Tag: digital tools

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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

Automating complexity: How JLR Is futureproofing production and skills

From goods-to-person automation and modular design strategies to technical training and career paths, Loretta Dittrich, logistics director for global manufacturing engineering explains how the OEM is reshaping both systems and skills to meet the demands of more customised, digitalised vehicle production.

AMS Editorial

BMW reinvents its Munich plant with AI, automation and digital logistics to support Neue Klasse production and meet rising demand in a constrained city-centre location

Speaking at the recent Automobil Produktion Kongress in Munich, Dr. Michael Nikolaides, BMW’s SVP of Production Network, Supply Chain Management and Logistics, laid out the company’s roadmap for the digitalisation of production and logistics operations.

Ilkhan Ozsevim

Nick Holt

Inside Dräxlmaier’s digital drive: COO Arno Güllering on AI, mindset shifts and global smart factory strategy

In a revealing interview at the Automobil Produktion Kongress in Munich, Arno Güllering, chief operating officer of Dräxlmaier Group, shares how the global supplier is accelerating its smart factory transformation. From unexpected digital frontrunners like Tunisia to the growing role of generative AI in maintenance, Güllering discusses his first-year priorities and why a shift in mindset is just as critical as technology.

Christopher Ludwig

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

Cybersecurity: Building defence-in-depth into smart factories

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Siemens.Seamless connectivity between IT and OT systems is essential to smart factory operations. But this integration expands the attack surface, exposing enterprises to escalating cyber threats

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

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

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

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

As automotive manufacturing digitises, new smart factory roles in AI, data and IIoT are replacing traditional shopfloor jobs and transforming skills requirements

As automotive manufacturing becomes more intelligent, connected and software-defined, factory roles are shifting. New digital profiles are emerging, while traditional ones risk becoming obsolete.

Chris Löwer

Digital twins: Boosting productivity in automotive manufacturing

The digital transformation of production operations is continuing at pace and while there is still much more potential to be realised, the focus is now firmly on digital tools making a practical contribution.

Nick Holt

Edge computing and AI: Transforming manufacturing at the source

In modern manufacturing, edge computing is becoming a game changer, enabling faster, more secure, and more efficient operations. Steve Mustard, an expert with the International Society of Automation (ISA), spoke with AMS on how this technology is shifting traditional processes and how it’s set to evolve with artificial intelligence.

Nick Holt

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

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

Future-ready: BMW’s digital transformation of its Munich plant and beyond

As the global automotive market pivots toward sustainability and electrification, BMW isn’t just adapting its product portfolio it’s reengineering the entire production operation, prioritising flexibility, digitalisation, and long-term operational efficiency. Plant Munich director, Peter Weber discusses the company’s approach to digitalising production.

Nick Holt

At its Berlin Digital Factory Campus, Mercedes-Benz is boosting its connected manufacturing through AI, cloud platforms and human-machine collaboration across its global network

At its historic Berlin-Marienfelde plant, Mercedes-Benz is building a new model of connected manufacturing. Through MO360, AI and cloud integration, it is turning data into action across a globally standardised production network

Ilkhan Ozsevim

Digital twin technology is bridging the physical and digital worlds in automotive manufacturing

OEMs and Tier suppliers are actively deploying digital twin solutions to enhance their manufacturing capabilities. This article explores the latest trends, ongoing developments, key challenges, and critical steps in deploying digital twins in the automotive industry.

Nick Holt

Henkel’s digital battery simulation team accelerates EV battery design and development, cutting costly iterations and physical testing for faster market readiness

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Henkel.Material supplier Henkel has created a new simulation team that is helping customers to be much faster and more efficient during battery design and development.

AMS

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

How ALM and PLM integration enhances collaboration, accelerates development and ensures compliance in automotive manufacturing

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with PTC.As the automotive industry transitions to software-defined vehicles, integrating Application Lifecycle Management (ALM) and Product Lifecycle Management (PLM) systems becomes crucial. This integration enhances cross-domain collaboration, accelerates product development, and ensures compliance with safety standards. Experts from PTC and Veoneer share insights on leveraging ALM-PLM integration to maintain competitiveness in this dynamic landscape.

