Tag: assembly

Why Chinese carmakers are rethinking Russia and turning to Central Asia for growth

As sanctions, investor pressure, and rising import fees reshape the Russian market, Chinese OEMs are pulling back and redirecting investment to Kazakhstan and Uzbekistan.

AR and VR boosting production planning and performance

From Ford and Volkswagen to BMW, Hyundai, Bosch, and ZF, Augmented Reality and Virtual Reality tools are becoming key to a faster, safer, more connected production environment.

Stellantis Factory Booster Day showcases AI driven manufacturing innovations

Stellantis gathered more than 80 partners in Detroit to unveil over 100 new solutions aimed at boosting efficiency, cutting downtime, and accelerating digital transformation across its global plants.

Five key trends in automotive manufacturing from a global automation leader

Continued innovation is key to the future growth of automotive manufacturing and lineside automation is essential for long-term OEM competitiveness

New alliances and innovative factory upgrades for US auto industry

GM and Hyundai form a wide-ranging new partnership, and Toyota reinvents its Kentucky plant to pioneer global manufacturing standards

Agility and collaboration key to manufacturing transformation: Aptiv’s José Carlos Jiménez

At AMS North America, José Carlos Jiménez, president of the connection systems division at Aptiv, discussed how modularity, simplification and a collaborative culture are reshaping the supplier’s operations to keep pace with rapid industry transformation.

Tariffs, delays, and doubt: Canada’s auto sector faces uncertain future

Canada’s automotive industry is caught in the crosshairs of a shifting US trade policy. Investment has stalled, jobs are at risk, raising urgent questions about the country’s role in North America’s automotive future.

Trump-era policy shift slows US EV investment plans

EV growth in the US is cooling as trade tariffs and weakened regulations under the second Trump administration reverse course from Biden-era incentives. Automakers including Ford, GM, and BMW are delaying or downsizing battery plant investments, reshaping the country’s electric future.

Porsche and VW dial back EV ambitions as market shifts and costs mount

Facing cooling demand and mounting platform delays, Porsche and the wider Volkswagen Group are scaling back their electric vehicle rollout plans. With €5 billion in write-downs, postponed launches, and a return to ICE and hybrid models, the road to electrification is no longer a straight line.

Tariffs redraw North American auto manufacturing map

From BMW to Nissan, automakers are shifting assembly lines to the US to avoid steep tariffs – while Canadian and Mexican operations face uncertain futures. Here's how tariffs are reshaping the industry's landscape.

Europe’s carmakers cut production as overcapacity bites

Stellantis, Volkswagen, and Ford are pausing production at multiple plants across Europe amid falling demand, rising inventories, and shrinking market share. With utilisation rates dropping, industry-wide plant closures are beginning to look inevitable.

Inside BMW’s smart logistics strategy at Debrecen

BMW is redefining automotive logistics with direct delivery systems, real-time tracking, digital twins, and autonomous transport at its Debrecen plant. The OEM’s tech-driven approach integrates production, quality, and sustainability – setting a new standard for next-gen vehicle manufacturing.

Renault, Nissan, and Mitsubishi ramp up EV production at Ampere’s Douai plant

The Renault-Nissan-Mitsubishi Alliance is accelerating its electric vehicle strategy at Ampere’s Douai plant, preparing for the launch of the all-electric Nissan Micra and Mitsubishi Eclipse Cross. The modular facility now serves four brands with six EV models.

US immigration officials raid $7.5bn Hyundai–LG plant, repatriation deal struck after 300+ South Koreans workers detained

The battery facility, part of the broader $7.5 billion Hyundai Motor Group Metaplant America complex, is a joint venture aimed at building cells to power Hyundai, Kia, and Genesis electric vehicles produced in the U.S.

Anushka Dixit

Marcus Williams

JLR shuts IT systems, halts UK plant production after cyberattack

Production at Solihull and Halewood have been suspended. JLR said it had taken “immediate action to mitigate” the impact and that it continues to investigate the source and scope of the incident.

Anushka Dixit

Tariffs, trade shifts, and EV turbulence: How Trump’s second term is reshaping North American auto manufacturing

North American vehicle manufacturing is undergoing major changes. These are in response to political actions, wider market factors and some interesting decisions by major vehicle companies

Automotive Wire Harness & EDS Conference Returns to Detroit in 2025

The Automotive Wire Harness & EDS Conference will return to the Detroit area this October, offering two full days of focused discussion, technical insight, and peer collaboration on the future of automotive electrical and electronic distribution systems. October 20–21, 2025 | The Henry, Dearborn, Detroit

Fiat 500 hybrid revives Mirafiori plant with scaled-up production and new investment

Production of the Fiat 500 Hybrid at Turin’s Mirafiori plant represents a significant reinvestment in the facility and marks a major step in Stellantis' manufacturing strategy.

Next steps for automating wire harness assembly

The wire harness assembly process has long been the most difficult to automate; complex layout, flexible wires, small connectors and tight grouping all conspire keep this job as a manual operation, until now.

Welcome to the new AMS experience

We’ve redesigned the AMS website to deliver sharper insight, faster access and a smoother, more intuitive experience at a time when you need it most.

How flexibility, digitalisation and workforce agility are reshaping auto manufacturing

From multi-powertrain assembly lines and digital twin-enabled operations to agile supply networks and adaptive workforce models, OEMs and suppliers are redesigning the production floor for a future that rewards flexibility and responsiveness.

ABB PixelPaint revolutionises the automotive paintshop

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with ABB Robotics.The paintshop has always been one of the most expensive and least sustainable areas of any production facility. Joerg Reger, Head of Automotive at ABB Robotics discusses the challenges and how the company has created a revolutionary solution.

