Stellantis appoints Fernando Andreu to lead EV manufacturing expansion at Ellesmere Port As Stellantis boosts its electric van output, the Ellesmere Port plant welcomes new Plant Director Fernando Andreu, who will oversee production of medium-sized battery electric vans alongside the site’s existing small van assembly line. AMS
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
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
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
GM invests $888M in Tonawanda plant to build next-gen V-8 engines for trucks and SUVs General Motors is reinforcing its commitment to American manufacturing and high-performance engines with a $888m investment in its historic Tonawanda Propulsion plant. The funding supports production of GM’s sixth-generation V-8 engines, powering full-size trucks and SUVs while bridging the gap to an electric future. AMS
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
Toyota to build GR Corolla in the UK starting 2026 Toyota Motor Europe has confirmed that its Burnaston plant in Derbyshire will begin production of the Toyota GR Corolla in 2026, marking a significant expansion of the company’s high-performance GR (Gazoo Racing) lineup. AMS
Honda ramps up motorcycle production in India with new line at Gujarat plant Honda Motorcycle & Scooter India (HMSI) is significantly expanding its production footprint in the world’s largest motorcycle market with the announcement of a new production line at its fourth manufacturing plant in Vithalapur, Gujarat. AMS
Tariffs changing the automotive landscape in North America Donald Trump’s tariffs have triggered some shorter-term shifts in US production operations and longer-term evaluation on investments and strategies as supply chains are restructured. Ian Henry
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
Volkswagen appoints Dr. Werner Tietz as new head of Group Research and Development Volkswagen Group has announced that Dr. Werner Tietz, currently the Executive Board Member for Research and Development at SEAT S.A., will take on the additional role of Head of Group Research and Development at Volkswagen Group, effective July 1, 2025. AMS
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
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
Stellantis: too big to fail or too big to be managed? With Stellantis experiencing financial woes and now facing tariff challenges across both its North American and European arms, its senior management team will be tested and stretched more than ever. Ian Henry
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
Will exports drive production growth across India? Building on the rising value of vehicle exports and components, the Indian government wants 50% of vehicles made in India to be exported by 2030 but there is some way to go before this ambition can be realised. Ian Henry
Ambitious targets and big investments for India’s carmakers After a period of downsizing or complete withdrawal by some foreign OEMs, investment in Indian production is on the rise again with the domestic vehicle makers leading the way. Ian Henry
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
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
Mazda’s Lean Asset Strategy: Driving efficiency in development and manufacturing Mazda has unveiled its “Lean Asset Strategy,” reinforcing its multi-solution approach to electrification. This initiative is aimed at optimising product development and manufacturing while accelerating time-to-market and reducing costs. Nick Holt
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
India aims to become a global player in automotive manufacturing India is potentially on the cusp of becoming a major global player in vehicle production. Whether it can achieve this status will become clear in the next couple of years. The transition to EVs adds to the national challenge as the domestic players are not really leaders in this sector. Meanwhile, the Indian EV supply base is nascent and dependent on foreign investors. Ian Henry
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
Honda upgrades production with advanced processes for 2026 Passport models Innovative manufacturing enhances efficiency, quality, and ergonomics at Alabama Auto Plant. Nick Holt
Will Volkswagen’s surplus German plants become Chinese production operations? As European vehicle makers continue to face challenging global markets and increased costs, many are having to make difficult decisions around underutilised production operations. Ian Henry looks at how Chinese OEMs could potentially buy or utilise some of Volkswagen’s production sites. Ian Henry
Solving EV battery pack development, cost and production challenges James Eaton, CEO of IONETIC, discusses the evolving landscape of EV battery pack development and production, focusing on the challenges facing low-volume manufacturers. Eaton shares insights into the importance of cost optimisation, flexible manufacturing, and overcoming the unique challenges of electrifying commercial vehicles such as buses. Nick Holt
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
Mercedes-Benz introduces new paint finish to improve sustainability at Wörth plant In a move toward reducing the facility’s carbon footprint, the Mercedes-Benz plant in Wörth is rolling out a new painting technology for its truck cabs, which is expected to cut energy consumption by up to 40%. Nick Holt
