Alex Costa

25 years delivering complex engineering programmes | Head of Programme Delivery | Electrification & Automotive

United Kingdom

About

Senior engineering and programme leader with 25 years delivering complex, multi-million programmes across automotive, electrification, industrial manufacturing, and vehicle technology sectors. I build PMO functions from scratch, embed governance frameworks that stick, and lead cross-functional teams to deliver on time, within budget, and to quality consistently. My track record spans Jaguar Land Rover (Electric Range Rover, 110+ suppliers, 8,000+ stakeholders), CNH Industrial / Stellantis (€115M+ electrification portfolio across 3 simultaneous product programmes, first fully electric product delivered on time and on budget), AGCO Corporation ($9M global PLM/NPI rollout across 5 South American sites, 400+ engineers), and Wrightbus (H2, BEV, ICE 20+ concurrent programmes, 75%+ rework reduction, PMO built from scratch). What I do well: designing portfolio governance and KPI frameworks that give leadership real visibility; leading matrix teams of engineers, PMs, and commercial staff through complex, multi-stakeholder programmes; embedding Agile and stage-gate discipline in organisations that need to scale delivery capability; and translating strategic intent into structured, measurable programme execution.

Experience

  • Head of Programme Delivery & PMO at Wrightbus
    May 2024 - Present · 2 yrs 3 mos

    Accountable for integrated programme delivery across H2, Battery-Electric, and ICE bus and coach product lines. PMO lead responsible for all vehicle contracts, improve P&L, Sales & Operations Planning, and alignment of programme outcomes with commercial and customer commitments. •     Built the PMO governance framework from scratch — contract management governance, KPI dashboards, stage-gate review processes, and weekly CEO and SLT reporting structures. •     Overseeing a portfolio of 20 concurrent programmes with 5 direct and 40 dotted-line reports across engineering, operations, and commercial functions. •     Introduced an upfront customer specification validation process that reduced post-sign-off rework from an average of 10–15 actions per programme to 2–3 — an improvement of over 75%. •     Implemented engineering review gates that significantly reduced downstream engineering changes, improving first-time delivery quality and schedule adherence.

  • Head of Electrification Portfolio & Senior Programme Manager at CNH Industrial
    Jun 2022 - May 2024 · 2 yrs

    Led CNH's electrification transformation strategy, overseeing €115M+ in programme investment across three simultaneous product development programmes on a new common platform. Partnered with senior leadership to define integrated schedules, allocate resources, and implement Agile governance across engineering teams. •     Developed and executed the delivery roadmap for three electrified products, managing rolling-wave planning and budget allocation across simultaneous development streams. •     Delivered CNH's first fully electric product on time and within the €3M budget, including full governance of an outsourced development partner from contract to production. •     Led the 2nd-generation hybrid tractor programme (€125M) through concept, project authorisation, and prototype validation — all milestones achieved on time and to cost. •     Created portfolio dashboards and programme KPIs tracking benefits realisation and strategic investment performance; reported directly to executive leadership.

  • Programme Manager - Flagship EV & Transformation at Jaguar Land Rover
    Mar 2017 - Jun 2022 · 5 yrs 4 mos

    Directed delivery of the flagship Electric Range Rover programme and led two major transformation initiatives across engineering operations. Managed programme interdependencies across 110+ suppliers and 8,000+ stakeholders throughout the product development lifecycle. •     Led cross-functional delivery through prototype series milestones for the Electric Range Rover, managing APQP compliance and design assurance across Tier-1 and Tier-2 suppliers. •     Redesigned the programme-level risk management process using PMI best practices, reducing budgetary contingency draw-down and improving proactive threat identification. •     Implemented a new Engineering Statement of Work standard across all engineering functions, saving £3M+ annually through improved compliance and reduced supplier delays. •     Deployed Agile (Jira/Confluence) across engineering delivery teams; led engineering communication portals and change management transformation programmes.

  • AGCO Corporation (14 yrs 7 mos)
    • Head of Programmes & Global Process Lead — South America
      Sep 2010 - Mar 2017 · 6 yrs 7 mos

      Led a team of 15–20 engineers, designers, and contractors responsible for NPI of special tractors, product running changes, field problem resolution, and global engineering process deployment across five South American manufacturing sites. •     Delivered AGCO's global PLM/NPI system (Creo) rollout across 5 SA sites on schedule and within the $9M budget, impacting 3,000+ employees. •     Delivered cost savings of $2M+ across the MF tractor range through product rationalisation and engineering standardisation programmes. •     Improved drawing right-first-time rate from 40% to 96% through quality auditing; achieved 25% improvement in team delivery efficiency through Agile (Scrum) adoption. •     Served as SA lead for AGCO global engineering standards deployment — DFMEA, DVP&R, emissions regulations — across 400+ engineers.

    • Strategic Industrial Manager
      Sep 2007 - Aug 2010 · 3 yrs

      Led industrialization of new combine harvester concepts and managed strategic relocation of product lines from Denmark to Italy. Enabled cross-continental collaboration and organisational transformation. Directed prototype development and industrial transfer of product data and assembly lines. Facilitated synergy between Italian, South American, and US engineering teams to ensure seamless product delivery. - Strategic responsible to create an organizational transformation at Laverda. - Encouraged Italian senior management to adhere the cultural change process and to support the communication plan. - Broke down cultural barriers and brought up engagement to the change in all hierarchical levels. - Built great teamwork among Italian workers and foreign employees.

    • Product Engineering Coordinator/Lead Engineer
      Sep 2002 - Sep 2007 · 5 yrs 1 mo

      Coordinated 6 engineers dedicated to Combine Harvester product changes and Field solutions for SA and EU. Lead and drive field problems resolution through root cause analysis tools (8D and FTA) and DFMEAs. Accountable for component and installation designing and detailing, on a localization project which moved a Tractor line range from UK to Brazil. Designed and modified Tractors CKDs during its product lifecycle.

  • Designer at Carrier Commercial Refrigeration
    2000 - 2002 · 2 yrs

    Design and development of Chillers and HVAC systems.