GM invests $888M in Tonawanda plant to build next-gen V-8 engines for trucks and SUVs

General Motors is reinforcing its commitment to American manufacturing and high-performance engines with a $888m investment in its historic Tonawanda Propulsion plant. The funding supports production of GM’s sixth-generation V-8 engines, powering full-size trucks and SUVs while bridging the gap to an electric future.

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.

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.

Mercedes-Benz blends AI, humanoid robots and craftspeople at its Digital Factory Campus to redefine the boundaries of human-machine collaboration in vehicle production

At its Digital Factory Campus in Berlin, Mercedes-Benz is pioneering new forms of human-machine interaction, from generative AI agents to humanoid robots, blending physical and digital intelligence in its production system.

Honda ramps up motorcycle production in India with new line at Gujarat plant

Honda Motorcycle & Scooter India (HMSI) is significantly expanding its production footprint in the world’s largest motorcycle market with the announcement of a new production line at its fourth manufacturing plant in Vithalapur, Gujarat.

Augmented reality, AI, cobots and digital twins are transforming automotive production by enhancing worker training, planning, inspection and collaboration

Human-machine interfaces are becoming central to car production. With AR, cobots, AI inspection and digital twins, OEMs like Ford, Volvo, GM and Mercedes are reshaping the way people and machines interact.

Toyota reorganises North American manufacturing into three pillars and seven regions as part of its long-term production and logistics strategy

Toyota has unveiled a sweeping reorganisation of its North American manufacturing, dividing operations into three strategic pillars and seven regions, alongside executive changes aimed at EV growth and production agility.

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.

JLR and Daimler Truck are building resilience through flexible manufacturing, agile supply chains and modular production systems

JLR and Daimler Truck are adapting their global production systems to meet rising demand for vehicle personalisation, electrification and supply resilience. From simulation to system design, flexibility is now built in from the start.

How Mercedes-Benz, BMW and Dräxlmaier are using digitalisation, automation and AI to transform production, logistics and sustainability across their global manufacturing networks

European automotive manufacturers are building digitally integrated production systems across their global operations to increase resilience, reduce emissions and prepare for new vehicle architectures and future technologies

Mercedes-Benz to localise GLC SUV production in Alabama amid tariff pressures and market shifts

Mercedes-Benz confirms plans to assemble the GLC SUV at its Alabama plant starting in late 2027, a move influenced by US tariffs and the need for localised production to meet North American demand.

Inside Tesla’s ‘radical’ manufacturing shift: How the “Unboxed” process could slash EV production costs and impact the automotive industry

As Tesla gears up to launch its $25,000 electric car, its “Unboxed” manufacturing process draws both praise and scepticism. AMS explores its potential to transform automotive production and its implications for the industry.

Automation gains new levels of traction as the automotive sector turns to robotics for safer, more efficient production and a redefinition of the human role on the line

A new global survey by QNX reveals how automotive manufacturers are increasingly embracing robotics to boost efficiency, address labour shortages and improve safety, while also navigating concerns over cost, trust, regulation and the future of the workforce.

China’s rare earth magnet export ban threatens global EV and automotive manufacturing, as US, European and Asian carmakers scramble to secure critical materials

The global automotive sector is facing renewed disruption as China tightens control over exports of heavy rare earths and magnets. With EV powertrains and chips at risk, OEMs are now racing to diversify supply.

Honda’s $1bn redevelopment of its Ohio plants sets a global precedent in integrating EV, hybrid and ICE production with smart manufacturing and supplier transformation.

Honda North America’s upgraded Ohio operations will be its template for flexible production of ICE, hybrid and electric vehicles on a single line. Project lead Mike Fischer speaks to AMS about the goals, planning and execution behind this major production shift.

As VW cuts back in Germany, Slovakia and Spain emerge as new pillars of cost-effective and future-focused production across Europe

As VW’s traditional German plants face uncertainty, its long-established facilities in Bratislava and Pamplona are stepping into the spotlight—producing top-selling models and gearing up for a new era of electric vehicles.

Henkel’s next-generation gap filler solutions for automotive electronics

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Henkel.Thermal gap fillers are under greater stresses from electronic components as trends like autonomous driving take shape.

How Mercedes-Benz Bremen manages combustion, hybrid and EV builds while preparing for Maybach and AI-driven smart production without going fully electric

In an interview with Timo Gilgen, the Bremen plant manager talks about his understanding of leadership, identifies the challenges facing the location, and explains how the north manages to build ten different models simultaneously and why a purely electric plant is not an option.

General Motors ramps up pickup truck production at Fort Wayne as US tariffs unsettle North American automotive trade and raise questions over Canada’s manufacturing footprint

General Motors is hiring temporary workers to boost production at its Fort Wayne plant in response to new US tariffs. While Oshawa output remains stable for now, the move reflects shifting trade and labour pressures across North America.

Nissan transfers Rogue SUV output from Japan to Tennessee to hedge against new US tariffs and preserve its share of the American market

Faced with rising tariffs on imports, Nissan will reduce Rogue SUV production in Japan and ramp up output in Tennessee. The move is a clear response to tightening US trade policy and reflects a wider recalibration of global manufacturing among carmakers.

ArcelorMittal’s Multi Part Integration enhances vehicle manufacturing with reduced costs, better flexibility, and improved safety, offering a scalable solution for the automotive industry.

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with ArcelorMittal.Philippe Aubron, Head of Global Automotive at ArcelorMittal explains how the automotive producer’s Multi Part Integration (MPI) solves multiple manufacturing challenges and assists automakers to cut costs and exceed critical targets.

Audi pioneers virtual control systems with Siemens and Broadcom to transform production efficiency and digital automation in its Böllinger Höfe bodyshop

Audi is rolling out virtual programmable logic controllers at its Böllinger Höfe site with Siemens, Broadcom and Cisco, replacing hardware with cloud-based automation to enhance agility, scalability and environmental efficiency

BMW ramps up Debrecen plant with cutting-edge modular assembly to lead Neue Klasse electric vehicle production from late 2025

BMW’s all-electric plant in Debrecen enters its final phase before full production. With modular systems, digital twin planning and just-in-sequence delivery, the site signals the future of scalable, fossil-free manufacturing.

