Predictive Maintenance has a rare-failure problem Automotive downtime now costs $2.3m an hour, yet fewer breakdowns mean less data to learn from. The plants getting Predictive Maintenance right are pooling knowledge, prioritising critical assets and earning the trust of the technicians who act on alerts. Ilkhan Ozsevim
Connected visibility: how automotive manufacturers are uncovering the "hidden factory" From micro-stops to stakeholder buy-in, panellists from Magna, Daimler Truck, BorgWarner and L2L explain how better visibility in shopfloor data is helping manufacturers maximise existing assets and scale pilot improvements into lasting operational change Nick Holt
Rivian and TE Connectivity strip the wiring myth bare Rivian's Dmitry Fudym and TE Connectivity's Bernard Vetten explain why zonal architecture lives or dies on the harness, from ECU consolidation to 800-volt clearances, and why the industry keeps learning the same lesson too late. Ilkhan Ozsevim
Cracking the automated wire harness assembly challenge Developments in machine vision, force control and a modular robot cells could finally close the automation gap for wire harness assembly Nick Holt
A global AI manufacturing transformation at Hyundai Motor Group Hyundai Motor Group has built a deeply integrated, AI driven manufacturing ecosystem that reduces errors, cuts downtime, preserves expert knowledge and connects data across the entire vehicle lifecycle Marcus Williams
How BMW and the University of Zagreb are increasing cell production knowledge BMW's Christian Siedelhofer explains how artificial intelligence, developed with the University of Zagreb, is cutting setup times, detecting defects invisible to the human eye, and building a validation framework for battery cells Nick Holt
Sponsored Automation-ready spray and the smart factory's data layer As stamping and paintshop lines digitise, fluid and lubrication systems are becoming networked, self-reporting assets rather than passive plumbing, according to the experts at Spraying Systems Co. Automotive Manufacturing Solutions
Sponsored How precision weighing is helping automotive test labs meet Euro 7 particulate emissions requirements Euro 7 is raising the bar for particulate emissions testing. Jan Bosse, Global Product Manager for Microbalances at Mettler Toledo, explains how precision weighing and robust laboratory practices help ensure accurate, traceable results AMS Editorial
Sponsored This is why AI inspection fails long after the pilot succeeds A recent peer-reviewed meta survey found that 77% of AI vision automotive production pilots never reach full deployment. A.J. Camber, VP at Solidigm, argues the problem is rarely the tech - and what it really takes to go from controlled trial to plant-wide reality. AMS
BMW Leipzig plant deploys terahertz technology to transform paint quality control BMW’s Leipzig plant has taken another step toward fully digitalised production, introducing an advanced, non-destructive measurement system that uses terahertz waves to inspect paint quality on plastic components Nick Holt
Sponsored LMI Technologies’ Gocator Smart 2D and 3D Imaging Is Reshaping Automotive Inspection LMI Technologies’ proven Gocator 3D Smart Sensors have long set the standard for high-performance inspection. With the addition of Gocator 2D Smart Cameras, the company now delivers a complete, unified vision platform that brings 2D and 3D imaging together in a single unified system. As Christian Benderoth explains, this expansion is about closing a critical gap in manufacturing capability-enabling customers to move from fragmented components to a fully integrated inspection solution that improves efficiency, scalability, and performance. AMS Editorial
AI vision finds its footing on the factory floor Three firms at the forefront of automotive AI vision inspection reveal why most pilots fail, why optics and lighting still govern outcomes, and how quality systems may soon prevent defects rather than merely catch them. Ilkhan Ozsevim
Tom Chackalackal takes over global manufacturing engineering at Ford Tom Scaria Chackalackal has been promoted at Ford to executive director global manufacturing engineering. In his new role, he is to strengthen technical excellence and align the manufacturing organisation with safety, quality, cost and capital efficiency. Timo Gilgen
How quality control in vehicle manufacturing is changing In car factories, quality is no longer just inspected, but increasingly safeguarded in real time. Cameras, AI, radar, lasers and digital inspection systems are intervening in production ever earlier. This is transforming not only final inspection, but the entire production logic. Timo Gilgen
AI vision raises the bar in EV battery assembly Atlas Copco's VisionTools platform brings AI-enhanced machine vision to EV battery production, combining neural networks with traditional inspection logic to achieve unprecedented quality assurance at speed and scale. Ilkhan Ozsevim
Quality Visions: AI inspection systems that learns from the line A factory producing EVs, hybrids and combustion variants simultaneously can no longer ask engineers to pre-define every failure mode. Rule-based vision has met its structural limit. What replaces it doesn't consult a rulebook - it learns from the line. Ilkhan Ozsevim
Why smart sequencing is becoming a backbone of modern vehicle assembly Rising product variety is forcing automakers to rethink sequencing strategies to stabilise assembly, protect workers and scale production efficiently. Timo Gilgen
Nissan is using AI to support engineering teams in accelerating vehicle testing Nissan’s collaboration with Monolith AI is speeding up vehicle validation while keeping engineers firmly in the loop and is reshaping how the OEM approaches testing in an era of rising vehicle complexity and electrification. Nick Holt
Sponsored SEAT automates bolt checks with 3D sensors at Martorell SEAT has introduced an automated inspection system at Martorell using 3D sensors and RFID tracking from LMI Technologies, STT Systems and Stemmer Imaging to detect missing bolts, improve traceability and reduce costly production delays. AMS
BMW Regensburg deploys GenAI to reinvent quality checks BMW’s Regensburg plant is using generative AI to automate bespoke quality inspections, enhancing speed and consistency across its complex, mixed-model production. Ilkhan Ozsevim
Benteler launches advanced manufacturing project in Morocco, integrating 4.0 tech The Benteler Group has launched construction of a smart automotive plant in Morocco’s Kenitra Free Zone, aiming to strengthen its global footprint, boost local employment and embed digital manufacturing technologies. Ilkhan Ozsevim
Automotive expert Tunç Kip: Human-machine interfaces essential in boosting flexibility, quality, and performance in global manufacturing From the factory floor to upstream design, digital human-machine interfaces are enabling smarter, leaner, and more flexible vehicle production - but humans need to be at the centre of gravity for it to work. Ilkhan Ozsevim
How Arno Güllering wants DRÄXLMAIER Group to harness shopfloor visualisation and genAI in production and maintenance The tier-1 supplier has established a highly connected production and logistics network, with a strong emphasis on data visualisation and a roadmap for AI. But to stay competitive and resilient, COO Arno Güllering wants to ensure both plants and HQ have a mindset ready to embrace change. Christopher Ludwig
BMW develops next-level digital manufacturing at Landshut and Regensburg plants BMW’s Landshut and Regensburg plants showcase how AI, automation, and smart logistics are transforming component production into digitally driven, future-ready operations. Nick Holt
