Manufacturers use digital tools and teamwork to futureproof flexible ICE, EV & Hybrid assembly lines Leading manufacturers reveal how cross-functional collaboration, real-time data and advanced automation are strengthening agility and flexibility across assembly lines, with lessons from Bosch, BorgWarner and Renishaw Ilkhan Ozsevim
Circular economy targets inspire new design, sourcing and supply‑chain strategies for EVs, batteries and interiors Leading OEMs and suppliers are no longer treating circularity as an end-of-life concern. Design, sourcing and localisation strategies are being rethought to prioritise reuse, remanufacture and material traceability from day one. Ilkhan Ozsevim
Hybrid vehicles return to North America’s production lines as automakers rethink strategy Automakers that once aimed to skip hybrids and go straight to electric vehicles are now reintegrating hybrids into their North American line-ups. Building “half-and-half” cars is proving technically tricky but strategically worthwhile. Ilkhan Ozsevim
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
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
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
How JLR’s circular manufacturing drives global EV growth and decarbonisation Tomasz Jozwiak explains how Jaguar Land Rover is driving circularity across its operations by reusing and refurbishing manufacturing assets, cutting emissions, saving millions, and supporting electrification. Ilkhan Ozsevim
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
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
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
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
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
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
Hyundai Motor Group advances hybrid technology with dual-motor transmission and electrification systems for higher efficiency and performance Hyundai Motor Group has revealed its next-generation hybrid system, combining a dual-motor transmission, turbocharged engines and electrification technologies that enhance power, fuel economy and ride refinement across its model range. Ilkhan Ozsevim
As VW cuts back in Germany, Slovakia and Spain emerge as new pillars of cost-effective and future-focused production across Europe As VW’s traditional German plants face uncertainty, its long-established facilities in Bratislava and Pamplona are stepping into the spotlight—producing top-selling models and gearing up for a new era of electric vehicles. Timo Gilgen
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
Software-defined vehicles are transforming value creation, customer models, and strategies across the automotive industry, from BMW to Stellantis and NXP It’s now time to take a more holistic view of software-defined vehicles (SDVs). After all, they involve completely new business models. Who is pursuing which strategy? By Andrea Hoffmann-Topp
Lucid acquires Nikola’s former Arizona facilities and offers jobs to over 300 former employees as it scales up EV manufacturing and testing operations Lucid has struck a deal to acquire two former Nikola facilities in Arizona, adding nearly 900,000 sq. ft to its production and testing capacity and offering jobs to over 300 ex-Nikola workers as it scales EV production Ilkhan Ozsevim
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
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
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
BMW ramps up Debrecen plant with cutting-edge modular assembly to lead Neue Klasse electric vehicle production from late 2025 BMW’s all-electric plant in Debrecen enters its final phase before full production. With modular systems, digital twin planning and just-in-sequence delivery, the site signals the future of scalable, fossil-free manufacturing. Ilkhan Ozsevim
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
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
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
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
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
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
A Mckinsey report warns that Europe’s automotive industry must adapt rapidly to electrification, software and global competition or risk falling further behind Europe’s automotive industry is under pressure. A McKinsey report outlines five major disruptions that threaten its future. From software to supply chains, the industry must move fast to avoid losing ground to global competitors. Ilkhan Ozsevim
Global battery industry enters new phase as demand surges and prices drop below key cost threshold for Electric Vehicles The global battery industry has entered a transformative phase. EV demand is pushing annual battery needs past 1TWh, while prices fall below a key cost threshold. China remains dominant, but market shifts and consolidation are poised to reshape supply chains worldwide. Ilkhan Ozsevim
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
Renault expands circular economy with new polish repair facility for sustainable used car refurbishment The French car manufacturer Renault has just opened a special workshop in the largest eastern EU market - even though Poland is not necessarily one of its strongest locations. The issue of sustainability plays an important role. By Sebastian Becker
BMW’s Neue Klasse redefines electric mobility with advanced Software-Defined Architecture and high-performance energy management BMW’s Neue Klasse redefines electric mobility with a software-centric vehicle platform, high-voltage 800V battery technology and four advanced computing modules. A new era of efficiency, flexibility, dynamic performance and seamless energy management is emerging? By Andrea Hoffmann-Topp
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