Skoda expands manufacturing operations with new Vietnam assembly plant

Skoda has officially begun local assembly of its Kushaq SUV and Slavia sedan at a newly established facility in Vietnam’s Quang Ninh province. Developed in partnership with Thanh Cong Group, the plant marks a significant step in Skoda’s global expansion, strengthening its foothold in Southeast Asia’s rapidly growing automotive market.

How digital twins are boosting efficiency and adaptability in automotive manufacturing: Stellantis, Webasto and Cintoo dig in

Digital twins are becoming essential in automotive manufacturing, helping OEMs and suppliers optimise efficiency, adapt to electrification, and enhance real-time decision-making. We look at how BMW, HORSE, Stellantis, Webasto and Cintoo are pushing the technology’s boundaries.

Hyundai Motor Group to invest $21bn in US vehicle production, future tech, energy infrastructure and supply chains, targeting 1.2m unit capacity and 100,000 new jobs by 2028

Hyundai Motor Group is deepening its US manufacturing footprint with a $21bn investment through 2028. The Group is scaling production, localising components and developing future mobility and energy technologies to strengthen industrial resilience.

JAC Motors expands production in Mexico to increase capacity by 30% and assemble electric and combustion SUVs, pickups, trucks and LCVs for future domestic growth

JAC Motors is scaling up production at its plant in Ciudad Sahagún, Hidalgo, with a 30% capacity boost and new flexible lines to assemble electric and combustion SUVs, pickups, LCVs and trucks for Mexico’s evolving market

Honda to source hybrid vehicle batteries from Toyota’s new US plant as tariff threats and shifting EV policies force Japanese carmakers to rethink their supply chains

Honda will source hybrid batteries from Toyota’s $14bn US factory starting in 2025, as rising tariffs under Trump and declining EV incentives prompt Japanese carmakers to reinforce local supply chains

JLR expands EV production with 150 new UK roles supporting Range Rover Electric and next-generation electric vehicle manufacturing

JLR is expanding its UK workforce with 150 new maintenance roles to support EV production. With Solihull and Wolverhampton at the heart of its transformation, the company is investing in people, technology and electrification.

Mercedes-Benz accelerates AI and robotics at Berlin-Marienfelde, transforming digital production with humanoid robots and next-generation automation technologies

At its Berlin-Marienfelde site, Mercedes-Benz is integrating artificial intelligence and humanoid robotics into automotive production. With new digital tools and axial-flux motor technology, the factory is setting new global standards for intelligent manufacturing.

Mazda’s Lean Asset Strategy: Driving efficiency in development and manufacturing

Mazda has unveiled its “Lean Asset Strategy,” reinforcing its multi-solution approach to electrification. This initiative is aimed at optimising product development and manufacturing while accelerating time-to-market and reducing costs.

A Mckinsey report warns that Europe’s automotive industry must adapt rapidly to electrification, software and global competition or risk falling further behind

Europe’s automotive industry is under pressure. A McKinsey report outlines five major disruptions that threaten its future. From software to supply chains, the industry must move fast to avoid losing ground to global competitors.

BMW plants prepare for a new era with Neue Klasse production

As BMW gears up production towards its Neue Klasse electric vehicles, the factories are to remain flexible. Gotz Fuchslocher looks at the strategies the manufacturer is pursuing as it prepares to launch production of the new models.

Evolution of EV platforms: Innovations in design, manufacturing, and scalability

Electric vehicle architectures must be adaptable, scalable, and cost-effective, but evolving battery technologies, crash protection, and manufacturing processes add complexity. While the skateboard design has become standard, innovations like gigacasting and hybrid adaptability are reshaping the industry. Automakers are racing to refine EV platforms, balancing speed to market with efficiency and safety in an increasingly competitive landscape.

Honda upgrades production with advanced processes for 2026 Passport models

Innovative manufacturing enhances efficiency, quality, and ergonomics at Alabama Auto Plant.

BMW’s Neue Klasse redefines electric mobility with advanced Software-Defined Architecture and high-performance energy management

BMW’s Neue Klasse redefines electric mobility with a software-centric vehicle platform, high-voltage 800V battery technology and four advanced computing modules. A new era of efficiency, flexibility, dynamic performance and seamless energy management is emerging?

How China’s BYD surpassed Tesla with production and battery tech - reshaping the global EV market

BYD has surged onto the global stage, challenging industry giants like Tesla with its aggressive expansion and pioneering battery technology. BYD’s production soared from half a million to over 4 million vehicles. As the company celebrates its 30th anniversary, its blend of vertical integration, cutting-edge automation, and global supply chain mastery has redefined the EV landscape.

Accelerating EV innovation transforms design and manufacturing processes as Toyota and Volkswagen lead cross-functional integration and digital twin adoption for future production

Industry experts at the AMS Evolution panel examine the accelerating EV shift and its impact on design and manufacturing. Toyota and Volkswagen share insights on engineering flexibility and digital twin simulation to streamline production

Why global automotive innovators must embrace Design For Manufacture to power production in an environment of increasing complexity and fierce foreign competition

Automotive manufacturers are streamlining production with Design for Manufacture (DFM), cutting complexity, reducing costs and driving EV innovation. In In this article, experts reveal the key strategies and digital tools that are reshaping vehicle production.

JLR and partners push seat foam circularity forward through digital tools and collaboration, accelerating sustainable material reuse in luxury vehicle production

JLR’s breakthrough in seat foam circularity is powered by digital tools, data-driven traceability and production/supply chain collaboration. The Circularity Lab’s ‘learn through doing’ approach is setting new industry benchmarks for material reuse and sustainable innovation. Ilkhan Ozsevim reports.

