Redefining the Automotive Sector with Innovative Manufacturing Systems

Trent Randles, Engineering Manager, BorgWarner

Trent Randles is a Manufacturing Engineering Manager at BorgWarner. He maintains a decade of experience in the automotive manufacturing sector and leverages his expertise to propel innovative initiatives and drive projects that harness the full potential of digital technologies. With prior engineering positions at Plastic Omnium, he excelled in operations, design, and launch teams. Throughout his career, Randles has spearheaded various digital transformation endeavors, such as implementing augmented reality and integrating manufacturing execution systems to enhance manufacturing processes.

In an exclusive interview with Manufacturing Outlook, Randles shared his valuable insights on the challenges, trends and best practices in the strategic hydraulic equipment space.

What are your current roles and responsibilities at BorgWarner?

During my career, I've undertaken diverse engineering positions within manufacturing and the automotive sector. These roles have spanned manufacturing, design, assembly line, and process design. In addition, I have collaborated with esteemed Tier-1 automotive suppliers like Plastic Omnium and Magna Seating. Early into my career, I recognized the constraints inherent in conventional assembly line design techniques reliant on standard work times and Excel spreadsheets. To address this, I delved into digital technologies such as digital twins, augmented reality, and machine learning. Leveraging process simulation software facilitated streamlined assembly process design, complemented by augmented reality for ergonomic assessments, which curtailed assembly line adjustments during equipment installation.

“I firmly advocate defining the five essential elements- vision, incentives, skills, resources, and action plan - for successfully launching and sustaining digital technologies in manufacturing”

In my current role at BorgWarner as a manufacturing engineering manager, I focus on nurturing the growth of my team members by coaching and up-skilling them to excel in their positions. I evaluate available technologies and identify operational gaps that could be addressed by implementing new technologies. This approach not only closes the gaps but also accelerates the achievement of our business goals.

What are some of the challenges that you have faced in the manufacturing sector?

One of the major challenges faced in the manufacturing industry is the labour shortage. To address this critical issue, automation of processes is a viable solution. Automation demands extra resources for design and support, and not all tasks are readily automatable. This underscores the significance of a lucid vision and meticulous planning when embracing novel technology. The lack of quality also emerges as a significant concern, necessitating the establishment of robust systems to ensure zero defects and precise assembly of parts. An articulated vision, compelling incentives, requisite workforce expertise, ample resources and equipment, and a meticulous action plan featuring designated leaders and deadlines are vital for effective technology assimilation. Neglecting any of these factors can lead to failure to fully deploy new technology or sustain its benefits over the long term.

What strategies do you employ to maintain the manufacturing process's efficiency, aligning with the latest industry trends?

BorgWarner strategically prioritizes establishing valuable partnerships as a key approach to remaining at the forefront of technology and innovation in the manufacturing industry. A significant collaboration is with the South Carolina Manufacturing Extension Partnership (SCMEP), with the help of which we actively engage in workshops conducted at numerous manufacturing facilities, gathering invaluable insights into best practices from a wide array of industries beyond the automotive sector. This network facilitates knowledge sharing and problem-solving for similar yet unique challenges.

Another essential aspect of Borg Warner's approach is collaborating with external suppliers when faced with complex problems requiring specialized expertise. The company delineates the issue and the desired solution to the sellers, seeking valuable feedback and insights. Borg Warner attends manufacturing conventions to expand the firm’s understanding of the latest technologies and advancements, gaining first-hand exposure to advanced solutions.

Furthermore, we have fostered partnerships with educational institutions like Clemson University and its International Center for Automotive Research. Through these collaborations, BorgWarner engages in joint research, leveraging Clemson's expertise in robotics, manufacturing processes, and material science. Additionally, the partnership with the industrial engineering department at Clemson allows us to explore emerging technologies through capstone projects conducted by senior students.

How do you foster a strong work relationship between the manufacturing teams in your organization, and other departments to ensure smooth operations?

BorgWarner excels by employing cross-functional teams and ensuring effective communication. Their customer-focused approach further drives success and innovation in the transfer case assembly process. This process involves assembling device components in certain vehicles like trucks and SUVs. This device facilitates power transmission to all four wheels, significantly improving traction, particularly on demanding terrains or slippery conditions.This collaborative approach guarantees the comprehensive involvement of all stakeholders, ranging from engineering maintenance to the production team. It encompasses brainstorming, process development, meticulous planning, seamless execution, vigilant supervision of projects, and resolution of issues. Consequently, we ensure the success of the manufacturing team by delivering impeccable products to the end customer.

Furthermore, we emphasize rigorous quality control through an encompassing strategy. This entails employing comprehensive quality systems with various protocols designed to uphold and enhance product quality. Additionally, we utilize engineering change management systems(ECM) to proficiently oversee and monitor alterations to products, processes, or systems. These systems gather input and approval from all stakeholders during the entire process. BorgWarner emphasizes open communication among all functions involved in assembly line operations, swiftly addressing any obstacles. To enhance collaboration, we employ an advanced electronic system for engineering change requests, enabling seamless interaction among team members and boosting problem-solving and productivity.

What advice would you like to impart to your peers in the manufacturing industry?

I firmly advocate defining the five essential elements- vision, incentives, skills, resources, and action plan - for successfully launching and sustaining digital technologies in manufacturing. As a passionate advocate for the potential of digital technologies in advancing manufacturing, I emphasize the importance of these elements in achieving long-term success. Many manufacturing initiatives, such as AI systems and digital twins, often fall short due to improper implementation and the lack of sustained efforts over time. By addressing these key elements from the outset, we can avoid such pitfalls and ensure digital technologies' effective integration and longevity in our industry.