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
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
The automotive industry weighs the challenges of geopolitics and market factors in 2025 Trade wars, geopolitical tensions, mergers, increasing competition are all considerations that need to be addressed and navigated by vehicle makers and suppliers. Ian Henry highlights some of the key factors to look out for in 2025. Ian Henry
Rolls-Royce invests £300m to extend Goodwood manufacturing facility The £300m site extension will expand Bespoke and Coachbuild capabilities, driven by a 10% increase in Bespoke content value per motor car year-on-year, and support future EV production. Nick Holt
Mazda to build module pack plant for cylindrical lithium-ion batteries Mazda’s new plant will be located in Iwakuni City, Japan and will produce battery packs for its new EVs. Nick Holt
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
Chinese vehicle makers look to international markets for growth, but domestic government pressure and trade barriers may slow expansion. The number of domestic vehicle manufacturers in China has increased rapidly in recent years. Some are spin-offs from previous joint ventures with foreign companies, others entirely new. A few, notably BYD, Geely and Chery, have become significant global players, as well as gradually overhauling the foreign players in their domestic market. Ian Henry
China: Fierce domestic competition sees international brands suffer lower sales and a contraction of output As China’s domestic brands consolidate and grow both at home and internationally, the international brands, which have benefited from growth in the Chinese market over the years, now face serious headwinds. Ian Henry
Stellantis struggles with managing multi-brand complexity and looks to regroup following Tavares resignation Carlos Tavares’ tenure in charge of Stellantis has ended abruptly but was the job of developing, producing and selling such a diverse range of brands across different continents an impossible one? Ian Henry unpicks some of the complexity facing Tavares and his team. Ian Henry
Stellantis advances its battery chemistries and improves sustainability by investing with CATL to build Spanish gigafactory Stellantis and Chinese battery manufacturer CATL have formed a joint venture to invest up to €4.1 billion ($4.3 bn) to construct a large-scale lithium iron phosphate (LFP) battery plant in Spain. Megan Kelly
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
Ford’s Halewood facility begins production of electric drive units strengthening the UK’s role in EV manufacturing The electrification of Ford’s Halewood plant is more than just a strategic pivot; it’s a testament to the company’s vision for sustainable automotive manufacturing. By producing over 420,000 electric drive units annually, the plant will power Ford’s top-selling EV models and support Europe’s transition to zero-emission vehicles. Ilkhan Ozsevim
Nissan’s Sunderland plant: Electric Vehicle hub or cost-cutting casualty amid global restructuring? Nissan’s Sunderland plant, pivotal to its EV ambitions, faces an uncertain future amid a sweeping cost-cutting drive. As CEO Makoto Uchida contends with falling sales and restructuring, the UK facility’s strategic importance may yet shield it from drastic cuts. Ilkhan Ozsevim
Hyundai Union’s metal workers to strike as calls grow for South Korean president Yoon Suk Yeol to step down after his declaration of Martial Law Hyundai Motor’s labour union will hold strikes tomorrow and Friday, adding to mounting political tensions. South Korea’s Metal Workers’ Union threatens a full strike unless President Yoon Suk Yeol resigns after a Martial Law controversy. Ilkhan Ozsevim
The declaration of Martial Law in South Korea raises challenges for automotive production and global supply chains amid political upheaval The declaration of Martial Law in South Korea has thrown its critical automotive production and logisitics into uncertainty. As political tensions mount, automotive manufacturers and supply chains brace for potential major disruptions in operations and logistics Ilkhan Ozsevim
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
What next for Chinese investment in Europe? China’s economy is slowing, and the US is threatening high tariffs on Chinese imports. Against this backdrop Chinese OEMs are looking to expand operations in Europe. Ian Henry examines the opportunities and challenges. Ian Henry
Honda sets up a demonstration production line for all-solid-state batteries Honda’s demonstration production line will support development for the mass production of solid-state batteries. Nick Holt
Stellantis launches, new multi-energy platform for body-on-frame trucks and SUVs Stellantis has launched its STLA Frame platform which supports internal combustion, hybrid, hydrogen, battery electric and range-extender electric vehicle powertrains. Nick Holt
BMW debrecen ramps up for Neue Klasse production as test vehicles signal progress in electric innovation BMW group’s debrecen plant in hungary has commenced near-series production of the Neue Klasse x model. The facility’s advanced processes are rigorously tested as it prepares for full-scale electric vehicle manufacturing by late 2025. 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