EU invests in AI to transform automotive manufacturing with ‘AI smart factories’, automation and next-generation production technologies

The EU’s new InvestAI fund will inject €200 billion ($208.4bn) into AI, transforming European automotive manufacturing. With AI gigafactories and smart factory technology, this initiative aims to drive automation, digitalisation and next-generation production systems.

Nissan to amplify green steel usage in Japan by 500% aligning with global automakers in pursuit of carbon neutrality by 2050

In an important move towards enhanced sustainable production, Nissan has declared a fivefold increase in the utilisation of green steel in its vehicle manufacturing. The initiative is part of the OEM’s wider carbon neutrality targets and reflects a growing industry trend.

Honda North America’s big investment in flexible manufacturing for EVs, hybrid and ICE vehicles

Honda invests $1 billion in retooling its Ohio manufacturing plants to build ICE, hybrid, and EV models on same production line. New technologies being introduced include megacasting, CDC and friction stir welding.

How OEMs such as BMW, Toyota and Ford are harnessing data-driven decision making drive sustainability in automotive manufacturing

Leading automotive OEMs and tier-suppliers are deploying cutting-edge data tools to transform their operations. This article explores how they are using AI and big data to enhance resource efficiency, reduce emissions, and pave the way for a greener future in manufacturing.

BMW’s San Luis Potosí plant in Mexico is driving global sustainability with solar power, water reuse, and AI-driven carbon reduction

BMW’s San Luis Potosí facility in Mexico exemplifies sustainability in action. From solar energy to water recycling and AI-driven efficiency, the plant demonstrates how local, effective green innovation can reshape automotive production on a global scale. Following a site visit, AMS delves into the facility’s world-leading sustainability intiatives. Ilkhan Ozsevim reports.

Rolls-Royce invests £300m to extend Goodwood manufacturing facility

The £300m site extension will expand Bespoke and Coachbuild capabilities, driven by a 10% increase in Bespoke content value per motor car year-on-year, and support future EV production.

How AI is transforming automotive manufacturing: A deep dive into key technologies, optimisations and efficiency gains

Automotive production is undergoing a seismic transformation with Artificial Intelligence driving unprecedented innovation. From predictive maintenance to autonomous robotics and generative design, here’s how AI is enhancing precision, adaptability and efficiency.

How Opel Eisenach’s New Grandland EV Production Blends Lean Principles, Flexibility, and Automation for Competitive Advantage in a Changing Industry

The Opel plant in Eisenach exclusively produces the new Grandland – the brand’s flagship. Plant manager Jörg Escher explains in an interview what impact the switch to the new model will have on the site.

VW Wolfsburg plant kicks-off Tayron production with precision and digital innovation

The VW main plant is once again producing four different models. After the Seat Tarraco is phased out, the VW Tayron is taking its place. Read how the start-up worked here.

Henning Habicht appointed Head of Volkswagen Chattanooga Operations

Habicht takes over from Chris Glover, who will retire in January 2025 after more than three decades with Volkswagen, including a three-year stint at Chattanooga.

BMW Leipzig starts production of the second generation 2 Series Gran Coupé

The new 2 Series Gran Coupé joins the 1 Series, 2 Series Active Tourer and MINI Countryman in production at Leipzig, with the four models with three different drive options made on a single production line.

Mercedes-Benz Trucks Mannheim plant to start production of eActros 600 components

Series production of the eActros 600 will start at the end of November this year at the Mercedes-Benz plant in Wörth supported by components produced at Mannheim.

Change is the only constant for Volkswagen Chattanooga EVP Christopher Glover

The head of Volkswagen’s US plant operations is managing market and technology complexity through flexible facility design, practical digitalisation, training and engagement with workers. He speaks to AMS ahead of a keynote presentation at AMS Evolution North America in Michigan.

“We cannot afford to make any mistakes” - Volkswagen’s Portugal boss Thomas Hegel Gunther

It’s not easy being the manager of a VW plant these days. In an interview, Volkswagen’s Portugal boss Thomas Hegel Gunther explains what makes the home of the T-Roc so special and how his team is continually increasing effectiveness through various lean principles.

Tier suppliers – Adapting to new challenges

BorgWarner shares insights into how the company is leveraging existing assets and using mergers and acquisitions to boost electric vehicle component production.

How cobots can support automotive production

Cobots enrich the industry with their ability to complete tasks in close cooperation with humans and are becoming increasingly intelligent thanks to modern technologies. This article takes a look at the different types of robots, and their benefits to the industry.

Stellantis turns to AI tools and fast deployment to cut production costs and launch times

Stellantis chief manufacturing officer Arnaud Deboeuf reveals technologies across automation, factory planning and lineside logistics that reduce transition costs and time to market.

Audi’s electric hopes rest on Györ

Györ plays a special role in Audi’s production network. Just as important as the approximately 176,000 vehicles produced each year are the almost 1.7 million drives produced. Now Györ must make the transition to electromobility.

Valmet Automotive’s battery business to become an independent company

Valmet Automotive is making its Electric Vehicle Systems business an independent company with its own leadership. The company says it plans to target markets beyond automotive.

Skoda builds updated Octavia at Kvasiny

Skoda shuffles production to add Octavia to Kvasiny and free up capacity at Mlada Bolslav for Enyaq and Elroq models.

Ford revises EV strategy and boosts hybrid production

Ford cancels planned three-row EV SUV, delays opening of Tennessee EV plant and realigns US battery cell production.

Can Rivian navigate production challenges and scale up in the electric vehicle world?

Rivian has emerged as an important player in the EV market, known for its adventure-oriented electric trucks and SUVs. But the OEM faces significant challenges to its production forecasts. Can Rivian maintain its momentum in EV production?

