Why are hybrids outperforming expectations while so many automakers went all-in on EVs?

 In this episode of Disrupted Factory, we unpack the biggest shifts reshaping the global automotive industry, from China’s rise and Europe’s growing pressure to India’s emergence as the next major automotive force. We explore why market value is increasingly driven by strategy, positioning, and narrative, not just production volume. 

My conversation with Dan Mottram covers Tesla, Toyota, BYD, Ferrari, Ford, and the legacy players trying to navigate one of the biggest industrial transitions in decades. We also dive into why hybrids have become the practical winner in the short term, what China got right, and why some traditional automakers are now being forced to rethink their bets. 

If you work in manufacturing, automotive, strategy, or industrial leadership, this episode will give you a sharper view of where the market is heading. 

Dan Mottram is a mechanical engineer turned business strategy consultant with deep experience across automotive, industrial, retail, and technology sectors. Over time, his work shifted from engineering and transformation programs into board-level strategy, with a strong focus on helping organisations align vision, capital allocation, and execution. 

Dan is known for simplifying complex business stories into clear visual frameworks and data-led insights, particularly for industrial and automotive companies. His current work focuses on strategy, branding, and helping leadership teams think more clearly about the future.

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In this conversation, Glenn Gardner joins us to unpack why so many digital transformation initiatives stall between executive dashboards and the factory floor. He explores the manufacturing strategy spectrum, from Lean pull systems to MRP-driven push environments, and explains why most plants operate somewhere in the messy middle. The discussion moves beyond theory into the practical trade-offs of just-in-time production, real-world constraints, and the operational friction that derails well-intentioned projects. We also dig into the true integration challenge inside modern factories. While many operational systems are designed for simple scalar data, maintenance and quality teams work with complex data structures such as vibration spectra, torque-angle curves, and force-displacement signatures. Glenn introduces Unified Namespace thinking, the idea of red versus blue data, and makes the case for designing systems bottom-up to serve operators and technicians first. The result is a grounded, practical view of how to make digital transformation actually work in manufacturing.

Glenn Gardner is a Mechanical Engineer, Predictive Maintenance specialist, and Co-Founder of Abelara. He works with maintenance and reliability teams to adopt the right mix of predictive technologies including vibration analysis, thermography, oil analysis, ultrasonics, MCSA, and motion amplification, integrating them into core plant workflows through CMMS and related systems. At Abelara, Glenn helps manufacturers build practical digital transformation roadmaps that connect PdM, CMMS, SCADA, MES, PLC and MQTT environments into coherent, plant-ready solutions. Known for his pragmatic, no-platitudes approach to AI and machine learning, he focuses on relevant use cases and fast, impactful proofs of concept that support long-term, right-sized transformation.

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Before the Tesla Model S redefined the industry, a team in Cape Town had already built the future. So why have you never heard of the Joule? 

While Silicon Valley was in its infancy, South African engineers were solving the EV puzzle: 6-seat capacity, 180-mile range, and a modular interior designed for global export. In this episode of The Disrupted Factory, I sit down with Gerhard Swart, former CTO of Optimal Energy, to discuss the high-stakes engineering behind the Joule and the heartbreaking 9.2-billion-rand industrialization "chasm" that swallowed the project whole. 

We go from the glitz of the Geneva Motor Show — where the Joule stood toe-to-toe with Lamborghinis — to the grim reality of being ordered to destroy the tooling when the government pulled the plug. But this isn't just a story of what was lost. 

We dive into Gerhard’s current work on the Square Kilometre Array (SKA)—the most ambitious radio telescope project in human history. Whether you are an EV enthusiast, a space nerd, or a systems engineer, this is a masterclass in why some of the world’s greatest innovations never make it to the driveway. 

Keen to get your hands on Gerhard's book - Hope Arising - click here: Official Site: https://joulebook.co.za/ Exclusive Books: https://tinyurl.com/ExclusiveBooksJoule Amazon: https://tinyurl.com/5dhtfmra 

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The Mr. Miyagi of LEAN brings his wisdom and teachings to our first LIVE podcast!

