Bentley Motors has started the series production of its recently unveiled Bentayga at its carbon neutral factory in Crewe. This follows a comprehensive review of the social distancing measures in place that have enabled Bentley production output to increase from 50% to 100%.

Consequently, a small number of assembly areas have been redesigned implementing a revised takt time while enabling a controlled, safe working environment at a social distance of more than 1m. All other areas will maintain a strict social distance of 2m and mandatory face masks will be worn throughout the factory.

As ramp up begins, over 100 people are working on the Bentayga production line as the car progresses through 43 stages of manufacture.

Peter Bosch, Bentley Motors member of the board for manufacturing, said: “The new Bentayga is a celebration of all that we can do in Crewe and is a testament to the skill, passion and dedication of all of our colleagues who produce cars unmatched by any other car factory in the world.

“To deliver a sector-defining car that meets our own and customers incredibly high standards and expectations is a significant achievement, particularly at this early stage of production. In the lead up to manufacture commencing we reviewed each individual process to ensure its efficiency and effectiveness, implementing industry-leading lean techniques with social distancing measures included.

“What we are seeing at start of production is a car that is significantly revised, both inside and out, and yet reaching record quality in manufacture levels across the industry. Raising the bar again as the sector-defining luxury SUV.”

This transformation of the build process allowed even greater lean manufacturing principles to be adopted. Over 1,500 engineers have undertaken education programmes in lean principles maximising value to customers while reducing waste in manufacture.

The new Bentayga is set to build on the success of its predecessor which sold more than 20,000 cars.