate as a global, agile task force helping international companies adapt swiftly to new conditions. The U.S. remains a high-potential market for German businesses, and we are confident that with quality, reliability, and innovation, companies like Schnitzer Group will continue to thrive. 

What has been your personal highlight in the U.S.? 

Professionally, it was winning our first major U.S. client under my leadership and hiring our first local employee – both proud milestones. Personally, it was welcoming my family to Charlotte for Christmas 2022, after nearly three years of Covid-related travel restrictions. 

Contact: robert.faeller@schnitzer-group.com 

Our team in the US (visit of CEO Andreas Kohler, second from left)

 

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Advanced Surface Finishing:
Focus on Grain Texture 

OEM Supplier Event in South Carolina – February 2025

From left to right: CEO Schnitzer Group USA Robert Faeller,  Ralf Weimar, Nicholas Giffel

In February 2025, Schnitzer Group USA was honored to be invited by a prestigious German OEM to actively participate in its supplier event in South Carolina, which focused on surface grain quality. During the morning session, the OEM’s quality representatives presented their expectations and standards for product quality to their suppliers in a formal auditorium setting. In the afternoon, suppliers had the opportunity to engage in deeper discussions at a "Marketplace" featuring six exhibition booths. Two material suppliers, two surface finishers (specialized in grain texturing), Schnitzer Group, and one additional service provider were selected to showcase their capabilities as benchmark companies. 

At the Schnitzer Group booth, Andreas Kohler, Robert Faeller, Ralf Weimar, and Nick Giffel represented the Schnitzer brand. Numerous in-depth discussions took place, many of them with a strong technical focus. Being one of only six external companies chosen to participate was both an honor and a recognition of our technical excellence. The invitation and active participation were the result of a challenging technical project previously solved by Schnitzer Group. 

Thanks to the expertise of Ralf Weimar, Project Manager at Schnitzer Group USA, a complex surface defect issue was permanently resolved. Within the industry, it is well known that challenges in the injection molding process for surface graining go far beyond flawless execution. They require optimal communication and process coordination, meticulous planning, cross-functional collaboration, and deep technical know-how to achieve perfect grain texture results. 

Detailed views of component

A brief look at the project summary… 

Starting Point: After the third unsuccessful surface evaluation at the Tier 1 supplier, the plastic components for the vehicle window area were still not approved for production. Following this third review cycle, tooling and process expert Ralf Weimar from Schnitzer Group was brought in to help identify a viable solution to meet the OEM’s surface and quality standards. 

Root Cause Analysis: A detailed tooling assessment revealed that the grain texture at the parting line had not been executed with the required precision. Improper masking at the parting line resulted in an undercut, which caused severe demolding scratches along the entire length of the cosmetic surface. A team of experts coordinated by Schnitzer Group removed the undercut and corrected the affected tool section.  

Outcome: After the professional repair, the optimized components were re-submitted to the OEM. The surface results met the OEM's high standards, securing the overall project timeline. Through clear communication and deep expertise in tooling, the root cause was successfully identified and eliminated. 

Well done, Ralf! 

Contact: ralf.weimar@schnitzer-group.com  

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Schnitzer Group – Experts in Production Relocation 

Transparency, technical expertise, and leadership as key success factors

We were pleased to be approached again by a long-standing business partner after several years, this time for a new project assignment. A TIER1 supplier commissioned us to provide external project management support—specifically, technical oversight of a complex relocation project. Our client, a global lighting manufacturer, was faced with the closure of a production plant in France. Our task was to ensure the secure transfer of spare parts production for multiple customers and product lines to a site in Spain. The primary challenge lay in the coordination of numerous individual sub-projects, tools, and technical details. In numbers, this meant managing: 5 different assembly lines, 280 tools across multiple technologies, 200 lighting variants, Composed of over 1,250 individual components 

Hubert Sinz of Schnitzer Group served as the overall project lead for nearly one year, overseeing coordination across all customers, projects, assembly systems, and tooling. His core responsibilities included: 

• Defining a unified strategy for all customers and relocation scopes 

• Maintaining proactive communication with OEMs 

• Developing solutions for unexpected challenges 

In short: delivering full transparency to both the internal organization and four OEMs to minimize risk. With over 15 years of experience in lighting and luminaire systems, Hubert Sinz provided exceptional value to both client and project. 

Thanks to his agile mindset and solution-oriented communication with the project team, management, and customers, Hubert successfully led the project to a positive conclusion. This relocation project once again demonstrated that the ability to clearly and effectively communicate complex topics is a critical success factor, especially in dynamic project environments where strategic goals must remain in focus despite ongoing disruptions. 

Client feedback following project completion: 
“The complexity of this relocation was significantly underestimated at the beginning. You did a fantastic job and always found a way to drive things forward positively. Thank you for your support and dedication.” 

