2024 Conference Programme

Volkswagen’s plant in Chattanooga, Tennessee is one of North America’s most notable examples of manufacturing transformation, revamping operations and training staff to produce electric and software-based vehicles and batteries. At the heart of this multi-billion-dollar investment has been the need for long-term planning to account for continuous change, and a strong consideration for manufacturing flexibility, including the ability to produce combustion and electric vehicles, multiple body architectures and powertrain types on the same assembly line. This flexible strategy has become especially relevant in the face of uncertain demand for EVs.

In this keynote, Christopher Glover, EVP of Volkswagen Group of America, Chattanooga Plant, will share insights into the carmaker’s fast-paced transformation amidst constant change, including in vehicle products, in manufacturing technology and talent. He will outline how Volkswagen has integrated new operations, such as new body shops and battery pack assembly, but also learned important lessons and guidelines when investing in key systems, tooling, layout and processes that help to secure long-term investment and competitiveness. He will demonstrate how a large, complex plant like Chattanooga needs to be managed like a multi-lane highway with diverse vehicles and varying speeds, rather than a single lane racetrack.

Join this keynote and learn more about:

• Insights into manufacturing processes and technology for building new products.
• Investment and planning considerations for increasing production flexibility, including across multiple body architectures and powertrains on the same line.
• The role of digitalisation in managing change, supporting staff and improving quality.
• Strategies for increasing manufacturing agility and competitiveness even as products, tech and human resource requirements change.

Many OEMs and suppliers have planned for manufacturing flexibility in their production, whether in body, press or assembly operations. However, preparing to produce electric and software-defined vehicles require significant capital investment with a long amortisation period, even while technology and consumer demand are rapidly changing. Keeping up will require a greater agility and capacity for flexibility than before, from early product engineering and facility decisions, through to tooling, automation, testing, logistics, quality control systems and sustainability.

This panel, hear from automotive manufacturing decision makers and experts on the critical technology, factory design, systems, training and collaboration that will support greater production agility.

This panel will include discussion on:

• Cross-functional collaboration in developing production flexibility, from R&D and finance, through to line integration.
• Digitalisation and technology that support multi-platform, multi-powertrain manufacturing.
• Skills, training and culture required to adapt manufacturing operations quickly and without compromising quality.
• Lessons and learnings in North America’s complex, uncertain transition to electric vehicles.

As automotive manufacturing faces disruption across digitalisation, changing requirements and uncertain supply chains, lean and continuous improvement principles can help manufacturers adapt, meet quality expectations and remain competitive. But although most OEMs claim to follow lean principles, many struggle to realise real benefits for workers and operations. Join this session with continuous improvement experts to gain strategic insights into the successful implementation of lean across the fast-changing landscape of automotive manufacturing and logistics.

Renowned experts, including Stellantis continuous improvement lead, Dr Asif Khan, and Stellantis head of Kokomo Transmission plant, Jeremy Keating, will discuss the processes, culture and key considerations that help manufacturers improve operations. Together with manufacturing leaders, they will discuss the most important strategies for developing and scaling lean processes. They will also demonstrate why lean and continuous improvement processes will matter even more as the North American industry strives to increase manufacturing flexibility, reduce cost and rollout new manufacturing technology, from parts and component production, vehicle assembly through to logistics.

Join this session to learn more about:

• The role that lean and continuous improvement plays in increasing operational quality and performance.
• How changes in manufacturing, including artificial intelligence and advanced digitalisation, should be considered in lean manufacturing production systems.
• How OEMs, suppliers and service providers can better apply lean principle and continuous improvement to meet shared goals and achieve win-win partnerships.

Brian Breuhan, Global Manufacturing Optimization Strategist at General Motors, will present GM’s vision for the "Factory of the Future." He will share insights on fostering innovation and achieving zero waste through advanced technologies like AI, robotics, and digital twins. Brian will also emphasize strategies for upskilling workers, improving key performance metrics, and reducing repair times to increase system reliability.

Additionally, Hiro Natsume, Sales Director of Industrial Production at Kistler Group, will delve deeper into the practical application of these flexible manufacturing systems. He will share how data-driven decisions, sensor technologies, and real-time analytics can optimize production processes and enhance sustainability.

This panel will include discussion on:

• The "Ideal Production System" as a continuous improvement strategy, including ways to bridge the gap between current and future states.
• The role of benchmarking and ideation sessions in developing technologies for long-term flexibility.
• Challenges and solutions for adapting automation across different types of plants (high vs. low volume, greenfield vs. brownfield).
• Strategies for managing resistance to change and fostering a culture of innovation in manufacturing.

Explore how manufacturers are leveraging data to enhance manufacturing processes, improve quality, and drive operational efficiency. In this panel, experts from Ford and PPG will share real-world examples of how they are using data to transform manufacturing, from predictive maintenance and process improvement to quality assurance and operational performance.

Join this session to learn more about:

• How manufacturers are using digital twins, AI, and IoT to improve predictive maintenance and reduce downtime, while optimising production processes.
• The impact of real-time data on decision-making in areas like quality control, including how machine learning models and data streams are applied to detect and prevent defects in real time.
• Collaborative approaches between suppliers and OEMs to use data effectively for process improvement, ensuring alignment across the production lifecycle.

The focus of transforming mobility and electric vehicles in North America has shifted from a race to get products to market fastest, to ensuring that vehicles and technology are affordable for consumers and profitable for companies. For manufacturing, that means a radical focus on reducing costs, with major manufacturers setting targets to cut production costs by 30% or more by the end of the decade. That includes eliminating waste and increasing value, from planning and engineering, through manufacturing and supply chain.

This session will demonstrate how OEMs such as Ford, together with key suppliers, are exploring cost reduction and process optimisation in manufacturing for future products and across its manufacturing footprint in North America. Strategies include fostering seamless collaboration between engineering and production teams to reduce complexity and time. Experts will discuss how artificial intelligence, machine learning, and automation can streamline manufacturing processes, enhance efficiency and improve quality. The session will provide a roadmap for manufacturers looking to create affordable vehicles while maintaining profitability in a highly competitive market.

Join this session and gain key takeaways such as how to:

• Reduce vehicle manufacturing costs by 30% or more through early alignment of product development and manufacturing.
• Leverage AI and digitalisation to enhance production efficiency and reduce waste, for example in digital twins.
• Ensure competitiveness through streamlined manufacturing practices.
• Engage employees in rewarding, value-added work and continuous training.