Tag: digital twin

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Inside Toyota’s 2025 Lean(er) Manufacturing System

Toyota’s lean production system enters a new phase in 2025. Combining its founding pillars of Jidoka and Just-in-Time with digital tools and tighter regional roles, the updated model aims to sharpen EV readiness and operational agility.

Ilkhan Ozsevim

Key insights from Daimler Truck’s Twin4Trucks project

Daimler Truck’s Twin4Trucks project has provided significant insights into AI-driven data consistency in truck production. Discover how its successes and challenges in AI, 5G, and local solutions are shaping the company’s roadmap for future manufacturing advancements.

Yannick Tiedemann

Benteler starts work on advanced manufacturing plant in Morocco, boosting job creation and integrating Industry 4.0 technologies

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

Key steps to building flexibility into production operations

The need for agility and flexibility in automotive manufacturing operations is greater than ever. AMS spoke with Trent Randles, Engineering Manager - Transfer Case Assembly & Operational Excellence at BorgWarner, about key steps towards developing agile production processes.

Nick Holt

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

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

Mercedes-Benz lays foundation for advanced paint shop in Sindelfingen, fusing sustainable design with digital twin, AI and smart energy management

Mercedes-Benz is investing heavily in a new state-of-the-art paint shop near Factory 56 in Sindelfingen. Built with Dürr, the site will feature AI, digital twins and smart energy systems to cut emissions and resource use by half.

Yannick Tiedemann

How digital twins, hybrid clouds and predictive AI are enabling connected manufacturing in the automotive industry

Automotive manufacturers are racing to connect systems, optimise production and secure supply chains through digital twins, hybrid clouds and AI. But legacy systems and organisational inertia remain major obstacles. By Ilkhan Ozsevim.

Ilkhan Ozsevim

Building better digital twins: Optimising visibility across production operations

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Cintoo.As automotive manufacturers digitise operations and look to modernise legacy facilities, the ability to convert laser scan data into actionable, cloud-based digital twins is becoming essential.

AMS

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

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

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

HORSE accelerates digital twin integration at Valladolid to optimise powertrain production, enhance sustainability and redefine EV manufacturing strategies

HORSE, the Renault-Geely joint venture, is harnessing digital twins at its Valladolid plant to transform powertrain production, boost flexibility in EV output, reduce emissions and embed data-driven decision-making across its operations.

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

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

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

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

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

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

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

Toyota’s Jaime Moore on engineering transformation: Agile teams, early collaboration, and the impact of digital tools

At the AMS Automotive Evolution NA 2024 event, Jaime Moore, Senior Principal Engineer at Toyota North America, highlighted the evolving role of engineers in manufacturing. She discussed the expanded skill set required, the need for cross-functional collaboration, and the potential of digital twins and AI in streamlining the automotive production process.

Christopher Ludwig

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

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

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

Global IT outage affects Mercedes-Benz production

The global IT outage that hit industries across the world today has affected automotive manufacturing across the world, causing problems for the automotive manufacturing industry globally.

Megan Kelly

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

Hyundai’s Metaplant America announces launch of 2025 IONIQ 5 to pioneer electric mobility

Hyundai’s new $7.59B Metaplant in Georgia gears up to commence production of the highly acclaimed 2025 Hyundai IONIQ 5, reinforcing its commitment to pioneering EV technology and creating thousands of jobs in the region.

Ilkhan Ozsevim

How Mercedes-Benz and Seat are transforming their plants

Michael Bauer, regional head of production at Mercedes-Benz and Jose Arreche, plant manager at Seat emphasised the importance of data and digitalisation in the transformation of their plants at the Automobil Produktion Kongress 2024, but stressed the evolving role that people will play in production.

Timo Gilgen

Balancing digitalisation with production output

The focus of the Automobil Produktion Kongress 2024 was on sustainable, efficient and digital production methods. Industry experts from car manufacturers and suppliers discussed the future of smart production.

Werner Beutnagel

ZF’s Arno Güllering on smart factory innovations and navigating volatility

AMS’ chief content officer Christopher Ludwig spoke to Arno Güllering, senior vice president, Operations – Electrified Powertrain Technology division at ZF at the Automobil Produktion Kongress 2024 at Munich to discuss the roadmap for navigating industry challenges and embracing the digital future.

AMS

Design4Production: Recap blog

Thank you for joining us for the Design4Production 2024 event, read the summary of the key sessions covered at the event below. Today’s discussions highlighted the critical integration of design, engineering, and production to foster innovation and collaboration in the automotive industry. Esteemed speakers from Ford, NOYO AG, Volvo Group, Hyundai, among others, emphasised the importance of breaking down silos, enhancing sustainability, and speeding up development processes.

AMS

AlixPartners reveals 60% of automotive executives are struggling to prioritise disruptions in the shift towards EVs and software

Automotive production facing significant disruptions from EVs and software shift, global consulting firm AlixPartners’ 2024 Disruption Index (ADI) reveals.

Ilkhan Ozsevim

“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

DESIGN4PRODUCTION brings together leaders in automotive production, design, and engineering

Explore the future of automotive design and manufacturing at Design4Production in Munich on 15 May and join leading designers, engineers and production leaders on Automotive design and manufacturing experts as they discuss how to accelerate innovation, efficiency and sustainability.