Toyota to build EV battery plant for Lexus in Japanese island

Toyota Motor is planning to build an EV battery plant for its Lexus brand in the Japanese island of Kyushu, according to Japanese newspaper Nikkei.

Stellantis and the UK government: sabre rattling or crying wolf?

Unhappy with the UK’s ZEV mandate Stellantis has suggested it might cease LCV production in the UK, but is there more to this than legislation?

European battery production needs greater speed and agility

Exhibitors at this year’s Battery Show in Stuttgart shared insights into EV and battery production challenges and how the industry needs to adapt with greater speed.

GM, Stellantis and Volvo Group to gain $1.7 billion in EV grants

The US federal government is set to contribute $1.7 billion in grants to GM, Stellantis, Volvo Group and more to support increased EV production.

In Emden, Volkswagen wants to leave the Passat behind

Volkswagen’s Emden plant has existed in northwest Lower Saxony for decades. Nowhere else is the change to electric drives so noticeable. With new logistics, new assembly and the new ID.7, a new era begins.

Designing manufacturing systems for flexibility and scalability

Comau discusses assembling e-drives, developing battery manufacturing solutions, and collaborations with universities for next-generation cells.

Virtual production networks are able to solve multi-level complexities across automotive manufacturing

Virtual production networks provide automotive manufacturing with myriad solutions like advanced time- and cost-saving simulations, global collaboration capabilities, and innovative tools like digital twins to harness untapped production flexibility.

Korea: the switch to EV production accelerates

Korean vehicle makers invest in flexible production and add more EVs. Foreign OEMs continue to invest in production for export.

Toyota Texas to expand manufacturing footprint with $531m investment

Toyota Texas’ new on-site 500,000 sq. ft facility will be for drivetrain parts production

The future may be all electric, but not just yet

With demand for battery electric vehicles lower than expected, OEMs are boosting hybrid output and extending ICE production.

Sames solves for BMW & Mercedes: Adhesive tech in bodyshop & glazing

Sames’ innovations support high-quality adhesive bonding in automotive manufacturing, optimising efficiency and standardisation across bodyshop and glazing processes.

GKN Automotive reduces direct CO2e emissions in 2023

GKN Automotive has published its second sustainability report, revealing a 10.5% reduction in CO2e emissions in 2023.

Honda starts production of fuel cell electric vehicles in the US

The 2025 CR-V e:FCEV fuel cell electric vehicle is now being produced at Honda’s Performance Manufacturing Center (PMC) in Marysville, Ohio.

Exclusive: BMW Group improves efficiency with additive manufacturing gripper

BMW Group has improved the speed, versatility and sustainability of its manufacturing and cut costs by using 3D-printed bionic robot grippers. Automotive Manufacturing Solutions reports on the latest innovations from the BMW Group Additive Manufacturing Campus and manufacturing plant in Munich.

Ford Otosan manufacturing for an economy in transition

Ford Otosan has upgraded its manufacturing facilities in Turkey to ensure the Transit is ready for an electrified future

How the Audi Q6 e-tron series is proof of the OEMs flexible and sustainable vehicle production ecosystem

Audi’s Ingolstadt plant pioneers sustainable manufacturing with net-zero emissions, showcasing flexible integration and cutting-edge technology: Q6 e-tron leads the way

Shifting gears – Electrifying the driveline

GKN Automotive has a long history as a driveline component and system developer, and manufacturer. Like many of the leading tier suppliers in this segment, the company has now added a range of products for electric powertrains to its range. Jorge Beja, VP of Operations Systems shares some insights into production at the company’s centre for excellence for eDrive systems, at Bruneck, Italy.

Europe: OEMs face multiple challenges ahead

With global geopolitics in increasing turmoil and ongoing economic uncertainty, Ian Henry shares his thoughts on the notable challenges facing the European vehicle manufacturing sector.

“Our future viability is not a given”: BMW Leipzig’s plant manager Petra Peterhänsel

Despite the crises, the BMW plant in Leipzig is optimistic about the future: in an interview, plant manager Petra Peterhänsel explains how investments in electrification and automation should contribute to a rosy future for the location

Toyota adds battery electric vehicle production to Kentucky

The $1.3billion investment at the Kentucky will support assembly of an all-new, three row battery electric SUV for the US market

Porsche plant in Leipzig wins Factory of the Year

The Porsche factory in Leipzig, germany has won the ‘Factory of the Year’ award, presented by consulting firm Kearney and Automobil Produktion, a sister publication of AMS.

Porsche launches all-electric Macan

Porsche has revealed its first native all-electric model, the Macan SUV, using the Premium Platform Electric (PPE).

The co-evolution of EVs, architectures and production processes

Electric vehicles and batteries are influencing automotive manufacturing decisions, driving changes in vehicle architectures, production processes and material choices. Gestamp and ArcelorMittal discuss their strategies

Rising labour costs become biggest concern for automotive manufacturing

Rising labour costs and skills shortages are the biggest concern for the automotive manufacturing industry this year, according to the latest AMS & ABB Automotive Manufacturing Outlook Survey 2023.

AMS & ABB Automotive Manufacturing Outlook Survey 2023 results: A positive outlook despite evolving challenges

Download our latest global survey results to gain expert insight into automotive manufacturing trends, gauge the current sentiment across the automotive sector and learn about the broader industry outlook for 2024 and beyond.

Tata subsidiary TPEM launches first Tata-branded vehicle and kicks off production at new Gujarat facility

Tata Passenger Electric Mobility (TPEM) has launched its parent company - Tata’s, first ever own-brand vehicle to mark the inauguration and opening of TPEM’s new vehicle production facility in Sanand, Gujarat, with clear indication of growth in the region.