Flexis accelerates European electric van manufacturing with a shared platform and localised production strategy Flexis, the electric van joint venture between Renault and Volvo, is leveraging a shared platform, European battery production and modular manufacturing to cut costs and enhance efficiency. With production set to begin in 2025, the company is positioning itself as a leader in scalable electric commercial vehicle production. Ilkhan Ozsevim Megan Kelly
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
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
EU invests in AI to transform automotive manufacturing with ‘AI smart factories’, automation and next-generation production technologies The EU’s new InvestAI fund will inject €200 billion ($208.4bn) into AI, transforming European automotive manufacturing. With AI gigafactories and smart factory technology, this initiative aims to drive automation, digitalisation and next-generation production systems. Ilkhan Ozsevim
Honda North America’s big investment in flexible manufacturing for EVs, hybrid and ICE vehicles Honda invests $1 billion in retooling its Ohio manufacturing plants to build ICE, hybrid, and EV models on same production line. New technologies being introduced include megacasting, CDC and friction stir welding. Nick Holt
US tariffs on Mexico and Canada threaten North American auto production and supply chains, raising costs for manufacturers The US is threatening to impose tariffs on automotive imports from Canada and Mexico, testing the resilience of North American manufacturing. The move could drive up costs, disrupt supply chains, and challenge the stability of the US-Mexico-Canada Agreement (USMCA), just as the industry navigates nearshoring, investment shifts, and electrification. 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
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
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
Dürr to equip BYD’s first European passenger car factory in Hungary with advanced sustainable painting and cleaning technologies, marking a milestone for both companies, and the EU tariff question BYD, one of China’s largest EV makers, has chosen Dürr to equip its first European car plant in Hungary with advanced painting and cleaning technology. This collaboration combines precision engineering with sustainability, showcasing the future of European EV production. Ilkhan Ozsevim
Coventry and Warwick Gigapark aims to transform UK EV battery production amid competition and policy pressure The Coventry and Warwick Gigapark seeks to anchor the UK’s position in Electric Vehicle (EV) battery Production. With 5.7m sq.f of industrial space, incentives, and a central location, it’s a critical response to ZEV mandates and global competition. Ilkhan Ozsevim
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
BMW Group strengthens circular economy through SK tes battery recycling, advancing sustainability in Europe and beyond The BMW Group has launched a partnership with SK tes to recycle high-voltage batteries across Europe. This closed-loop process reclaims critical materials such as cobalt, nickel, and lithium, boosting sustainability and reducing supply chain risks. Ilkhan Ozsevim
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
2024 wrap up and 2025: EV batteries, gigafactories, sustainability and smart factories in auto manufacturing Take a look back at AMS’ biggest stories in automotive manufacturing in 2024, and our predictions for 2025 from smart factories to digital twins and more AMS
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
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
Volkswagen Chattanooga and Christopher Glover: a masterclass in flexible manufacturing in North America As Volkswagen celebrates its 75th year in the US, its Chattanooga plant exemplifies a flexible manufacturing model that integrates electrification, workforce innovation, and supply chain resilience. With Chris glover as EVP, the plant has become a benchmark for industry transformation. Ilkhan Ozsevim
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
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
Exclusive: BMW Group improves efficiency with additive manufacturing gripper BMW Group has improved the speed, versatility and sustainability of its manufacturing and cut costs by using 3D-printed bionic robot grippers. Automotive Manufacturing Solutions reports on the latest innovations from the BMW Group Additive Manufacturing Campus and manufacturing plant in Munich. Megan Kelly
Electric promise in the Middle East: Why Statevolt is building a gigafactory in the UAE instead of Europe Despite regional challenges and skepticism, serial gigafactory founder Lars Carlstrom sees untapped potential and strategic advantages in the UAE and Middle East, and worries that Europe is missing a huge opportunity to reindustrialise. With Lucid’s foray into EV production in Saudi Arabia and Ceer’s imminent market entry, is the Middle East primed to embrace electrification? Ilkhan Ozsevim
Green Revolution: How renewable energy is fuelling sustainable automotive manufacturing Adopting renewable energy in automotive production requires a comprehensive strategy, integrating solar, wind, biogas and electric solutions to drive sustainability and mitigate environmental impact effectively. OEMs, strategies and technologies are converging on different approaches to achieve sustainability goals across regions. Here are some notweworthy projects to keep an eye on… Ilkhan Ozsevim
Rising labour costs become biggest concern for automotive manufacturing Rising labour costs and skills shortages are the biggest concern for the automotive manufacturing industry this year, according to the latest AMS & ABB Automotive Manufacturing Outlook Survey 2023. AMS
Megacasting: a chance to rethink body manufacturing The aluminium die-casting process could revolutionise body construction. Professor Wolfram Volk, the department head for forming technology and casting at the Technical University of Munich, explains the advantages and disadvantages of so-called ‘mega’- or ‘gigacasting’. Götz Fuchslocher
