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
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. AMS Editorial
Volvo Cars to use recycled, near zero-emission steel in 2025 models under SSAB deal Volvo Cars has signed an agreement with Swedish steelmaker SSAB to begin using recycled, near zero-emission steel in its manufacturing operations from 2025, reinforcing its goal to reach net-zero emissions by 2040 and increase circularity across its supply chain. AMS
GM promotes Mike Trevorrow to head global manufacturing, align with EV and software shift General Motors has appointed Mike Trevorrow to oversee global manufacturing and engineering operations, unifying leadership to drive faster industrialisation of software-defined and electrified vehicles across 110 sites. Ilkhan Ozsevim
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
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
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
5G networking: How JLR is building smarter factories As manufacturing operations become more data-driven, traditional network technologies are struggling to keep up. Steve Mason, JLR’s Advanced Digital Technologies Manager for Global Industrial Operations speaks to AMS about the integration of 5G networks into factory environments. Nick Holt
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
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
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
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
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
Renault expands circular economy with new polish repair facility for sustainable used car refurbishment The French car manufacturer Renault has just opened a special workshop in the largest eastern EU market - even though Poland is not necessarily one of its strongest locations. The issue of sustainability plays an important role. By Sebastian Becker
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
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
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
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
Gestamp employs gigastamping and advanced material solutions to drive lightweighting and sustainability The Spanish supplier believes it is well prepared for the transformation of the automotive industry. Innovations from a wide range of areas are intended to help. The company presented some of these at the IZB in Wolfsburg. Timo Gilgen
BMW group plant Regensburg integrates hydrogen to reshape production logistics by 2030 The Regensburg plant is transitioning its logistics fleet from electric to hydrogen power. With hydrogen filling stations and efficient refuelling, this shift aligns with the bmw iFACTORY vision of a digital, sustainable production future. Ilkhan Ozsevim
BMW conquers Mexico with sustainable production at San Luis Potosí: "It's about more than cars" The BMW factory canteen in San Luis Potosí serves cactus salad made from nopal leaves – harvested in the gardens on the factory premises. An example of the site philosophy: using local resources, promoting sustainability and delivering the highest quality. By Andrea Hoffmann-Topp
Watch now: How to maximise efficiency in battery tray manufacturing and integration This webinar showcased innovative, cost-efficient quality processes to assure 100% quality in battery manufacturing. New quality solutions from Hexagon enable automakers to detect defects efficiently and ensure a perfect fit into the underbody of the car.
BMW Group Plant Regensburg honoured for excellence in large-scale assembly, recognised for flexibility, digital innovation, and leadership in prestigious Factory of the Year competition The coveted “Factory of the Year” award has gone to Regensburg in the category of large-series assembly. The plant was lauded for its remarkable flexibility, workforce dynamism, and cutting-edge digital innovation, further solidifying its place as a leader in automotive production. Ilkhan Ozsevim
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
How VW’s Palmela plant excels with lean production, in-house 3d printing, and 90% automation to produce the T-Roc while preparing for the next generation of vehicles While the continued existence of German VW plants is being questioned, Volkswagen Autoeuropa in the middle of Portugal is operating at a good capacity. Here’s a look at the lean principles that ensure that the T-Roc plant is running so well. Timo Gilgen
“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
Henkel celebrates 100 years of automotive innovation and sustainability PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with HenkelHenkel is celebrating its 100-year anniversary serving the automotive industry. To mark this milestone, the company speaks to AMS about its heritage, its impact on the industry today, and how Henkel will shape the vehicles of the future. AMS
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
Megacasting: a new frontier or unfounded flare-up for automotive production? From Tesla to Volvo, Megacasting is gaining traction. While it offers efficiency and sustainability benefits, challenges remain. Stellantis, however, remains unconvinced. Ilkhan Ozsevim
Watch Now: Next-Gen Gapfillers: Henkel’s Blueprint for Automotive Electronics This webinar explored Henkel’s latest innovations in thermal gap fillers, designed specifically for automotive electronics.