Project Lead Hubert Sinz: 
"At Schnitzer Group, we consider the combination of technical and managerial expertise one of our core strengths—and open, transparent communication at eye level is a given for us." 

Contact: hubert.sinz@schnitzer-group.com

International project team with SYSTEMIC Project Manager Hubert Sinz (Middle)

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Schnitzer Group USA delivers successful support in maintenance management 

Robert Faeller appointed interim manager

In 2024, our U.S. site was awarded a highly significant project by a Spanish Tier-1 automotive supplier specializing in metal stamped parts and welded assemblies. The client was facing severe challenges related to the availability of chassis components. The Schnitzer Group provided Robert Faeller as an interim manager for 13 months, with the objective of stabilizing production through targeted maintenance and escalation management measures.

The Tier-1 supplier, which produces chassis components for an OEM, was under considerable pressure. The plant was under customer escalation due to consistently failing to meet the daily production target of 1,200 units. Despite operating seven days a week, the plant was only producing an average of 850 units per day. A lack of leadership, organizational instability, and an overwhelmed maintenance team resulted in reactive workflows and ineffective maintenance practices. The team struggled to resolve recurring failure patterns. Weekly downtimes were primarily caused by five main failure categories: robot malfunctions, welding equipment failures, milling and conveyor (crane) disruptions, pump and sensor errors, and cable breaks. 

The Schnitzer Group, with Robert Faeller as interim manager, joined a cross-functional task force with the goal of stabilizing and sustainably transforming the supplier’s operations. The task force established several core processes that delivered measurable and lasting improvements: 

• Development of a structured escalation plan to stabilize operations and align cross-functional teams 

• Immediate implementation of corrective actions to increase daily production output 

• Targeted root cause analyses of the main downtime drivers (as listed above) to significantly reduce unplanned stoppages 

• Design and implementation of a sustainable preventive maintenance process to shift from reactive to proactive maintenance 

• Introduction of a dynamic TPM (Total Productive Maintenance) system to foster close collaboration between production and maintenance 

• Implementation of a modern mobile CMMS (Computerized Maintenance Management System), resulting in better task assignment, faster response times, complete maintenance documentation, and automated, data-driven KPIs 

• Spare parts risk analysis and development of a new spare parts strategy to ensure availability of critical components, reduce risk, and optimize inventory levels 

Schnitzer Group expert team

With the support of the Schnitzer Group, the daily production target was reached and sustainably maintained after just nine months. Moreover, the five most common machine failure causes were significantly reduced. Maintenance response times improved thanks to the newly introduced mobile CMMS, and preventive maintenance became structured and reliable. Spare parts availability and inventory levels were aligned with operational needs. The proactive maintenance approach enabled by TPM and digital workflows fostered a collaborative, team-driven working culture. 

Contact: robert.faeller@schnitzer-group.com 

 

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We did it! - Schnitzer Group certified for the first time according to ISO 9001:2015 

We did it again! - TISAX AL3 re-certification also successfully completed 

Since May 2025 it’s official: The Schnitzer Group is now successfully certified according to ISO 9001:2015. 

After having guided numerous technical companies through ISO certification in recent years, it was only natural for the Schnitzer Group to take on the challenge themselves. They succeeded on the very first attempt. Congratulations to Peter Schnitzer and his team for completing this marathon! 

Is it just a tedious obligation – or does the company actually benefit from it? 

Certification according to ISO 9001:2015 streamlines numerous internal processes and offers long-term benefits for companies: 

• Higher customer satisfaction: By complying with the standard, customer requirements are better met, leading to increased satisfaction 

• More efficient operations: The standard promotes a structured approach to improving operational efficiency and quality 

• Competitive advantage: ISO 9001-certified companies are often seen as more credible and reliable, giving them an edge over the competition 

• Improved decision-making: The standard emphasizes fact-based decisions, resulting in better business outcomes 

• Stronger employee engagement: Clear processes and a focus on quality boost motivation and employee commitment 

• Global recognition: This certification is internationally recognized, making international business easier 

• Continuous improvement: ISO 9001 highlights ongoing improvement, helping companies to constantly evolve and stay competitive 

• Optimized resource use: More efficient processes lead to better resource utilization and cost savings 

Need support with ISO 9001 certification? 

Contact: peter.schnitzer@schnitzer-group.com 

 

TISAX Re-Certification Successfully Completed in April 2025! 

Reliability, data security, and trusted collaboration define our relationships with clients. This has now been officially confirmed once again. After three years, our processes, IT workflows, and security systems at the Schnitzer Group were re-audited, optimized, and certified according to TISAX AL3. Our clients and their technical development projects remain at the heart of everything we do – The SYSTEMIC Upgrade for your engineering project!