AMS

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.

AMS

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.

Christopher Ludwig

Henkel supports innovation with 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, has opened its revolutionary Battery Engineering Center within its Inspiration Center in Duesseldorf, to address the need to improve safety, performance, quality and price of EV batteries.

AMS

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

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

AMS

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

Nick Holt

Renault unveils ambitious Re-Industry transformation roadmap to reshape its production infrastructure for elevated industrial agility and enhanced sustainability commitment

Renault Group’s Re-Industry plan involves a comprehensive transformation of its industrial foundation, leveraging digital technologies, AI and agile practices to achieve significant cost reductions, improve efficiency and meet sustainability goals. The Industrial Metaverse and the adoption of cutting-edge technologies are central to this strategic vision.

Ilkhan Ozsevim

UK Government injects £2bn into automotive industry to drive sustainable growth: Nissan leads with announcements of three EV models to be produced at its Sunderland plant

The UK government injects £4.5bn into strategic sectors, with £2bn for the automotive industry, signaling a green revolution. Nissan swiftly follows, investing £2bn in electric car production at its Sunderland plant. Digital twins and self-driving cars make the cut.

Ilkhan Ozsevim

BMW: ‘Flexibility is in our genes’

BMW, Mini and Rolls Royce are driving a tight electrification course. Nevertheless, the group remains open to drive diversity. In an interview, production director Milan Nedeljković talks about flexibility and the concept of the iFactory.

Götz Fuchslocher

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.

Megan Kelly

Interview with Greg Everly, Molex - Automotive Wire Harness & EDS Conference 2023

Automotive Wire Harness delegate Greg Everly, Molex, speaks about his experience of the conference and the most prominent issues facing the industry today.

AMS

Interview with Garrett McIntyre, APTIV - Automotive Wire Harness & EDS Conference 2023

Automotive Wire Harness delegate Micah Durham, Schleuniger North America, speaks about the growth of the US Wire Harness & EDS Conference and the biggest challenges facing the automotive industry.

AMS

Interview with Micah Durham, Schleuniger North America - Automotive Wire Harness & EDS Conference 2023

Automotive Wire Harness delegate Micah Durham, Schleuniger North America, speaks about the growth of the US Wire Harness & EDS Conference and the biggest challenges facing the automotive industry.

AMS

Interview with William Bieniek, KOSTAL Connectors - Automotive Wire Harness & EDS Conference 2023

Automotive Wire Harness delegate William Bieniek, KOSTAL Connectors, speaks about the importance of the second Automotive Wire Harness Congress in Detroit for networking and addressing the challenges of electrification and rapid technology

AMS

Interview with Manuel Fey, Sonosystems - Automotive Wire Harness & EDS Conference 2023

Automotive Wire Harness delegate Manuel Fey, Sonosystems, speaks about the success and challenges in the Automotive Wire Harness industry

AMS

Interview with David Gonzalez, SE Bordenetze Mexico SA de CV - Automotive Wire Harness & EDS Conference 2023

Automotive Wire Harness delegate David Gonzalez, SE Bordenetze Mexico SA de CV, speaks about the importance of networking and new technologies in wire harness production

AMS

Interview with Home Mojal, Telsonic Solutions - Automotive Wire Harness & EDS Conference 2023

Automotive Wire Harness delegate Home Mojal,Telsonic Solutions, speaks about the success of the second edition of the conference and the importance of digitalization in the automotive industry

AMS

Interview with Thomas Mathews, APTIV - Automotive Wire Harness & EDS Conference 2023

Automotive Wire Harness delegate Thomas Mathews, speaks about the importance of collaboration in a disruptive marketplace

AMS

Delegate Interview with Jud Estes, Daimler Truck North America - Automotive Evolution North America 2023

Automotive Evolution North America delegate and speaker Jud Estes, Daimler Truck North America, spoke about his experiences at this year’s conference and what he’s looking forward to in 2024

AMS

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

AMS

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

AMS

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

AMS

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

AMS

Highlights - Automotive Evolution North America 2023

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

AMS

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.

AMS

Day 1 Wrap-up - Automotive Evolution North America 2023

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

AMS

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

AMS

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

AMS

How digitalisation is ramping up battery cell production for EVs

Digitalisation is helping to scale up battery cell production in North America through improving standardisation and traceability and ensuring quality of materials.

Megan Kelly

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.

Nick Holt

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

AMS

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

Michael Nash

How Mercedes-Benz's Concept CLA Class showcases its ‘digital first’ production model

The carmaker is strengthening its digital first production model with upgrades and enhancements throughout.

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.

Ready for the next generation in Spartanburg

As BMW prepares to build EVs and batteries in Spartanburg, it has expanded training programmes, with emphasis on safety, change management and youth outreach. The head of talent and training, Paul Sinanian, is focused on preparing for the decades ahead.

Christopher Ludwig

Six trends that will shape the automotive industry’s future

From integrated factory planning to virtual reality, Autodesk highlights six key trends primed to disrupt the automotive industry in the future

Friederike Voigt