BMW’s shop floor digital transformation: Driving standardisation, AI, and human-centric innovation BMW layers lean manufacturing principles with the application of digital technologies to develop standardised, human-centric production processes. Nick Holt
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. Anushka Dixit
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. AMS
Automotive expert Tunç Kip says human-machine interfaces are essential in boosting flexibility, quality, and performance in global automotive 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
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. Ilkhan Ozsevim
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. AMS
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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
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. Ilkhan Ozsevim
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 Götz Fuchslocher
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Nick Holt
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. Timo Gilgen
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. AMS
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. Timo Gilgen
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. AMS
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 Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Nick Holt
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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 Ilkhan Ozsevim
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 Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Nick Holt
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. Ilkhan Ozsevim
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. Götz Fuchslocher
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. Nick Holt Anushka Dixit
Honda upgrades production with advanced processes for 2026 Passport models Innovative manufacturing enhances efficiency, quality, and ergonomics at Alabama Auto Plant. Nick Holt
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? By Andrea Hoffmann-Topp
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. Anushka Dixit
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 Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Nick Holt
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. Ilkhan Ozsevim
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. Ilkhan Ozsevim
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. Nick Holt
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. Anushka Dixit
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. Timo Gilgen
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. Timo Gilgen
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. Nick Holt
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. Nick Holt
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. Nick Holt
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. Christopher Ludwig
“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. Timo Gilgen
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. Nick Holt
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. Ronja Schmiedchen Werner Beutnagel
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. Nick Holt Christopher Ludwig
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. Werner Beutnagel
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. Marcus Williams
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. Nick Holt
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. Nick Holt
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? Ilkhan Ozsevim
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. Megan Kelly
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? Ian Henry
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. Nick Holt
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. Megan Kelly
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. Timo Gilgen
Designing manufacturing systems for flexibility and scalability Comau discusses assembling e-drives, developing battery manufacturing solutions, and collaborations with universities for next-generation cells. AMS
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. Ilkhan Ozsevim
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. Ian Henry
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 Nick Holt
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. Ian Henry
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. SAMES
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. Nick Holt
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. Nick Holt
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. Megan Kelly
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 Mark Smyth