Design and manufacturing integration key to BMW’s Neue Klasse

To realise large cost and emission savings on its EV architecture, BMW is redesigning vehicles and manufacturing in parallel, and rolling out rapid digital solutions.

BMW Munich plant to go full electric with Neue Klasse and revamped, digital production system

BMW’s home plant will produce only EVs by 2027, with much of the century-old factory rebuilt to meet new levels of efficiency and digitalisation, without missing a beat of ongoing production.

AMS Winter 2023/24 – BMW’s battery boost

Our Winter digital edition takes an in-depth look at how OEMs are getting to grips with developing and manufacturing new electric vehicles and powertrains

Simultaneous engineering – accelerating production line design, development and commissioning

The transition to electric vehicles has increased pressure on speeding product development and starting production operations. AMS spoke with experts at NIO and Comau on how they had successfully accelerated the commissioning of new e-motor lines

Whitepaper: Thermal Potting for EV Components

Learn how superior thermal potting materials enhance heat management, durability, and innovation in electric vehicle components with this exclusive whitepaper from Henkel

Henkel powers EV evolution with cutting-edge battery sealing technology

PARTNER CONTENTThis content was paid for by Henkel and produced in partnership with Automotive Manufacturing SolutionsInnovative solutions from Henkel ensure safety, reliability, and durability for EV battery manufacturers worldwide, setting new standards in performance.

Advanced materials application for EV battery production

Coatings, adhesive and sealant application equipment, plays a crucial role in enabling the efficient implementation of advanced materials in the EV battery manufacturing process. SAMES discusses how its technologies and experience can be instrumental in ensuring the quality and safety of EV batteries.

How BMW will maintain quality in its 3,000-step battery cell production process

At its recently opened German Cell Manufacturing Competence Centre (CMCC) in Parsdorf, BMW is aiming to achieve ‘expertise in every cell’ of its generation six batteries for its Neue Klasse EV models. But to do this, the carmaker needs to ensure the 3,000-step production process is consistently quality checked along the way.

JLR expands EV production to Slovakia

JLR has used the fifth anniversary of its plant opening in Nitra, Slovakia to announce that it will develop the plant to produce electric vehicles by 2030.

Delegate Interview with Maggie Gehrlein, General Motors - Automotive Evolution North America 2023

Automotive Evolution North America delegate and speaker Maggie Gehrlein, General Motors, spoke about her experiences at this year’s conference and what she’s looking forward to in 2024

Delegate Interview with Leonel Leal, Stealth-mode EV - Automotive Evolution North America 2023

Automotive Evolution North America delegate and speaker Leonel Leal, Stealth-mode EV, spoke about his experiences at this year’s conference and what he’s looking forward to in 2024

Delegate Interview with Greg Ruscak, Telsonic - Automotive Evolution North America 2023

Automotive Evolution North America delegate Greg Ruscak, Telsonic, spoke about his experiences at this year’s conference and what he’s looking forward to in 2024

Delegate Interview with Mark Miller, GM - Automotive Evolution North America 2023

Automotive Evolution North America delegate Mark Miller, GM, spoke about his experiences at this year’s conference and what he’s looking forward to in 2024

Highlights - Automotive Evolution North America 2023

View the highlights from both days of AMS Automotive Evolution North America 2023

Day 2 Wrap-up - Automotive Evolution North America 2023

Day 2 of Automotive Evolution North America has now wrapped, and what a day it was! Watch above as AMS Editor-in-Chief Christopher Ludwig covers the day’s events and our various panels and VIP speakers.

Day 1 Wrap-up - Automotive Evolution North America 2023

AMS Editor-in-Chief Christopher Ludwig introduces the inaugural Automotive Evolution North America 2023 conference

Reactive problem-solving - Interview with Humam M. Alwan, Stellantis

Humam M. Alwan, Software X Quality Management at Stellantis discusses reactive problem-solving at Automotive Evolution North America 2023

Expansion, new gigafactories, and sustainability - Interview with Abby Chitwood, Panasonic Energy of North America

Abby Chitwood, Director of Expansion Engineering for Panasonic Energy of North America discusses sustainability and more at Automotive Evolution North America 2023

Back in the USA

Returning to Detroit for the first time in over 10 years the AMS Automotive Evolution North America event delivered expert panels and a fully engaged audience who combined to share their valuable insights and experience, through panel discussions, Q&A and networking. Here are some of the highlights from the sessions.

Fanuc and Volvo Cars sign deal to transform automotive manufacturing with sustainable robotics

In a landmark collaboration, Fanuc, the global leader in industrial robotics, and Volvo Cars are to reshape auto manufacturing with sustainability at the forefront

The future of Ford in a flash of lightning

The Ford Dearborn Truck Plant is a benchmark for managing complexity, quality and software, and is setting standards for the future. Plant manager Corey Williams shares learnings and lean principles across ICE production and fast-growing EV output at the plant’s newly expanded Rouge Electric Vehicle Center

AMS Autumn 2023 – Continental Shift

In this latest AMS digital edition we have a special focus on the North American automotive industry as the region’s OEMs make big investments in electric vehicle and battery production

Battery production and design need to be optimised together, says Volvo Trucks and ABB

Václav Švub from ABB Robotics and Wenting Hu from Volvo Trucks pointed to the benefits of aligning battery engineering and production processes in an exclusive AMS livestream, including opportunities in automation, new materials and production processes.

Panasonic sparks scalable and sustainable US battery production

Abby Chitwood, who leads new product introduction and new factories at Panasonic Energy of North America, discusses maximising output and reducing emissions in battery cell production ahead of the first AMS Evolution North America conference, where she is a speaker.

Skoda Kvasiny to become electromobility powerhouse

Head of Skoda Kvasiny plant, Miloš Halbich, talks to Mike Nash about recent socioeconomic challenges, fluctuating markets and how the facility is a “crucial pillar” in the company’s global production network

UAW workers start strike against GM, Ford and Stellantis

Members of the United Auto Workers (UAW) union have started a strike against the ‘big three’ Detroit OEMs GM, Ford and Stellantis, after their contracts expired and no agreements were reached.

