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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

Hybrid powertrains will continue to support the transition to vehicle electrification

Weak EV demand, critical mineral supply challenges and tariff-driven market uncertainty keeps hybrid vehicles in the big picture for model development and production investments.

Ian Henry

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

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

China’s rapid rise in electric vehicle adoption is reshaping global auto manufacturing, forcing Western OEMs to rethink costs, portfolios and consumer strategies

As China leads the global EV transition with record-breaking sales and technology advances, Western carmakers face mounting pressure to cut costs, target regional needs and rethink loyalty strategies.

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

Jaguar Land Rover accelerates EV production with hairpin winding machines for high-efficiency electric motors at its Wolverhampton site

At its Wolverhampton plant, Jaguar Land Rover is deploying high-speed hairpin winding machines to increase electric motor performance while retraining its workforce for a future of electric propulsion.

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

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

India targets $500bn in EV investment as government boosts manufacturing incentives and new players like Tesla, VinFast prepare entry

Significant investments are now under way at domestic and international vehicle companies in India, in component production, electric and hybrid vehicle production for the domestic market, and to facilitate rising exports across the world. This is being encouraged under the government’s strapline of “Make in India for the world.”

Ian Henry

hofer powertrain and Pollmann International accelerate EV powertrain manufacturing

hofer Powertrain and Pollmann International have teamed up to accelerate the industrialisation of next-generation electric powertrain solutions. The partnership aims to bring advanced EV powertrain technologies to market faster.

Nick Holt

AAM’s $1.4bn acquisition of GKN Automotive could mark a major shift in automotive manufacturing, strengthening its position in driveline systems and electrified vehicle production

American Axle & Manufacturing’s $1.4 billion acquisition of GKN Automotive is set to reshape global automotive manufacturing, strengthening its position in driveline systems and EV production as the industry moves towards electrification

Ilkhan Ozsevim

JATCO opens new manufacturing facility to supply electric vehicle powertrains for Nissan’s Sunderland plant

Nissan and the Japan Automatic Transmission Company (JATCO) have secured a £50m investment deal, in partnership with the UK government, to create a new manufacturing plant in Sunderland.

Nick Holt

HORSE launches new high-performance eMotor production at Aveiro, Portugal, for hybrid and plug-in hybrid vehicles, enhancing automotive electrification

HORSE, a leader in hybrid and combustion powertrain solutions, has started producing its high-performance eMotor at Aveiro, Portugal. Designed for hybrid and plug-in hybrid vehicles, the motor delivers 49kW and 212Nm torque, with a capacity of 160,000 units annually.

Ilkhan Ozsevim

Asahi Kasei breaks ground on Canada lithium-ion battery separator plant

Asahi Kasei has broken ground on its new lithium-ion battery separator manufacturing facility in Port Colborne, Ontario, Canada. The plant will operate as a joint venture with Honda and is expected to begin commercial production in 2027.

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

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

Oyak Horse celebrates production of 7.5 million engines at its Türkiye plant while expanding its workforce with 100 new jobs and scaling output to meet rising hybrid demand

Oyak Horse has achieved the milestone of producing 7.5 million engines at its Bursa, facility, in Türkiye. As hybrid demand grows, the plant adds 100 jobs, expands to a third shift, and increases daily output. The company continues to play a key role in low-emission powertrain solutions for global markets.

Ilkhan Ozsevim

Hybrid powertrains – building the bridge to e-mobility

The future of internal combustion engines (ICE) is being extended through growing demand for hybrid powertrains as OEMs rebalance EV product line-ups.

Nick Holt

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

Scania progresses production by integrating remanufactured components on its main assembly line, reducing material use by 50% and cutting carbon emissions by 45%

Scania has become the first truck OEM to integrate remanufactured components directly into the main assembly line. The innovative approach aims for a circular economy in vehicle production.

Ilkhan Ozsevim

Mexico’s automotive industry is a balancing act between foreign investment and domestic concerns

While the US government encourages domestic production, Mexico continues to attract foreign automotive investment. The trend is particularly evident in the arrival of Chinese manufacturers, poised to have a significant impact on regional production.

