Stellantis’ Asif Khan on driving cost control and profitability through lean manufacturing in a competitive market

We spoke with Dr. Sardar Asif Khan, Continuous Improvement Lead at Stellantis, during the Automotive Evolution NA conference 2024. Dr. Khan shared his insights on the enduring importance of lean methodologies in automotive manufacturing, particularly for cost control and profitability in a rapidly changing market.

“Lean manufacturing is not just a set of tools; it’s a strategic approach,” Dr. Khan explained, emphasising that lean principles help Stellantis maintain efficiency and reduce waste, even as new digital technologies transform the industry. He shared a success story about revitalising an underperforming engine plant, where lean practices led to significant improvements in key performance indicators.

A major focus of Dr. Khan’s discussion was the critical role of leadership and workforce engagement in lean transformations. “Strong leadership and team buy-in are essential to making lean work,” he noted, highlighting common pitfalls and the importance of involving all organisational levels in continuous improvement efforts.

Dr. Khan also discussed how digitalisation complements lean, enhancing value-added activities without replacing the core principles of lean manufacturing. “Digital tools make lean even more effective by optimising processes and helping us focus on what truly adds value,” he added, underscoring the synergy between lean and digital innovation as Stellantis adapts to an evolving automotive landscape.

Here are some more key takeaways from the discussion:

• Dr. Khan highlighted the essential role of lean manufacturing in maintaining profitability amidst market shifts, with a focus on reducing costs and enhancing operational efficiency.
• He shared a case study where lean methodologies were instrumental in turning around an underperforming engine plant, resulting in improved key performance indicators.
• Dr. Khan emphasised that digitalisation and technological tools enhance lean manufacturing by improving value-added processes, rather than replacing lean principles.