Zeekr VP and plant director discusses mass volume EV production

Zhao Chunlin of Zeekr sits down with Michael Nash to talk about the company’s ‘intelligent factory’ in Ningbo, China, as well as the various challenges that come with EV production

Watch: The advance of automation: what next-gen vehicles and batteries mean for robotics

OEMs are transforming not only their respective vehicle types, transitioning to electric and connected models, but also the manufacturing operations to build these new vehicles. This creates challenges in integrating new vehicle architectures, powertrains and electronics into existing manufacturing facilities, boosting demand for more advanced automation.

BMW’s aspirations to the X degree in Spartanburg: Special series

The carmaker is investing in capacity, suppliers and people to prepare for EV production in South Carolina, with a focus on flexibility, resiliency and sustainability. Interviews with the plant CEO, Dr Robert Engelhorn, and key leaders in battery, logistics and training outline BMW’s huge ambitions in the region.

Master of complexity in Spartanburg

Dr Robert Engelhorn is leading transformation of BMW’s operations in Spartanburg, South Carolina for EV production, whilst ensuring manufacturing and workers remain highly flexible in managing vehicle variations and market changes.

Ford restarts electric F-150 Lightning production in Dearborn following retooling and expansion

The OEM has retooled its Rouge Electric Vehicle Center to build 150,000 units per year at, and is increasing manufacturing capabilities to produce more trim options.

On advanced robotics, skills and training: “Machines can’t do everything”

Next-generation vehicles require new production processes, above all in automation, digitalisation and employee qualifications. Carolin Platz from the Auto-Motive Academy and Jörg Reger from automation expert ABB discuss the intersection of major topics in scaling up EV manufacturing.

BMW begins production of its fully-electric i5 model at Dingolfing plant

Phasing into the EV market, the i5 hits production lines at BMW’s largest European plant, expected to cover 40% of the OEM’s total EV output by 2024

VW to make Spain an electric vehicle hub

The VW Group is building new battery production capacities in Valencia and at the Seat headquarters in Martorell to support further electric vehicle production in the region

Audi leads manufacturing skills transformation as it launches first EV from Ingolstadt plant

Audi’s launch of the all-electric Q6 e-tron series has catalysed a major reskilling project, as the shift to e-mobility is demanding skills development. Other manufacturers, such as ZF, have also been cultivating internal talent.

Kia plans $200m expansion at Georgia plant for assembly of EV9 SUV

Kia is investing $200m into an expansion of its Georgia West Point plant to accommodate the assembly of its new EV9 SUV in the second quarter of 2024.

Joining forces – technical partnerships supporting vehicle manufacturers

As the automotive industry seeks to reduce costs and improve efficiencies and productivity, there are a growing number of new partnerships being formed. Experts from automation specialist Magswitch discusses how these new relationships are proving more necessary and beneficial than previously.

Volta Trucks partners with ZF Commercial Vehicle Solutions for core systems for its all-electric urban delivery truck

Scandinavian electric vehicle OEM, Volta Trucks, partners with ZF Commercial Vehicle Solutions (CVS) to leverage their expertise and tech, accelerating the advancement of the Volta Zero—a fully electric 16-tonne truck designed for urban deliveries

Supporting ADAS – AMS Expert Interview with Henkel

BMW electrifies South African plant

BMW is investing more than 4.2 billion ZAR ($224m) in the electrification of its plant in Rosslyn, South Africa.

Audi uses AI for quality control of spot welds

Audi is using artificial intelligence (AI) to improve its quality control in spot welds in car body construction.

BMW batteries: made and trained in South Carolina

The carmaker’s upcoming battery plant in South Carolina will use regionally sourced cells to power EV production in Spartanburg, and help establish the area an electrification hub in the Americas.

AMS Summer 2023 – JLR goes electric

In our AMS Summer digital edition, we have features on JLR’s plans to transform its end-to-end industrial system, ready for new electric models, Seat’s technical upgrades to production operations and upskilling the workforce and insights into developments at Audi’s Neckarsulm plant, and more.

A culture of quick decisions for Mercedes-Benz production

Jörg Burzer, the carmaker’s manufacturing chief, explains how it has reorganised its production network for electric vehicles and powertrains, while speeding up the rollout of digital tools. Now, another phase of change is just ahead.

Fisker to open China delivery centre in 2023

Luxury electric vehicle (EV) maker Fisker is set to start deliveries of its Ocean SUV in China in Q1 next year, and expects to start local production with a contract manufacturing partner.

GM invests $632m in Fort Wayne ICE truck assembly plant

General Motors (GM) is set to invest $632m in its Fort Wayne Assembly plant for the production of its next generation internal combustion engine (ICE) trucks.

Ford opens $2bn carbon-neutral EV assembly plant in Cologne

Ford has opened the Cologne Electric Vehicle (EV) Center which will produce a new generation of EVs for the European market and will be Ford’s first carbon neutral assembly plant.

Neckarsulm – Audi’s plant prepares for more electric vehicles

Audi’s Neckarsulm plant manager Fred Schulze discusses sustainability and digitalisation, and shares some insights into the transformation of the factory and its importance within the Audi production network

General Motors to invest $1 billion in Flint ICE truck plants

GM will expand the body shop and assembly, and add stamp and press tooling at its plants in Flint, Michigan, as part of a major investment in the production of internal combustion engine trucks alongside EV investments.

Scania to stop bus body production in Poland

Scania is set to gradually discontinue bus body production at its plant in Słupsk, Poland by 2024, instead outsourcing the production to local bodybuilders.