Ian Henry

Northvolt slashes workforce by 1,600 as Europe’s largest EV battery manufacturer stumbles with slow demand, scaling issues, and Chinese competition, pausing major expansion plans

Northvolt, once the great hope for Europe’s EV battery industry, is shedding 1,600 jobs and shelving expansion plans. With slow market demand and fierce Chinese competition, Europe’s green ambitions face a critical test, leaving Northvolt to recalibrate its strategy.

Ilkhan Ozsevim

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

HORSE powertrain continues to expand supply in range extender market

HORSE will supply Brazilian EV start-up manufacturer Lecar with its HR10 range extender engine, to be fitted to the Lecar 459 hybrid.

Nick Holt

Denso expands electrification-focused inverter line and sustainable digital production

Denso is bolstering its position in the electrification market with the launch of inverter production at Denso Fukushima. Simultaneously, the company has unveiled plans for a next-generation, fully automated plant at Zenmyo, set to modernise ECU production with 24-hour unmanned operation and sustainable energy use.

Ilkhan Ozsevim

Canada – Mixed fortunes for production operations

Canadian vehicle and component production operations are feeling the impact of slow EV sales. However, the country has many assets making it attractive to investment, especially in battery production.

Ian Henry

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

Korea’s LG, SK On and Samsung lead Prismatic battery revival impacting Electric Vehicles and Automotive Production

The prismatic battery is making a comeback, with Korean battery giants leading the charge. Offering advantages in safety and cost, this technology could have lasting implications for the Electric Vehicle, battery, and automotive production landscape.

Ilkhan Ozsevim

Despite industry fears, global EV sales reach record highs in 2024 and remain on an upward trajectory

How will slowing growth in EVs impact auto industry investment strategies? As the industry navigates challenges from rising costs and charging infrastructure gaps, to consumer range anxiety and rising competition, Daniel Harrison explodes some EV myths.

Daniel Harrison

Nissan and Honda agree to joint research for next-gen SDV platform

The two companies have agreed to joint research in fundamental technologies next-generation software-defined vehicles (SDVs).

Nick Holt

Toyota West Virginia starts production of new hybrid transaxle

Production of this fifth-generation hybrid transaxle is part of Toyota’s multi-pathway approach to electrification.

Nick Holt

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

Electric Dreams: Tesla’s gigafactory network and EV battery production blueprint

From Fremont to Berlin, Tesla’s gigafactories are the drivers in its goal to lead the EV market. Each site plays a crucial role in electric vehicle and battery innovation, ensuring Tesla meets global demand and maintains its lead in the electrification race.

Ilkhan Ozsevim

Ampere supports Renault Group with LFP technology and cell-to-pack solutions

Ampere will integrate LFP (Lithium Iron Phosphate) technology to complement NCM batteries (Nickel Cobalt Manganese) and create a European value chain.

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

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

Stellantis and French energy expert CEA collab on next-gen battery cell tech

In a five-year collaboration, automaker Stellantis and France’s CEA will develop next-gen EV battery cells. The partnership targets advanced technology with improved performance, durability, and sustainability, potentially leading to more affordable electric vehicles.

Ilkhan Ozsevim

Arno Güllering lands Chief Operating Officer position at Dräxlmaier after ZF

Arno Güllering has been appointed Chief Operations Officer (COO) of the Dräxlmaier Group, effective July 1, 2024, for which he will be responsible for the company’s production and logistics functions.

Ilkhan Ozsevim

BeyonCa sets stage for Hong Kong’s automotive jump with new EV assembly plant

Renault (and Dongfeng)-backed BeyonCa plans to transform Hong Kong’s automotive sector with its first EV brand and assembly plant in Tseung Kwan O, potentially shifting towards high-tech production post-2019 protests and COVID-19 challenges.

Ilkhan Ozsevim

HORSE Powertrain welcomes Aramco as strategic investor, leveraging chemical expertise

Aramco invests 10% in HORSE Powertrain Limited, a joint venture by Renault Group and Geely. This partnership will enhance the development of sustainable powertrains and synthetic fuels, driving the future of automotive decarbonisation.

