Tag: lean manufacturing

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Ford reshapes EV manufacturing with new platform

Ford’s $5 billion EV platform and factory investment

Ford has committed $5 billion to its Universal EV Platform and Production System, overhauling production at Louisville and BlueOval Battery Park Michigan. The new approach introduces parallel assembly, structural batteries, supplier integration and workforce transition.

Charlie Blackie-Kelly

Emily Uwemedimo

Ilkhan Ozsevim

Inside Toyota’s 2025 Lean(er) Manufacturing System

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

Ilkhan Ozsevim

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

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

Automation gains new levels of traction as the automotive sector turns to robotics for safer, more efficient production and a redefinition of the human role on the line

A new global survey by QNX reveals how automotive manufacturers are increasingly embracing robotics to boost efficiency, address labour shortages and improve safety, while also navigating concerns over cost, trust, regulation and the future of the workforce.

Ilkhan Ozsevim

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

How Opel Eisenach’s New Grandland EV Production Blends Lean Principles, Flexibility, and Automation for Competitive Advantage in a Changing Industry

The Opel plant in Eisenach exclusively produces the new Grandland – the brand’s flagship. Plant manager Jörg Escher explains in an interview what impact the switch to the new model will have on the site.

Timo Gilgen

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

Gestamp’s Paul Belanger on reducing EV production costs with giga-stamping and cross-functional collaboration

At the AMS Automotive Evolution NA 2024 event, Paul Belanger, Director of R&D North America at Gestamp, shared how giga-stamping and customer collaboration are helping reduce production costs, making affordable EVs a realistic goal for the North American market.

Christopher Ludwig

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.

Christopher Ludwig

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.

Christopher Ludwig

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

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

Ilkhan Ozsevim

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

“We cannot afford to make any mistakes” - Volkswagen’s Portugal boss Thomas Hegel Gunther

It’s not easy being the manager of a VW plant these days. In an interview, Volkswagen’s Portugal boss Thomas Hegel Gunther explains what makes the home of the T-Roc so special and how his team is continually increasing effectiveness through various lean principles.

Timo Gilgen

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

UK car production drops 8% in first half of 2024

Car production in the first six months of 2024 has dropped by 7.6%, according to new figures released today by the Society of Motor Manufacturers and Traders (SMMT).

Megan Kelly

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

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

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

Ilkhan Ozsevim

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

Is ABB Robotics’ new inkjet paint tech the future of automotive paintshop?

Automotive production paintshop is energy-intensive and costly. Could a new ‘inkjet’-type paintshop technology solve several production issues at once? With major implications for sustainability and customisation, ABB’s PixelPaint sees an explosion in demand.

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

Design4Production: Recap blog

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

AMS

“We have a clear strategy towards electromobility”: Gerd Walker, Audi

Gerd Walker controls production and logistics on the Audi board. In this interview, he explains how Audi flexibly and digitally designs the production network and what role the target image of the 360factory plays.

Götz Fuchslocher

ZF unveils automotive tech facility in Monterrey, Mexico, focused on fusing engineering, design and product development

ZF’s $200m investment will establish one of the most advanced automotive complexes in Mexico and will focusing on driving automotive developments through collaboration

Ilkhan Ozsevim

Reshaping the future: Innovations and developments in automotive production engineering: propulsion by Electrification and Digitalisation

Manufacturing engineering both powers and underpins production ecosystems across the industry. From BMW’s Munich plant to Porsche’s Zuffenhausen facility and Toyota’s expansions in Kentucky, we take a look at transformative initiatives shaping the industry.

Ilkhan Ozsevim

Compas wins category for site transformation at FYA: Interview with Santiago Jurado, chief quality officer

Watch how Compas, winner at the Factory of the Year Awards, reshaped quality production management to overcome extreme complexity in automotive production. Chief Quality Officer Santiago Jurado shares insights with AMS Chief Content Officer Christopher Ludwig.

AMS

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

“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

Toyota Alabama accelerates production unveiling the i-FORCE engine line to power the enhanced Tacoma, focused on versatile powertrains and demand-led job stability

Toyota Alabama launches i-FORCE 2.4L turbo engine line, fortifying commitment to responsive powertrains amid market shifts. The OEM ramps up towards its wider electrification goals

Ilkhan Ozsevim

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

Škoda accelerates SUV innovation with second-generation Kodiaq launch in Kvasiny

The OEM has invested €49m ($53.3m) in the Kvasiny plant, Czech Republic, for the advanced production of the new-generation Kodiaq, showcasing significant advancements in SUV manufacturing.

Ilkhan Ozsevim

Tata subsidiary TPEM launches first Tata-branded vehicle and kicks off production at new Gujarat facility

Tata Passenger Electric Mobility (TPEM) has launched its parent company - Tata’s, first ever own-brand vehicle to mark the inauguration and opening of TPEM’s new vehicle production facility in Sanand, Gujarat, with clear indication of growth in the region.

Ilkhan Ozsevim

Is cost-cutting the newest trend among OEMs in Europe 2024? Watch this space…

As Renault and VW move towards major and comprehensive cost-cutting projects, with the squeeze of uncertainties and inefficiencies, is this liable to spread?

