In the rapidly evolving automotive industry, where precision, speed, and innovation define competitiveness, Angel Guillen, Vice President of Operations for the Americas at Motherson SAS, is driving the next wave of manufacturing transformation. With a career rooted in operational excellence, Angel has championed the integration of advanced technologies that enhance efficiency, quality, and flexibility across global production networks.
In this exclusive Speaker Spotlight, Angel offers a preview of his plenary session at the American Automotive Summit. His session titled “Driving Efficiency with Digital Twins: AI-Powered Insights for Smarter Manufacturing” will explore how AI-enabled simulation and digital twin technologies are revolutionizing decision-making, reducing downtime, and powering data-driven productivity gains across the automotive value chain.
Get an inside look at how Motherson SAS is leveraging digital twins to bridge the gap between physical and virtual operations — and learn how these innovations are shaping the future of smart, connected automotive manufacturing.
Can you introduce yourself, and share more about your career journey leading up to
your current role as VP, Operations at Motherson?
I’m Angel Guillen, Vice President of Operations for the Americas at Motherson SAS. My career spans over two decades in automotive manufacturing, with a strong foundation in lean practices, digital transformation, and operational excellence. I hold dual engineering degrees in Mechanical and Industrial Management from universities in Spain, and I’m a certified Green Belt Six Sigma in Lean Manufacturing.
Before joining Motherson, I led advance manufacturing and digitalization initiatives at Forvia, where I focused on integrating Industry 4.0 technologies and optimizing supply chains. My earlier roles at Android Industries and SAS Automotive Systems helped me build a deep understanding of plant operations, team leadership, and continuous improvement.
Throughout my career, I’ve specialized in implementing Just-In-Time (JIT) and Just-In-Sequence (JIS) production systems across multiple OEM and Tier 1 environments. These methodologies have been instrumental in reducing inventory costs, improving delivery precision, and enhancing responsiveness to customer demand.
Today at Motherson SAS, I oversee multiple production facilities across the Americas, driving strategic initiatives that enhance efficiency, quality, and innovation. My focus is on building resilient operations that can scale with customer needs while maintaining agility and excellence in execution
How do you personally approach scaling digital twin technology from a pilot to full production deployment?
Scaling digital twin technology requires a structured and cross-functional approach. I start by ensuring the pilot is aligned with clear KPIs—whether it's throughput, quality, or predictive maintenance. Once validated, I focus on integration: embedding the digital twin into existing MES, PLC and ERP systems, and ensuring data flows are robust and secure.
Equally important is change management. I work closely with plant managers and IT teams to train operators and build trust in the system. We also create feedback loops so that insights from the digital twin are continuously refined.
"The goal is not just deployment, but adoption—making the digital twin a daily decision-making tool across operations."
What risks or limitations have you encountered when relying on AI-driven insights for manufacturing decisions?
AI is a powerful tool, but it’s not infallible. One key risk is data quality—if the input data is flawed, the insights will be misleading. I’ve seen cases where sensor drift or incomplete datasets led to incorrect predictions. Another limitation is interpretability: AI models can be complex, and frontline teams may struggle to understand or trust the recommendations.
To mitigate these risks, we pair AI outputs with human validation. We also invest in explainable Motherrson AI tools and dashboards that make insights more transparent.
"Ultimately, AI should augment—not replace—human judgment, especially in high-stakes manufacturing environments."
How do you use insights from simulations to drive a culture of continuous improvement across your teams?
Simulations are a cornerstone of our continuous improvement strategy. We use them to test layout changes, workflow optimizations, and even staffing models before implementing them on the shop floor. This reduces risk and accelerates innovation.
But the real value comes from democratizing these insights. We share simulation results in daily huddles and kaizen events, encouraging teams to challenge assumptions and propose improvements. By visualizing the impact of changes, simulations empower employees to take ownership of performance and foster a proactive mindset.
How do you personally ensure that digital twin insights are actionable and shared effectively across the organization?
Actionability starts with relevance. We tailor digital twin dashboards to each user group—operators see real-time alerts, supervisors get performance trends, and executives view strategic KPIs. We also embed insights into existing workflows, such as shift handovers and weekly reviews.
To ensure effective sharing, we use a mix of digital tools and in-person forums. For example, we hold monthly cross-functional reviews where digital twin insights are discussed alongside operational data. This creates alignment and ensures that insights lead to decisions—not just reports.
What are you most looking forward to at the American Automotive Summit?
I’m excited to connect with peers who are shaping the future of automotive manufacturing. The summit’s focus on innovation, talent development, and digital transformation aligns perfectly with our priorities at Motherson. I’m particularly looking forward to the panel on Building the Next Generation of Automotive Talent, where I’ll share strategies for workforce transformation and leadership development.
It’s also a great opportunity to learn from other leaders and bring fresh ideas back to our teams.
As the automotive industry advances toward a more connected and intelligent future, Angel’s perspective offers a clear roadmap for turning digital twin and AI innovations into measurable operational results. His session will provide practical insights for manufacturers aiming to drive smarter, faster, and more efficient production.
Don’t miss the chance to hear directly from Angel Guillen at the American Automotive Summit, October 21–22, 2025 at the MGM Grand Detroit.
For more information and registration details, visit usautosummit.com