In this episode of The Disrupted Factory, we sit down with Vitor Ferreira, the Mr. Miyagi of LEAN. After four decades across Michelin and Bridgestone, he’s trained more than 8,000 people and earned a reputation for cutting through noise with simple, practical truth.

Vitor explains why the world’s best manufacturers, no matter the culture, all share the same obsession: finding and fighting waste. That mindset, he says, is the competitive advantage. When Vitor talks 5S, he strips away the buzzwords: it’s not about neatness, it’s about making waste visible so productivity can rise!

He also shares the lesson that shaped his entire career: respect the operator. They’re the true masters of the process. 

From there, Vitor breaks down the Five Principles of Lean, the Seven Wastes (TIM WOODS), and introduces his own “Ninth Waste”: resistance to change. And because tools only matter when they move numbers, he shows how SMED took a tire changeover from more than twelve hours to just two!

Finally, he calls out the uncomfortable truth: too many ISO and Lean programmes have become tick-box exercises. As AI speeds up the pace of change, he argues that leaders must stop firefighting and start focusing on effectiveness, capability and real financial impact.

If you enjoyed this conversation with the Mr. Miyagi of LEAN, hit Like, drop a comment and Subscribe to The Disrupted Factory for more straight-talk insights from the people ACTUALLY shaping modern manufacturing. 

Thanks for watching and see you in the next episode.

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In this roundtable discussion at the Nelson Mandela Bay Business Chamber, we unpack the future of mobility, the politics, the infrastructure challenges, and whether EV adoption makes sense for Africa right now. South Africa’s automotive component sector plays a vital role in keeping the country’s manufacturing economy moving. In this episode, we unpack the key takeaways from the NAACAM Show, where industry leaders, government officials and business partners came together to discuss the road ahead. The conversation explores how localisation, skills development and digital readiness can drive growth, and why reforms such as the APDP2 review are so important for restoring competitiveness. We also look at the growing focus on electrification, the role of software in modern vehicles, and how initiatives like ODIN and MESITA are helping to prepare young people for the factory floor of the future. Along the way, the guests share frank views on infrastructure challenges, cybersecurity risks and the practical steps needed to strengthen South Africa’s automotive supply chain.

Beth Dealtry is the Executive Director of NAACAM, representing South Africa’s automotive component manufacturers. With a background in industry development and stakeholder engagement, she has been instrumental in driving collaboration between government, business and training institutions to strengthen the local manufacturing base. Martin Zano is the Managing Director of Eberspächer South Africa and a leading voice on electrification and future mobility. He brings deep insight into the evolution of propulsion technologies and the practical steps needed to prepare local manufacturers for the global transition to new energy vehicles.

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Right now, Africa is a dumping ground for second-hand imports, killing local industry, jobs, and growth. If every African country shut that tap tomorrow, our market could jump from 1 million to 3 million new vehicles a year — instantly.

In part 2 of my conversation with Justin Barnes, we break down why Africa’s auto industry is stuck, what needs to change, and how countries like India and China built policies that turned them into automotive giants. Spoiler: it’s not about population size — it’s about serious strategy!

Join us as we explore the uncomfortable truths, the massive opportunities, and why Africa could be the next big growth story in global automotive. We also dive into some shocking facts like why Africa has more people who can afford new cars than India… but only sells a fraction of the vehicles!

If you liked part 2 of our podcast with Justin, consider hitting that subscribe button. That way you'll always be notified when we release new industry related content!

#AfricanAutomotive #FutureOfAfrica #AutoIndustry #Jendamark #DisruptedFactory

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In this candid and insightful episode of The Disrupted Factory, Yanesh speaks to industrial policy expert Justin Barnes about South Africa’s automotive industry, currently facing severe challenges. They discuss the consequences of weakening infrastructure, global trade shifts, and Nissan’s exit from the local market. Justin highlights gaps between government policies and industrial realities, explores the viability of local OEM operations, and shares his views on why Africa might not yet be ready for large-scale electric vehicle production. Essential listening for understanding the future of manufacturing in South Africa.