Unipart strengthens UK lightweighting production expertise with polymer and composite solutions for automotive production Unipart expands its automotive capabilities with the acquisition of Formaplex, creating Unipart Polymer and Composite Solutions. The deal enhances the company’s lightweighting expertise, supporting the transition to electric vehicles. Ilkhan Ozsevim
Mahindra & Mahindra to pioneer ABB’s Inkjet paint technology in Indian EV market Mahindra & Mahindra partners with ABB Robotics to implement PixelPaint technology in its new EV line. The innovative system ensures precise paint application with minimal waste; a key step in automotive personalisation and efficiency for the Indian market. Ilkhan Ozsevim
Gestamp signs agreement with Acciaieria Arvedi for the supply of low-emissions steel Gestamp will return high-quality steel scrap from stamping parts production to Acciaieria Arvedi, who will reprocess and reintroduce it into the production cycle. Nick Holt
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
Is ABB Robotics’ new inkjet paint tech the future of automotive paintshop? Automotive production paintshop is energy-intensive and costly. Could a new ‘inkjet’-type paintshop technology solve several production issues at once? With major implications for sustainability and customisation, ABB’s PixelPaint sees an explosion in demand. Ilkhan Ozsevim
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
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
Watch on demand: Sustainable Steel Automotive Manufacturing Survey 2024 Webinar Discover the latest insights from a cutting-edge discussion featuring AMS and SSAB on the key challenges faced by automotive OEMs, tier suppliers and other stakeholders in transitioning to sustainable steel.
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 Ilkhan Ozsevim
Changing dynamics– developing the next generation of vehicle architectures Building electric vehicles has demanded big changes in OEM production operations and increased support from tier suppliers. Gestamp’s director of R&D North America, Paul Belanger, shares some insights into the company’s development and how it’s managing the engineering challenges around EVs Nick Holt
“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 Yannick Tiedemann Ronja Schmiedchen
Porsche launches all-electric Macan Porsche has revealed its first native all-electric model, the Macan SUV, using the Premium Platform Electric (PPE). Megan Kelly
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 Ilkhan Ozsevim
Watch Now: Shaping the future: How electric vehicles are driving manufacturing decisions Dive into the intricacies of EV platform design with industry experts from Gestamp and ArcelorMittal. Looking at how current trends are influencing manufacturing processes and the balance between innovation, sustainability, and efficiency.
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. Ilkhan Ozsevim
Steel resolve: why ArcelorMittal’s Multi Part Integration is leading the charge in sustainability and efficiency PARTNER CONTENTThis content was paid for by ArcelorMittal and produced in partnership with Automotive Manufacturing SolutionsFrom simplifying assembly processes to slashing carbon emissions, ArcelorMittal’s innovative approach emerges as a key player in the race towards sustainable automotive manufacturing. ArcelorMittal
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. Christopher Ludwig
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. Nick Holt
How Vitronic’s Weldloop software reimagines the welding process Find out how Weldloop’s technology achieves quality enhancements in automotive welding through machine vision technology. Ilkhan Ozsevim
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.
Technical partnerships – AMS Expert Interview with Magswitch As the automotive industry seeks to reduce costs and improve efficiencies and productivity, we are seeing an increasing number of partnerships being formed. It’s nothing new to this industry but these new relationships are proving much more necessary and beneficial than previously Nick Holt
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. Christopher Ludwig
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. Götz Fuchslocher
Steel solutions for e-mobility PARTNER CONTENTThis content was paid for by ArcelorMittal and produced in partnership with Automotive Manufacturing SolutionsArcelorMittal is engaged in the development of the future mobility through the Steel E-Motive project lead by WorldAutoSteel and creating new solutions to simplify the car manufacturing operations ArcelorMittal
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. Nick Holt
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. Pascal Nagel
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. Megan Kelly
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 Michael Nash
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. Megan Kelly
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. Megan Kelly
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 Nick Holt Christopher Ludwig
Watch: Structural change – Developing vehicle architectures optimised for EV manufacturing Transitioning to build electric vehicles in high volumes is an engineering challenge for OEMs and suppliers, but one that also presents opportunities in manufacturing processes and efficiencies.
Form and function: Developing production processes and structures for electric vehicle architectures As much as we read about battery cell development and production, in parallel the new electric vehicle architectures are also continuing to evolve as vehicle makers strive to find the optimum balance between platform flexibility to meet changing market demands for new models, while also being viable for high-volume production. To get some insights in to this ongoing process AMS spoke with Paul Belanger, Gestamp’s R&D Director for North America Nick Holt Christopher Ludwig
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 Christopher Ludwig
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 Christopher Ludwig
Gestamp announces fourth hot stamping line in India Gestamp has announced its fourth hot stamping line in India at the 16th edition of Auto Expo 2023- Components
