A featured contribution from Leadership Perspectives, a curated forum for automotive and mobility leaders across manufacturing, supply chain, and connected vehicle ecosystems, nominated by our subscribers and vetted by the Auto Business Outlook Editorial Board.

Bentley Motors

Miguel Ocana, Head of Manufacturing Engineer

Planning the Future by Embracing New Technologies

Miguel Ocana is a Senior Manager with a proficiency in manufacturing operations and possesses extensive knowledge in the application of continuous improvement techniques in recognised industry production systems. With several years of experience working in cultures across the globe, he is capable of managing development projects in a multidisciplinary environment.

Miguel Ocana shares his thoughts with Manufacturing Technology Insights Europe about the ongoing trends and challenges in the industry, and how Bentley Motors is navigating the market.

How did the Pandemic Disrupt Manufacturing Processes, and What are the Prevalent Challenges in the Industry Today?

The manufacturing sector has been encountering several challenges even before the pandemic. In the UK, Brexit had a significant impact on the industry. Following COVID, the war broke out in Ukraine. This is also amplified by rising energy costs, primarily due to the Ukrainian conflict. Such situations constantly influence everything we do in the manufacturing industry. 

Electrification of the industry coincides with all of these other factors, which is very challenging. We are also approaching a once-in-a-lifetime transition from combustion, petrol, and diesel engines to electric cars. This has resulted in regulatory changes- all aimed at eliminating issues related to climate change.

What Measures are taken to Combat the Increased Prices in Automobile Manufacturing?

Our most significant advantage is that we are part of a large group, the Volkswagen Group, which gives us access to comprehensive networks and connections, increasing our purchasing power. We leverage the potential of the vast networks within our group to ensure that the best possible deal is secured. Instead of just one scenario, we plan for multiple and formulate plans to prepare for the worst, leading to very effective risk management. The planning process is updated frequently; lessons of the recent crisis are incorporated into each decision as much as possible.

How does Bentley Motors go about Ensuring the Success of a Project?

In the Volkswagen Group, we follow a structured planning approach developed over time. Defined gateways are adhered to throughout the project lifecycle, ensuring the processes are completed on time. We identify critical paths with a bottleneck and promptly resolve the issue. It is all about having a detailed plan to measure against defined objectives and deliverables. Every stage of the project is outlined and measured, and we act quickly to rectify any deviations before we move on to the following deliverable. 

Please Provide us with an Overview of the Latest Project you are Working on and the Technologies used to Ensure its Success.

Our CEO announced that the company will be fully electric by 2030, which will significantly transform Bentley. We will invest about 2.5 billion dollars internally. We are reinventing our Dream Factory to meet the demand for all-electric Bentleys. And from a company perspective, we plan to make our manufacturing and supply chain carbon-neutral by the end of the decade. The Dream Factory concept is an opportunity and a challenge simultaneously because manufacturing electric cars entails various factors, from cars with internal combustion engines (ICE). Our goal is to harness the power of digital tools. We plan to leverage the advantages of digital twins within the new factory to replicate data stacks, perform extensive simulations and assess changes efficiently.

The unique relationship between those who build the cars and those who drive them has helped create an enthralling story unlike any other.

Bentley cars are known for their craftsmanship and unique finishing that can only be achieved with the human touch. We want to maintain that level of authenticity and craftsmanship. While adopting automation and digital tools, we want to be leaner, more sustainable, and preserve our customers' expectations. We already have robots in our factory, and now we have collaborative robots, or cobots, which operate in a targeted manner. This technology would prove to be a game-changer for Bentley. From the paint shop to the final assembly, we will upgrade everything adhering to industry-leading standards.

Are there any Innovations in Manufacturing Strategies that you would Like to apply in your Organization?

Digital transformation and the use of virtual reality on the factory floor are already mentioned. What excites me is additive manufacturing and 3D printing. Additive manufacturing is going to transform not just automotive but all industries.

At Bentley, we already use additive manufacturing with an internal facility capable of printing more than 10,000 components per year. It is only used in the development of prototypes, tools for assembling cars, as well as for emergency maintenance repairs and feasibility assessments, where we see a big opportunity in additive manufacturing.

We have deployed 3D printing capabilities in small degrees. The opportunity here lies in enhancing our customer personalization options and providing a massive catalog to choose from, which we want to deliver in the future. Additive manufacturing enables us to deliver products in a shorter lead time. This aligns with our environment-friendly approach as you can print the parts at the point of assembly without needing to ship them worldwide, reducing energy consumption and CO2 emissions.

To be more specific, we foresee more potential in metal additive manufacturing, with its capabilities like in-house polymer printing. We have plans to focus on metals in the next few years and see if we can harness all the potential to use them.

Do you have any piece of advice that you would like to share with the industry leaders?

While it may be challenging, there are many opportunities in the manufacturing space.

As unexpected things keep happening, we must embrace the developments and cater to them during the planning process. Scenario planning and constant revisiting of schedules is the only way a company, irrespective of its size, can remain competitive and take advantage of the opportunities that arise. We know that there are opportunities in those challenges. Therefore, it is crucial to embrace this scenario planning and adopt the latest technologies, like additive manufacturing, because it can lead to new solutions that were previously unsolvable.

The articles from these contributors are based on their personal expertise and viewpoints, and do not necessarily reflect the opinions of their employers or affiliated organizations.