Tag: flexible production

Honda’s Ohio Anna engine plant turns 40 with EV ambitions

Honda celebrates 40 years at its Ohio engine plant as it scales flexible manufacturing, invests in megacasting and prepares for EV battery case production from 2026.

Ilkhan Ozsevim

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.

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

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.

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.

Automating complexity: How JLR Is futureproofing production and skills

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

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.

BMW’s digital brain: Dr. Michael Nikolaides on AI, robotics and resilience in a complex global supply chain

BMW’s Dr. Michael Nikolaides discusses how the OEM is leading with intelligent intralogistics, AI-powered automation, and data-driven decision-making. From real-time reallocation to humanoid robotics, BMW is future-proofing its production network in a volatile global landscape.

Cybersecurity: Building defence-in-depth into smart factories

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

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.

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.

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.

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.

Why global automotive innovators must embrace Design For Manufacture to power production in an environment of increasing complexity and fierce foreign competition

Automotive manufacturers are streamlining production with Design for Manufacture (DFM), cutting complexity, reducing costs and driving EV innovation. In In this article, experts reveal the key strategies and digital tools that are reshaping vehicle production.

Revolutionising Automotive Manufacturing: Flexibility, Efficiency, and Sustainability with Siemens

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with SiemensDiscover how Siemens’ innovative solutions empower automakers to meet the challenges of EVs, sustainability, and smart manufacturing. Download the whitepaper to explore actionable insights.

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.

Rockwell strengthens autonomous production logistics with Clearpath Robotics and OTTO Motors in a major move towards fully integrated smart manufacturing

Rockwell Automation has acquired Clearpath Robotics and its industrial division OTTO Motors, integrating autonomous mobile robots into its portfolio. The move signals a transformation in production logistics, optimising efficiency and connectivity across factories.

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.

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

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

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.

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.

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.

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.

Stellantis’ Jeremy Keating on comprehensive lean practices: Achieving zero waste through organisational alignment and proactive problem-solving

At the AMS Automotive Evolution North America conference, Jeremy Keating, Vice-President of Operations at Stellantis’ Kokomo Transmission Plant, shared insights on lean manufacturing’s value in achieving efficiency. He discussed early lean integration, financial assessments for cost control, and the critical role of union partnerships.

Stellantis’ Asif Khan on driving cost control and profitability through lean manufacturing in a competitive market

At the AMS Automotive Evolution NA 2024 event, Dr. Sardar Asif Khan, Continuous Improvement Lead at Stellantis, discussed the critical role of lean manufacturing in cost control and profitability. He highlighted the importance of leadership, workforce engagement, and the complementary role of digital tools in enhancing lean methodologies.

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.

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

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

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.

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…

BMW Group Plant Regensburg honoured for excellence in large-scale assembly, recognised for flexibility, digital innovation, and leadership in prestigious Factory of the Year competition

The coveted “Factory of the Year” award has gone to Regensburg in the category of large-series assembly. The plant was lauded for its remarkable flexibility, workforce dynamism, and cutting-edge digital innovation, further solidifying its place as a leader in automotive production.

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.

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.

Jaguar Land Rover to invest in UK manufacturing plants to ramp up EV and flexible production

JLR will invest billions over the next five years to upgrade its UK plants for an electric-first future, including transforming Halewood into an all-electric plant, adding an electric Jaguar in Solihull, producing electric drives and battery packs in Wolverhampton and expanding stamping in Castle Bromwich

Solving electric vehicle production challenges with smart manufacturing and logistics

Siemens discusses how the latest digital tools are enabling the transition to e-mobility and explains why these are now essential to OEMs and tier suppliers if they are to create transparent, sustainable supply chains

Building on the edge of the virtual and physical worlds

As Audi aims to bring its local production cloud to plants, head of manufacturing engineering Jörg Spindler sees opportunities to scale digital control systems, digital twins and virtual reality.

Tools for progress: real-time tracking and monitoring in Audi’s toolmaking

The carmaker’s Toolmaking 4.0 system is bringing greater visibility of suppliers and potential disruption of machines and operations at tool shops, with high productivity gains.

Setting the pace for Audi’s global production

Head of manufacturing engineering Jörg Spindler is leading Audi’s push to virtualise production planning, ramp up battery production and use data to reduce emissions and improve productivity in areas like toolmaking and body shop

Italvolt enters a strategic collaboration with StoreDot

Italvolt will license StoreDot’s extreme fast charging technology (XFC) and intellectual property rights to manufacture XFC lithium-ion batteries at its plant in Italy

Audi plans for future production

Audi says it’s all in on electromobility, planning to launch only all-electric models from 2026, and gradually phasing out production of its combustion engine models by 2033

BMW Dingolfing plant turns to modular systems to simplify assembly

BMW’s Plant Dingolfing is integrating automated modular production technology into production of chassis components, boosting manufacturing flexibility.