AMS

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

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

Volkswagen partners with Dassault Systèmes to accelerate software-defined vehicle development with the AI-powered 3DEXPERIENCE cloud platform

Volkswagen has selected Dassault Systèmes’ AI-powered 3DEXPERIENCE platform as its primary engineering and manufacturing system. The move aims to drive software-defined vehicle innovation, enhance efficiency and unify fragmented processes across the group.

Ilkhan Ozsevim

Audi is transforming vehicle production with AI-powered image processing, eliminating errors and setting new standards for quality control and smart factory innovation

Artificial intelligence is accelerating transformation in automotive production. Audi’s Industrial Computer Vision is proving how AI-driven image processing enhances quality control, minimises defects and paves the way for scalable smart factory innovation.

Ronja Schmiedchen

BMW drives CO2 reduction with workforce engagement: Transformation only succeeds with head and heart

The BMW Group is driving forward decarbonisation, digitalisation and modern leadership with ambitious CO2 targets and a clear strategy. Human Resources Board Member Ilka Horstmeier outlines the economic policy opportunities and challenges in this Q&A.

By Andrea Hoffmann-Topp

AI: Enhancing predictive maintenance in production lines

Unplanned downtime is costly and something that the automotive industry has been working hard to reduce through predictive maintenance strategies. AI now offers a significant step forward in real-time monitoring and data gathering and analysis.

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

Shape the Future: Join the 2025 Survey on Digital Transformation in North American Automotive Manufacturing and Win Exciting Prizes

The North American Automotive Manufacturing Digital Transformation Survey 2025, in partnership with Kyndryl, explores AI, IoT, and automation in production. Join the survey, win prizes, and access vital insights on sustainability, nearshoring, and workforce evolution.

AMS

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 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

Thomas Dose discusses leadership, diversity, and challenges at BMW’s Chennai Plant

How do you go from being a consultant to being a plant manager? Thomas Dose, managing director of the BMW plant in Chennai, India, talks in an interview about his path, the challenges and opportunities in India and the importance of diversity and sustainability.

Ronja Schmiedchen

JLR’s Rudy the Robot will be hard at work this Christmas in Gaydon

JLR will be using an automated robot over Christmas to carry out a lifetime of door usage checks within 12 weeks, completing 84,000 door shuts.

Megan Kelly

Skoda’s Andreas Dick on driving flexible manufacturing, digitisation and the role of AI in transforming automotive production for future competitiveness

Two measures are at the top of Skoda’s new production boss, Andreas Dick’s, to-do list: digitalisation and flexibility. In the interview, he also reveals what impact the weak demand for electric cars has on his area of responsibility.

Yannick Tiedemann

The digital production hub at BMW’s San Luis Potosi blends electrification, AI, and sustainability to lead the way in next-generation automotive manufacturing

BMW’s San Luis Potosi facility is a testbed for next-generation automotive production. From digital twins and AI to high-voltage battery assembly, it pioneers lean, green, and smart manufacturing to meet global demands for electrification and sustainability.

Ilkhan Ozsevim

ABB robotics partners with ESS to advance simulation tools for cost savings, efficiency, and emissions reduction in automotive paint shop operations

ABB’s collaboration with ESS marks an important step in digitising automotive manufacturing in paintshop. By harnessing advanced simulation technology, the partnership aims to cut paintshop costs by up to 30 percent and reduce emissions significantly, while levelling the digital playing field.

Ilkhan Ozsevim

Automotive OEMs and suppliers look to continued development of smart factories and the deployment of digital tools to optimise production operations

The concept of the smart factory offers highly efficient, optimised production operations. Ford, ZF and PPG reveal how they are working to realise this potential.

AMS

Exclusive: How Henkel is co-developing the EV batteries of the future at its Battery Engineering Center

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with HenkelHenkel, a global leader in adhesives, sealants and functional coatings, inaugurated its revolutionary Battery Engineering Center (BEC) within its Inspiration Center Düsseldorf (ICD) in November last year. Henkel invited AMS as its first visitor, to take a tour of the Battery Application Center (BAC) and Battery Test Center (BTC) within the BEC and the innovations happening inside.

