Following his tenure at Tesla, Mr. Rebo, the founder and owner of GERMANENGINEER.COM, turned his Lean Project Management skills to another renowned automaker – Volvo. From September 2022 to January 2023, he was engaged by ThyssenKrupp to oversee the completion of the body-in-white project at the Volvo Cars plant in Ridgeville, South Carolina.1

This state-of-the-art facility, Volvo’s first automotive plant in the United States, began production in 2018. It initially rolled out the S60 sedan, but recently added the all-new Volvo EX90 Pure Electric SUV to its repertoire. Designed with sustainability in mind, the plant operates an on-site recycling center that processes more than 90 percent of the plant’s waste. It also houses an energy-efficient paint shop and is powered primarily by renewable energy.

Mr. Rebo was tasked with overseeing the installation and commissioning of more than 50 robots, three laser welding systems, and adhesive bonding systems, all critical to the production of doors and tailgates for the upcoming Volvo EX90 Pure Electric SUV. By implementing the KANBAN system, his project was able to eliminate a significant backlog, successfully complete equipment commissioning, integrate the new model into the existing body assembly line, and start production of the first vehicles on time.

  1. retrieved 6/12/2024. ↩︎