Ilkhan Ozsevim

BMW opens its first North American press shop at Spartanburg and unveils the new BMW X3

BMW Manufacturing celebrates 30 years in Spartanburg with the opening of its first North American press shop and the debut of the fourth-generation BMW X3. The $200M investment will create over 200 jobs and pave the way for electric vehicle production by 2026.

Ilkhan Ozsevim

Europe’s tariffs on Chinese EV imports stresses importance of local production

The European Commission (EC) has decided to impose additional tariffs of up to 38% on Chinese EVs following preliminary results of its anti-subsidy investigation, which found that prices are being distorted by Chinese state support.

Megan Kelly

HORSE announces next-generation Range Extender powertrains

HORSE has introduced innovative Range Extender powertrains for passenger and light commercial vehicles. Offering a 200km electric range plus an additional 600km from an onboard engine, this technology reduces battery size by over 50%, cutting costs and weight.

Ilkhan Ozsevim

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

Vietnam’s VinFast weighs delaying $4 Billion US assembly plant to refocus expansion in Southeast Asia

Vietnamese EV maker VinFast is considering another delay for its $4 billion US assembly plant, originally set for July 2024, as it shifts focus to Southeast Asia. Amid challenges in the US market, VinFast plans to open six dealerships in the Philippines and expand its vehicle lineup

Ilkhan Ozsevim

Vitesco Technologies supplies electric drive system for Honda plug-in fuel cell vehicle

Vitesco’s EMR3 axle drive will be integrated into the Honda CR-V e:FCEV and will be the first time this system has been used for a hydrogen fuel cell vehicle.

Nick Holt

Q&A with Patrice Haettel: CEO of powertrain technology company HORSE

Renault’s powertrain tech company, HORSE, has begun mass-producing the Power Electronics Box (PEB); crucial for HEVs and PHEVs. The redesigned PEB boosts performance by managing Emotors more efficiently. Here’s CEO, Patrice Haettel on electrification and more.

Ilkhan Ozsevim

Breaking down silos: the necessity for co-creative collaboration

The Design4Production event in Munich proved that collaboration between is key to success across automotive production, engineering and design. The topic was present across every single session in one form or another. Here are the highlights of the theme…

Ilkhan Ozsevim

Weak demand dims electric future

Consumer resistance and trade disputes mean the future may not be so electric after all as vehicle makers express caution on zero emission vehicle targets.

Ian Henry

Driving Innovation: The 3rd International Automotive Wire Harness Conference Returns to Detroit in 2024

Our presentations will focus on showcasing solutions, strategies, and tools for a range of topics such as electrification, advanced E/E architecture, functional safety, sustainability, mass reduction, high-speed data networks, commercial vehicle unique topics, simulation, and labor/complexity reduction through manufacturing automation and digitalisation.

AMS

BMW builds gigafactory for Neue Klasse in Mexico

BMW Group is taking its ‘local for local’ approach to manufacturing and supply chain to Mexico, and has started construction on an 80,000 sq.m battery manufacturing facility next to its assembly plant in San Luis Potosi. The plant is due to start making the Neue Klasse electric sports activity vehicle there from 2027.

Marcus Williams

Rivian secures $827m funding, plans expansion and brings in Javier Varela as new COO

Rivian secures $827m in public funding from Illinois Department of Commerce & Economic Opportunity despite announcing 10% workforce cuts earlier this year. Javier Varela appoitned new COO ahead of R2 production

Ilkhan Ozsevim

Honda grows its North American EV footprint

Honda is investing heavily in growing its electric vehicle production operations in North America but is also leveraging expertise and capacity for hybrid powertrain production

Nick Holt

Toyota invests $1.4B in US manufacturing for new BEV SUV

With a focus on sustainability and job creation, Toyota’s investment in its Princeton facility in Indiana aims to solidify its position in the electrification market, adding up to 340 new jobs and bolstering its long-standing partnership with the state

Ilkhan Ozsevim

VW focuses on Chinese market boosting cost competitiveness and local partnerships

VW seeks to strengthen its position in the Chinese automotive market through achieving cost reductions in production and boosting local partnerships

Nick Holt

Impacts of global geopolitics on European production

Geopolitical influences on the automotive manufacturing sector are intensifying and becoming ever more powerful. European trends cannot be looked at in isolation; their impact on the ground in Europe have their roots in wider global factors…

Ian Henry

OEMs jointly develop green battery prototypes with Henkel

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Henkel More OEMs are looking to build their own EV batteries in-house to streamline production and logistics and have more visibility on costs and efficiencies. In a fast-paced competitive market where technologies evolve and overtake one another quickly, carmakers are keen to keep their progress under wraps – particularly when it comes to battery prototypes. But they are making an exception for the purpose of recycling and repair, according to Henkel’s battery sustainability expert, Philipp tho Pesch.