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
Henning Habicht appointed Head of Volkswagen Chattanooga Operations Habicht takes over from Chris Glover, who will retire in January 2025 after more than three decades with Volkswagen, including a three-year stint at Chattanooga. Nick Holt
Rivian and Volkswagen Group JV to create electric architectures and software The new joint venture (JV), with a potential investment of up to $5.8 billion, will see engineers from both partners developing software and electronics architectures and scale the electric vehicle platforms and architectures. 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
How Trump’s presidency could reshape automotive production, trade relations, and the green transition for manufacturers across the US, Europe, and Mexico With Trump as President, automotive manufacturers are bracing for major policy shifts affecting production, tariffs, and the electric vehicle landscape. With opposing stances on trade and green policies, candidates Kamala Harris and Donald Trump could alter the course of the automotive sector across the US, Europe, and Mexico. Ilkhan Ozsevim
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
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
Mercedes-Benz opens battery recycling facility to create a closed loop system The new recycling facility, located in Kuppenheim, Germany, will utilise an integrated mechanical-hydrometallurgical process. Nick Holt
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
Stellantis transfers supply chain and logistics oversight from purchasing to production with strategic leadership shake-up The carmaker is reorganising its supply chain, separating the purchasing department to report directly to the manufacturing chief to boost collaboration and flexibility. Ilkhan Ozsevim Christopher Ludwig
Honda expands new energy vehicle manufacturing in China with new Wuhan plant Honda opens its first dedicated new energy vehicle (NEV) production plant in Wuhan, China, boosting its electric vehicle production capabilities with advanced automation and eco-friendly technology. Nick Holt
General Motors shifts EV battery strategy by scrapping Ultium name as it balances EV ambitions with strong ICE demand The carmaker has announced it is making a strategic shift by dropping its Ultium battery branding as it reconfigures its EV business. While reaffirming its commitment to electric vehicles, GM also continues to invest in internal combustion engines to meet demand. Ilkhan Ozsevim
Volkswagen faces manufacturing challenges amid financial troubles Volkswagen is grappling with mounting financial troubles, signalling a worsening situation in its global manufacturing operations. With two profit warnings in three months, the automotive giant faces falling EV sales, factory underutilisation, and tariff threats from China. Ian Henry
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
How BMW is ‘Designing for Circularity’ to become a sustainability leader in automotive production BMW’s Roberto Rossetti, Total Vehicle Life Cycle Development, elucidates BMW’s innovative ’Design for Circularity’ approach. From using recycled materials to optimising vehicle disassembly, BMW is redefining how vehicles are produced and consumed. 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
EV transition slowdown and domestic politics challenge the US Big Three in new and unexpected ways US automakers face a tangled web of tariffs, union issues, and a slowing EV market. The threat of Chinese competition looms large, while the IRA’s complex rules create new challenges. Ford, GM, and Stellantis are each fighting to navigate these obstacles. Ian Henry
How cobots can support automotive production Cobots enrich the industry with their ability to complete tasks in close cooperation with humans and are becoming increasingly intelligent thanks to modern technologies. This article takes a look at the different types of robots, and their benefits to the industry. Ronja Schmiedchen Werner Beutnagel
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
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
Volvo’s 100% EV strategy shift: facing the unavoidable truth Lower-than-expected EV sales continues to have repercussions for production plans, with Volvo the latest vehicle maker to delay 100% EV target. Ian Henry
Lowering costs through sustainable manufacturing Sophisticated and complex technologies could be used to reduce costs and make manufacturing more eco-friendly, but simple solutions might be the most effective Michael Nash
Reinventing the wheel: the race towards sustainable tyre production Nokian Tyres is building the world’s first zero-carbon tyre factory, with Michelin, Continental, Bridgestone, and Pirelli leading the charge with recycled materials, bio-based components, and innovative sustainable production methods. 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
BMW and Toyota’s mixed powertrain approach sees collaboration to produce Fuel Cell Electric Vehicle options for passenger cars Utilising a fuel cell powertrain, developed in collaboration with Toyota, BMW plans to launch its first-ever series production fuel cell electric vehicle (FCEV) in 2028. Nick Holt