A friend of flexible lines – upgrading JLR production for EVs and more

Barbara Bergmeier is driving digitalisation, sustainability and resilience across JLR’s operations. Now she will help ramp up EV and battery output whilst keeping manufacturing flexible

Focus on flexibility – optimising battery pack production

The AMS Evolution Livestream expert panel representing Ford, AMTE Power and Henkel, discussed the fast-changing production requirements as cell manufacturers and OEMs ramp up Gigafactories and battery pack assembly.

New engine production line boosts Toyota’s hybrid vehicle manufacturing

The new flexible engine line at Toyota Kentucky can produce three different engine types simultaneously on one line and is part of a $145m investment

BMW to produce Neue Klasse in China from 2026

The BMW Brilliance Automotive (BBA) joint venture has announced it will build the next model generation, Neue Klasse at its production plant in Shenyang

Mercedes will use VAN.EA architecture for its next generation of midsize and large vans

Mercedes says starting 2026, all newly developed midsize and large vans will be built on VAN.EA, using three modules to allow for a clear differentiation between private luxury vans and premium commercial vans

Fisker begins production ramp-up of Ocean SUV

Fisker is accelerating the launch of its Ocean SUV with the first deliveries to European and US markets planned for June this year

Powering up: AMTE ramps up cell production volume

AMTE CEO Alan Hollis discusses ramping up cell production, establishing a new Gigafactory and developing a flexible, sustainable manufacturing approach

SMMT reports UK car output increase as supply shortages ease

UK vehicle production increased by 6% in the first quarter of 2023, according to new figures from the Society of Motor Manufacturers and Traders (SMMT). Vehicle makers turned out just under 220,000 units as supply shortage began to ease, said the industry body.

Ford to upgrade its Oakville, Ontario, plant to build electric vehicles

Ford invests C$1.8 billion to transform Oakville (Ont.) Assembly Complex into a Canadian hub of electric vehicle manufacturing that will include vehicle and battery pack assembly

Hyundai and SK On to establish EV battery cell production joint venture in US

Hyundai Motor Group and SK On to invest US$5 billion in a new EV battery cell plant to be constructed in Georgia, US, with production slated to start in the second half of 2025

Jaguar Land Rover to invest in UK manufacturing plants to ramp up EV and flexible production

JLR will invest billions over the next five years to upgrade its UK plants for an electric-first future, including transforming Halewood into an all-electric plant, adding an electric Jaguar in Solihull, producing electric drives and battery packs in Wolverhampton and expanding stamping in Castle Bromwich

Seat: Digital tools, shopfloor innovations and multi-brand manufacturing

After stints at Volkswagen in Portugal and Spain, Markus Haupt has returned to his professional roots in Barcelona. As the board member in charge of production and logistics, he now has the fortunes of Seat’s manufacturing operations in his hands. Here, he talks about the special aspects of the Iberian Peninsula, good ideas from the shop floor, and the logistical challenges of the recent past

Solving electric vehicle production challenges with smart manufacturing and logistics

Siemens discusses how the latest digital tools are enabling the transition to e-mobility and explains why these are now essential to OEMs and tier suppliers if they are to create transparent, sustainable supply chains

Solar power for Toyota’s North Alabama engine plant

A new solar project aims to generate 70% of Toyota Motor Manufacturing Alabama’s power requirements

Kia starts building facility for electric purpose-built vehicle (PBV) production

The new plant will be dedicated to production of Kia’s electric PBVs, with planned annual capacity of 150,000 units

AMS Spring 2023 – Next level digital production engineering

In this latest AMS digital edition we have features on Audi’s digital production engineering strategy, Dacia’s vehicle plant Mioveni, production cloud systems, toolmaking, China, sustainability and more.

Stellantis invests €130m in Eisenach Assembly Plant for electric Opel Grandland successor

Production of the new BEV is scheduled to begin in the second half of 2024

Virtual production underway in BMW Group’s future plant Debrecen

NVIDIA Omniverse is enabling virtual production in the plant more than two years before actual series production is launched

PowerCo starts construction of Valencia gigafactory

The gigafactory will start production of unified cells in 2026 and will directly employ more than 3,000 people

Honda announces next steps in US EV production

The Marysville Auto Plant will be Honda’s first auto plant in the US to transition to making EVs

Auto industry urges Government to get behind UK EV production

The SMMT has published a new blueprint which sets out the UK’s strengths in advanced automotive manufacturing, low carbon energy, and R&D

VW Group and PowerCo to establish battery cell gigafactory in Canada

The plant will be located in St. Thomas, with production set to begin in 2027

Adopting circular economy principles in car production

As the automotive industry looks at how to be more eco-friendly, car companies are taking various approaches to lower emissions across their manufacturing operations. Experts at Stellantis and Mazda speak about the implementation of circular economy principles in vehicle production

Stellantis allocates BEV-centric STLA Large vehicles to Cassino Assembly Plant

The Cassino plant in Italy produces premium vehicles for Alfa Romeo and Maserati

VW-backed Scout Motors to establish manufacturing plant in South Carolina

The plant will build next-generation trucks and rugged SUVs, harkening back to Scout vehicles produced from 1960 to 1980

Building on the edge of the virtual and physical worlds

As Audi aims to bring its local production cloud to plants, head of manufacturing engineering Jörg Spindler sees opportunities to scale digital control systems, digital twins and virtual reality.

Setting the pace for Audi’s global production

Head of manufacturing engineering Jörg Spindler is leading Audi’s push to virtualise production planning, ramp up battery production and use data to reduce emissions and improve productivity in areas like toolmaking and body shop

BMW Group’s Leipzig plant prepares production of electric Mini Countryman

The company says this will be the first time that a Mini model is produced entirely in Germany

Tesla to build new factory in Mexico

The company, which also has factories in the US, Germany and China, has chosen the northern border state of Nuevo Leon for the plant