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
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
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
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.
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
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.
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
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
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.
The state and stipulation of automotive production: Retrospect 2023 to prospect 2024 Using 2023 as a launchpad into the coming trends of 2024, we take a dive into the coming automotive production trends set to shape the industry Ilkhan Ozsevim
Gestamp joins Catena-X to push digital and decarbonisation strategies Gestamp has joined the Catena-X data-sharing platform, which is designed to increase visibility in the supply chain and improve the flow of parts and materials. Marcus Williams
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
Tools for progress: real-time tracking and monitoring in Audi’s toolmaking The carmaker’s Toolmaking 4.0 system is bringing greater visibility of suppliers and potential disruption of machines and operations at tool shops, with high productivity gains. 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
Stellantis to localise production of new electric drive module in Indiana Investments to be made at Indiana Transmission, Kokomo Transmission and Kokomo Casting Plants, with the company investing a total of $155m Rebecca Morley
Dacia – building on a successful formula Speaking to AMS, Carlos Carrinho, General Manager Dacia Vehicle plant Mioveni, discusses the factory’s unique position within the realm of European car manufacturing and how it has been continuously developing to meet future production challenges Michael Nash
GM invests $918m in four US powertrain production facilities Investment will prepare four GM plants for production of 6th generation small block V8 and EV components AMS
Material matters: body, forming and process transformation Michel Peña at Teknia, Jesse Paegle at ArcelorMittal and Jonas Adolfsson at SSAB joined the seventh panel at Automotive Evolution Europe to discuss how new technology and materials are ushering in new innovations in manufacturing. Christopher Ludwig
Watch: Are all OEMs start-up manufacturers now? Hear how start-ups are changing car production and established OEMs are reinventing themselves in manufacturing and engineering, featuring start-up EV truckmaker Volta’s co-founder and chief manufacturing officer Kjell Walöen, and automotive steel solutions director Jesse Paegle from ArcelorMittal. AMS
Watch: The AI/data loop leading the digital revolution Tomorrow’s digital smart factories will be more efficent, improve quality, cut costs and unlock insights into deeper automotive manufacturing say this panel of experts from BMW, Secondmind, ATS Global and Lancaster University. Christopher Ludwig
Watch: New magic in the dark art of lightweighting Ignacio, Jérôme and Prof. Volk explain the magic behind the art of lighweighting all whilst factoring in cost, performance, safety concerns and the impact on manufacturing process. Nick Holt
BMW Landshut is now using new multi-plate die casting technology The light metal foundry at the BMW components plant in Landshut is using multi-plate die casting technology, which offers function-optimised component design and design of the required sprue positions and flow paths AMS
Megacasting: a chance to rethink body manufacturing The aluminium die-casting process could revolutionise body construction. Professor Wolfram Volk, the department head for forming technology and casting at the Technical University of Munich, explains the advantages and disadvantages of so-called ‘mega’- or ‘gigacasting’. Götz Fuchslocher
The die is cast for Volvo’s future EV production One of the key pillars of Volvo’s investment in electric vehicles will be the application of aluminium megacasting to produce large structural parts. Mikael Fermér, solution architect for vehicle platforms at Volvo Cars, explains the significance of this change for EV production. Nick Holt Christopher Ludwig
Watch: Shopfloor revolution – how data, software and AI are rebooting production OEMs and suppliers are transforming vehicle production through data and connectivity as much as hardware, with new artificial intelligence opportunities emerging. Watch this AMS Livestream Hour to hear about the standards, systems and applications underpinning these changes, with insight from robotics experts at VDMA, AI robotics firm Symbio and Fraunhofer IPA. AMS
Aluminium applications Electric vehicles battery enclosures are increasing overall vehicle weight, with lightweight materials for structural components, such as castings, can offset the rise. Rio Tinto’s Jerome Fourmann tells Nick Holt about new opportunities and production innovations Nick Holt
Volvo Trucks buys Chinese manufacturing site to expand heavy duty truck manufacturing As part of the company’s broader plans to develop global reach, Volvo has acquired Chinese truckmaker JMC Heavy Duty Vehicle to produce and sell more heavy-duty trucks in China. Jason Dunn
Watch: Vehicle lightweighting rises to the top of the agenda for designers and engineers This livestream investigates how designers and engineers at Ford, Gestamp and key suppliers are using innovative materials and creating lightweight architectures, including for models like the Ford F-150 Lightning and Maverick compact truck. AMS
Watch: Supporting production through automation – from AI to cobots (EP.2) This Livestream Hour episode discusses how automation and AI can support automotive manufacturing with technology leaders from BMW and Ford, together with systems and software specialists. AMS
Watch: Strategies for Greener Production (EP.1) This AMS Livestream Hour episode discusses how automotive manufacturers are making their plants and value chains more sustainable through new processes and technology, with special guests including Scania and ArcelorMittal. Watch the full episode and download slides. AMS
Breaking the mould: Grainger & Worrall go beyond the block With the onset of the EV age, casting specialists are demonstrating versatility and diversifying away from engine block production. AMS reports on the solutions Grainger & Worrall has developed to produce its new generation of cast parts Mike Farish
A flexible solution Metal-component supplier Gestamp outlines the challenges ahead and its strategy for meeting higher demand for lightweight parts Nick Holt
Casting a duo Two innovative metal forming techniques could have a significant impact on the press shop of the future Mike Farish