AMS

Watch: Henkel invites AMS for an exclusive look inside its Battery Engineering Center

AMS

Scaling agility in auto manufacturing: Volkswagen and Toyota on flexibility, digitalisation, and workforce innovation

Through a series of insights shared by Chris Glover, executive vice-president of Volkswagen Group of America, Chattanooga Plant, and Jaime Moore, senior principal engineer at Toyota North America, the discussion called for a vital need for flexibility, collaboration, and technological innovation in navigating constant change.

Anushka Dixit

BMW’s iFactory Network expands automated driving technology across production with Dingolfing now acting as testing ground

BMW’s dingolfing plant pioneers automated in-plant driving, achieving CE certification and setting a benchmark for efficiency in automotive production. Expansion across its global network is underway.

Ilkhan Ozsevim

JLR advances circular economy with closed-loop seat foam recycling, reducing waste and emissions in luxury vehicle production

JLR’s Circularity Lab leads an industry breakthrough by creating closed-loop recycled seat foam for luxury vehicles. This innovation addresses recycling challenges, reduces emissions, and supports the Reimagine strategy for an all-electric future.

Ilkhan Ozsevim

ZF’s Fernando Bera on prioritising real-time data and people-centric strategies for smart factory success

At the AMS Automotive Evolution NA 2024 event, Fernando Bera, Engineering Supervisor and Smart Factory Coordinator at ZF, outlined how real-time data and a people-focused approach are driving efficiency and quality improvements, shaping the company’s smart factory transformation.

Nick Holt

AMS Automotive Evolution: Reducing costs, fast-tracking development, embracing change

The AMS Automotive Evolution conference in Detroit brought together leading car makers and tier suppliers to discuss managing production operations as the EV transition continues. AMS Editor Nick Holt shares some takeaways from the event.

Nick Holt

Automotive leaders discuss strategies to bring electric vehicles within reach of the masses through cost-cutting, advanced technologies, and new approaches in North American manufacturing

At the AMS Evolution North America Conference, Ford and Gestamp leaders outlined strategies to slash production costs, tackle supply chain hurdles, and enhance manufacturing efficiency, laying out the groundwork for affordable EVs that meet consumer demand

Ilkhan Ozsevim

Smart manufacturing: Data, AI, and digital transformation

The process of digitalising manufacturing operations continues to change rapidly with new software and hardware developments and the growing application of artificial intelligence, but challenges remain in optimising these opportunities.

Nick Holt

HORSE’s smart factory model sets new standards in digital powertrain production, leveraging cobotics, virtual twins, and real-time data for efficiency and sustainability

HORSE is pioneering a smart factory approach for powertrain production, integrating cobotics and virtual twins in a fully digital environment that adapts to changing demands, enhancing both efficiency and sustainability across its global operations. CTO Julien Faure, and CPEO, Antonio Vaz expound…

Ilkhan Ozsevim

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

Bodo Philipp joins MHP Consulting UK as CEO, driving digital transformation and building OEM partnerships to navigate the future of the UK automotive industry

Bodo Philipp, with over 20 years of automotive experience at global names like Bugatti Rimac, Audi and Volkswagen, takes over as CEO of MHP Consulting UK. His mandate is to drive digital innovation, empower teams and strengthen partnerships with OEMs to navigate both traditional and EV sectors.

Ilkhan Ozsevim

EV batteries – Increasing quality and reducing costs

A new eBook from Hexagon examines how AI and smart factories are revolutionising EV battery manufacturing, helping Europe and North America catch up with China.

Hexagon Manufacturing Intelligence

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

With the hope of exponential problem-solving on the horizon, are quantum computers the future of the automotive industry?

Quantum computers promise to give industry and science a boost when it comes to solving complex tasks in the future. But how exactly do quantum computers work and which model currently has the highest computing power?

Götz Fuchslocher