What Vorsprung durch Technik means for Audi manufacturing in 2022

Digital over physical: Audi is making progress in production through virtual reality, AI and software prototype builds, modular assembly, quality control and energy conservation. AMS gets a tour of manufacturing digitalisation in Ingolstadt, and learns what keeps production chief Gerd Walker up at night.

Cars à la carte – Audi trials modular production to control customisation costs

The German premium carmaker is applying the efficiency focus that has fine-tuned production lines over many years to the more bespoke tasks in modular assembly as EV and supply complexity increases. AMS visited Audi’s Ingolstadt plant for a chance to see the technology in action.

Watch: Reinventing the wheel – Ree’s flexible EV architecture and modular production approach

The Israeli startup is rolling out low-cost, flexible plants for its EV platforms based on drive-by-wire technology, according to COO Josh Tech.

An exclusive focus on flexibility as OEMs look to modular-based manufacturing

Modular production in automotive manufacturing is rapidly becoming more innovative and flexible with the ability to multitask. As a result, OEMs are increasingly rethinking their methods and working closely with technology providers to make flexible manufacturing hegemonic.

Interview: Scania’s super charge to battery assembly

Tony Persson, head of battery production, reveals how the Traton Group truckmaker is preparing to launch battery module assembly in half the time it would normally have for manufacturing launches, and the innovation in assembly and digitalisation that will support it.

Watch: Making it modular - vehicle production’s flexible future

Flexibility in automotive assembly is now a competitive advantage. This AMS livestream features leaders from automation experts Ewellix and Rockwell and AMS discussing innovations in modular production and how to improve assembly lines at brownfield and greenfield factories. It previews wider discussions on new assembly concepts ahead of the AMS Automotive Evolution Summit in May.

Watch: Packing the power in battery system production

Increasing EV battery output is essential to automotive electrification targets. Watch this AMS Automotive Evolution Livestream on-demand about ramping up the battery value chain, from raw material risk through to lithium-ion cell and battery module producton. Featuring experts from Scania, Verkor, S&P Global, Henkel and Recharge.

From assembly to modular production lines

Automotive manufacturers need to manage more part variety and complexity than ever, which is why more are implementing autonomous logistics, cobots and other technology to support more flexible, modular concepts. Experts from ABB, Conductix-Wampler and Panasonic discuss the technology roadmap.

Complex problems, flexible solutions: how modular production and autonomous logistics are helping OEMs keep up with a changing powertrain mix

As automotive manufacturing becomes increasingly complex, primarily driven by rising demand for more sustainable production processes as well as zero-carbon vehicles, the question of flexibility is becoming more central to both producers and customers.

Porsche production: moving faster around the bend

Porsche’s top manufacturing executive, Albrecht Reimold, explains the carmaker’s progress towards sustainable, connected manufacturing, and why he thinks the automotive industry needs to talk less and act more when comes to solving production problems

Watch: Factory of the future Livestream – The software-defined assembly line

As automotive OEMs digitalise and connect factories, hear how the Audi Production Lab, ABB and Cosmotech are using real-time data, smart software and advanced automation to reshape vehicle production processes.

VW and Ford invest in flexible production for an uncertain future

The speed of change in the technology of cars, electrification and the introduction of advanced software is requiring new manufacturing equipment and is making expensive old machines redundant, but exactly where the industry is going next is hard to predict. More flexible manufacturing is the answer for Ford and VW.

Global suppliers need modularity and flexibility in the EV age

Electric vehicles bring with them high development costs and large expenses for retooling plants. To get around that, OEMs and tier suppliers must work together to develop flexible, modular production systems, according to panellists from ZF and ABB at last week’s AMS Livestream on electrification.

Your webinar questions answered: How tier 1 suppliers are responding to tough headwinds

You asked, we answer. We return to the questions from our audience that we didn’t have time to answer in our live webinar, ranging from which parts of automotive tier 1 suppliers’ business models are at risk of commodification, to how tier suppliers are changing manufacturing processes

AMS on Africa: Part 5 – Heavy-duty headway at Scania

There may be less reliance on automation at Scania’s Johannesburg plant but flexibility and workflow keep operations in smart shape for the needs of its commercial vehicle customers

Special deliveries

The deployment of automated guided vehicles (AGVs) in automotive manufacturing applications is now well-established. Mike Farish reports on some of the latest developments

Investment motors on

OEMs continue to repurpose established engine plant sites for the electric age

Plug and produce

Pressing ahead at Volvo