AMS

How BMW is ramping up its circular production and sustainability principles as it drives towards electrification

BMW’s Dr. Irene Feige, Head of Climate Strategy and Circular Economy says that circular economy is becoming central to BMW’s automotive production landscape, part of its wider push for sustainable production and supply chains.

Ilkhan Ozsevim

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

Shifting gears – Electrifying the driveline

GKN Automotive has a long history as a driveline component and system developer, and manufacturer. Like many of the leading tier suppliers in this segment, the company has now added a range of products for electric powertrains to its range. Jorge Beja, VP of Operations Systems shares some insights into production at the company’s centre for excellence for eDrive systems, at Bruneck, Italy.

Nick Holt

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

Google’s Clausen takes GM manufacturing mantle as EVP Johnson retires

GM’s longtime EVP Gerald Johnson announces retirement after 44 years. Clausen appointed new EVP, Abbott to step down due to health. Leadership transition underway for manufacturing and software divisions.

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

Challenges looming for US vehicle production

EV production in the US is facing headwinds from both weakening demand and foreign competition.

Ian Henry

Magna has landed a major eDrive system contract for a niche, high-end vehicle Original Equipment Manufacturer in North America

Magna has landed a crucial contract to provide a specialised eDrive system for a well-known North America-based OEM, marking a pivotal step in the automotive industry’s shift towards electric mobility

Ilkhan Ozsevim

GM appoints ex-Tesla executive to new VP of batteries role

GM has appointed Kurt Kelty, a battery expert and former Tesla executive, to its new role of vice-president of batteries, in a move that aims to help the carmaker become a leader in EV manufacturing.

Megan Kelly

Powertrain – Reducing waste in machining fluids

Sustainability projects at plant and team levels are vital to reducing the operational carbon footprint in manufacturing operations. These range from simple energy management protocols to more involved process improvement related projects. JLR offers a very interesting case study on the latter at its Electric Propulsion Manufacturing Centre.

Nick Holt

GKN Automotive – Embedding sustainability in the business

GKN Automotive’s director of sustainability, Tom Salisbury discusses the importance of Science Based Targets, managing supply chains and the need to embed sustainability throughout the organisation.

Nick Holt

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

How Farasis will bridge the EV battery gap in Europe

The Chinese battery manufacturer’s new European general manager, Marcel Brömlage, will lead an evolving strategy in the region including increasing engineering and acquisition capabilities, and targeting automotive as well as non-automotive customers to support the growth strategy for the Siro joint venture and Farasis group.

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

How battery and electric motors and EVs are reshaping the European automotive supply chain

The automotive industry is in a major shift with EVs reshaping the supply chain. Challenges and opportunities include replacing traditional components tied to combustion engines, new players in the battery market, disruptors facing tariffs, and the looming influence of China in Europe; all adding new layers of complexity.

Ian Henry

How Europe’s Big 3 (Volkswagen, Stellantis, Renault) are evolving their manufacturing arrangements and production strategies in the European automotive industry as electrification takes hold

As the automotive industry in Europe undergoes a seismic shift from internal combustion engines (ICE) to electric vehicles (EV), major players like Volkswagen, Stellantis and Renault are navigating complex changes in their production strategies.

Ian Henry

ONE’s innovative strategies in chemistry, manufacturing and sustainability are transforming EV safety

AMS explores Our Next Energy’s (ONE) innovative approach to EV battery safety. The company’s CEO and founder, Mujeeb Ijaz, discusses manufacturing solutions to eliminate thermal runaway, enhance range, and optimise sustainability

Martin Kahl