Justin Barnes is an industrial development specialist with nearly 30 years of experience dedicated to building thriving manufacturing ecosystems across Africa. With a career spanning engagements in 37 countries, Justin has guided major industrial strategy and policy projects, notably through his leadership roles at B&M Analysts and the Toyota Wessels Institute for Manufacturing Studies (TWIMS). Passionate about African industrialisation, Justin recently founded a new venture focusing on sustainable, labour-intensive manufacturing, aiming to unlock socio-economic growth and empower the continent’s greatest asset - its people.

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A veteran of American manufacturing joins me in this episode of TheDisrupted Factory. Tim Stuart, founder of @VisualDecisions, takesus through how digital tools can supercharge Lean Six Sigma

Withoutdrowning teams in admin work or checkbox culture.With decades of experience at Black & Decker, Cummins, andToyota, Tim shares straight-talking insights into what it really takes tomake smart manufacturing stick in the U.S. and beyond—fromempowering thinking employees to building digital strategies thatactually get adopted on the factory floor. 

Tim and I also exchangesome entertaining stories about the use of Gamification infactories and in our personal lives. @StarWars, @WHOOPand @FitbitOfficialSite all make an appearance!If you're involved in operations, continuous improvement, or leadingdigital transformation in industry, this episode delivers practical, nononsenseinsight from someone who’s walked the walk.

Subscribe to The Disrupted Factory for real conversations fromthe front lines of industrial innovation, we sure wouldappreciate it!Check out Tim's YouTube channel Visual Decisions. 

Click right here forextra content and insights -https://www.youtube.com/@VisualDecisions

#SmartManufacturing #USManufacturing #LeanSixSigma#DigitalTransformation #Industry40 #TheDisruptedFactory#VisualDecisions #TimStuart #FactoryFloor #ManufacturingLeadership

TIMESTAMPS:
00:00:00 - Introduction Tim Stuart
00:05:00 - First Jobs & frustrations with LEAN
00:12:50 - Start of Smart Manufacturing presentation by Tim Stuart(CESMII)
00:23:00 - Pilot programs for comanies wanting to transform
00:39:25 - Customer success stories shared & end of presentation
00:46:22 - Tim & Yanesh discuss Gamification (positives andnegatives)
00:54:55 - Tim’s advice to TECH vendors
00:59:55 - Closing thoughts and thanks

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Lego, we all know what is does and have all played with it before. These basic building blocks allow ANYONE to create ANYHTING they can imagine. 

Join me and Etienne Lacroix from @Vention as we discuss his “Legoify” approach to his global company. In our latest Disrupted Factory Podcast, Etienne discusses

Vention’s early struggles, focusing on the need to connect the software design, material sourcing and production process. We also discuss the importance of passion and grit in entrepreneurship that we have both experienced in our business journeys.

Despite numerous hardships and challenges, Vention has managed to grow and innovate, recently releasing advanced automation controllers and simulation tools that were unheard of just a few years ago. Vention provides an online platform for manufacturing automation, enabling companies to design, program, and deploy automated systems. Their modular hardware and software simplify the process of building custom machines and robots.

Head on over to their website to sample their online “LEGO" approach to automated systems and see what you can create! 

https://vention.io/?home

Enjoy the podcast but don't forget to like and subscribe to our channel, we

sure do appreciate it! 

#Lego #Vention #DisruptedFactory #Podcast #IAmJendamark

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Learn how to tighten bolts so your wheels don't fall off! POWER tools are smarter than you think! In this episode of Disrupted Factory, we sit down with Jason Benford, the “Guru Of Tightening" from @Atlas Copco.

Follow along as he shares his journey from automotive engineering to becoming a leading expert in bolt tightening. Discover how small changes in friction can DRAMATICALLY impact bolt performance, the importance of tightening with precision tools and how improper techniques can lead to failure.  

Ryan also reveals the hidden role bolts play in engineering, from engines to construction, and how understanding tightening processes can improve manufacturing practices. With over a decade of experience, Ryan emphasises the often overlooked science behind tightening, urging engineers to embrace proper techniques for better manufacturing outcomes.

The Guru of Tightening: A Deep Dive into Bolt Science with Jason Benford! 

#AtlasCopco #Bolts #DisruptedFactory #Jendamark #Podcast #FollowUs 

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