National Manufacturing Month: Webasto Roof Systems

Webasto Work Station
Photo courtesy of Webasto Roof Systems
EDITOR’S NOTE: Commerce Lexington is proud to recognize the impact and importance of manufacturing to our regional economy during National Manufacturing Month in October. According to the International Trade Administration, U.S. manufacturing is an enduring and ever-evolving sector that contributes $2.9 trillion to the U.S. economy, employs nearly 12.9 million American workers, and accounts for 11 percent of the nation’s GDP. We caught up with the leaders of several of Greater Lexington’s key manufacturers to find out more about their operations, secrets to their success, advantages of being located in the region, and how their industry is evolving.   Search more Commerce Lexington member manufacturers in our on-line Business Directory here. 
Webasto Roof Systems

Dan Klug Headshot

As one of the top 100 automotive suppliers worldwide, Webasto actively supports the transformation of the industry with decades of expertise and future‑oriented products, such as innovative roof systems, battery solutions, and heating and cooling products.  Approaching 30 years in the Blue Grass Business Park, most of the jobs at the Lexington facility involve the manual assembly of automotive sunroofs, including pre-assembly steps related to polyurethane encapsulation of glass panels.  There are also support functions like maintenance, shipping and receiving, and engineering and administrative.

Automobile roof systems were Webasto’s largest product group by revenue (78-percent) in 2025. Thermo management solutions and battery systems contributed approximately 13-percent and 8-percent, respectively, to the group’s sales.

According to Dan Klug, project manager for roof and components at Webasto, some of the company’s key challenges include the need for additional floor space due to new business and increases in the tariff rates. He said, “New business has required that we move some raw material to an off-site warehouse, and so it is always a challenge to continue high customer satisfaction during such a transition.”

Meanwhile, tariffs have put considerable pressure on the company’s overall profit margins. Klug said that Webasto has launched strategic initiatives to mitigate these adverse economic effects by actively identifying and developing alternative shipping routes. By diversifying the supply chain and exploring new logistical pathways, the company aims to optimize cost structures and build long-term resilience against ongoing trade volatility.

Culture is a big thing for companies these days as they work to attract and retain workers.  What has Webasto implemented over the years to strengthen company culture? 
“We have regular company meetings to ensure good communication,” said Klug.  “Company cookouts, cookie and coffee trucks, and similar activities help the culture and team engagement.  Recent ‘Perfect Future’ workshops included full-day, off-site meetings of a cross-functional group of about 100 colleagues to focus on the most important topics in the eyes of our colleagues and assign actions to follow.”

The company continues to add to its workforce.  Klug said, “Recent recurring hiring seminars have targeted adding about 30 colleagues per month.  This has been due to new business opportunities and regular turnover/attrition.  A two-day DOJO and mentored on-the-job training make it possible for new colleagues to be trained relatively quickly. Some jobs, which are more product safety critical, require advanced training.”

“The Lexington area offers a great culture mix with a lot of talent for our workforce.  Further, we are situated very well at the hub of many surrounding automotive customers within a day’s drive.”

Has Webasto introduced AI into its operations and how has the company approached its use among employees?
“Webasto has embraced the AI opportunity with thorough testing and oversight to help streamline our business in many departments, including finance, engineering and technology, and many day-to-day work tasks.  Suggestions for new opportunities are always welcome for submission, testing, and payback analysis.  We see it as an important tool to leverage going forward.”

So, what’s next for Webasto in the future? Klug said, “Our team does a great job of looking at new trends in the automotive market.  There’s always a spectrum of wanting the latest and greatest technology, and the most cost-competitive option.  We have groups developing models to support both extremes so that we can continue to be number one in sunroofs.”
Webasto Workstation
News & Press

More from the blog