Ilkhan Ozsevim

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

The automotive value-add of additive manufacturing and simulation technologies: an agile and resilient powerhouse in engine development

Markforged’s additive manufacturing solves Punch Torino’s automotive challenges with robust camshaft tools. Simulation technology streamlines design, reducing iterations with a future focus on sustainable internal combustion engines and alternative fuels.

Ilkhan Ozsevim

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

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

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

Ilkhan Ozsevim

JLR accelerates digital transformation with Tata Communications connecting 128 of its global sites through cloud-based digital production network

The two companies are collaborating to build JLR’s robust digital network to foster supply chain resilience. The collaboration integrates AI for real-time data analysis, enhancing production efficiency and security.

Ilkhan Ozsevim

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

Ford scales down planned Michigan EV plant, GM scraps EV target

Ford is downsizing the capacity and investment in its planned EV plant in Marshall, Michigan, following suit of GM scrapping its EV production targets.

Megan Kelly

Porsche elevates Zuffenhausen production with €250m investment, focusing on mixed production lines

Porsche’s €250m Zuffenhausen plant transformation signals a new era in sports car production. The facility, embracing smart factory principles, integrates traditional and electric models, employs advanced technologies like AGVs, and anticipates the new generation Macan in 2024, marking a historic shift in efficiency and quality.

Ilkhan Ozsevim

Impact of UAW strikes could leave suppliers at financial risk

The impact of the recent UAW strikes could leave suppliers at financial risk, according to a supply chain and manufacturing legal expert.

Megan Kelly

Stellantis’ Factory Booster Day 2023 fosters OEM/supplier collaboration to solve automotive production challenges

The eighth instalment of Factory Booster Day produced ninety-nine solutions demonstrated by sixty-four partners to tackle thirty-five Stellantis plant challenges setting an example to other OEMs

Ilkhan Ozsevim

Watch: Pretreatment becomes modular and scalable

Dürr’s EcoProWet PT is an innovative pretreatment system for vehicle bodies that uses modular chambers instead of large dip tanks.

By Dürr, sponsor partner

Volvo Cars selects Ghent for production of EX30, aligning with Zhangjiakou to meet demand

With high interest for the compact EV SUV, Volvo Cars selects Belgium to ramp up production levels to meet both local and global demand.

Ilkhan Ozsevim

How digitalisation is ramping up battery cell production for EVs

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

Megan Kelly

Fanuc and Volvo Cars sign deal to transform automotive manufacturing with sustainable robotics

In a landmark collaboration, Fanuc, the global leader in industrial robotics, and Volvo Cars are to reshape auto manufacturing with sustainability at the forefront

Ilkhan Ozsevim

The future of Ford in a flash of lightning

The Ford Dearborn Truck Plant is a benchmark for managing complexity, quality and software, and is setting standards for the future. Plant manager Corey Williams shares learnings and lean principles across ICE production and fast-growing EV output at the plant’s newly expanded Rouge Electric Vehicle Center

Christopher Ludwig

Toyota Japan's production halt expands across ten assembly lines following supplier explosion

From explosions to system failures, Toyota Japan’s production standstills highlight the need for diverse supplier networks, robust safety measures and resilience

Ilkhan Ozsevim

West Midlands Gigafactory announces “advanced discussions” with leading Asian battery manufacturers

The Coventry site’s exclusive UK Gigafactory status makes it the key player in the country’s electrification drive. International investment to catalyse the process.

Ilkhan Ozsevim

Toyota addresses production system malfunction that put the breaks on Japanese production

The OEM finally releases statement regarding the nationwide disruption; identifying “insufficient disk space.”

Ilkhan Ozsevim

Watch: It becomes colorful: EcoSupply P – Special paint supply

Dürr’s special paint supply system EcoSupply P provides an almost unlimited number of paint colors quickly, economically and without residues

By Dürr, sponsor partner

Toyota’s production grinds to a halt in Japan amid system failure

The carmaker’s Japanese production suffers a sudden system failure, impacting one-third of global output and exposing supply chain vulnerabilities and recovery hurdles.

Ilkhan Ozsevim

BMW’s aspirations to the X degree in Spartanburg: Special series

The carmaker is investing in capacity, suppliers and people to prepare for EV production in South Carolina, with a focus on flexibility, resiliency and sustainability. Interviews with the plant CEO, Dr Robert Engelhorn, and key leaders in battery, logistics and training outline BMW’s huge ambitions in the region.

Christopher Ludwig

Master of complexity in Spartanburg

Dr Robert Engelhorn is leading transformation of BMW’s operations in Spartanburg, South Carolina for EV production, whilst ensuring manufacturing and workers remain highly flexible in managing vehicle variations and market changes.

Christopher Ludwig

Automation – boosting efficiency, flexibility and sustainability

Developments in hardware and increasingly sophisticated software and data management have created more opportunities for automated production systems. Automation expert Jörg Reger, managing director of ABB Robotics’ automotive OEM business line, discusses the challenges and opportunities created by the transition to electric vehicles.

Nick Holt

Scania to stop bus body production in Poland

Scania is set to gradually discontinue bus body production at its plant in Słupsk, Poland by 2024, instead outsourcing the production to local bodybuilders.

Megan Kelly

Focus on flexibility – optimising battery pack production

The AMS Evolution Livestream expert panel representing Ford, AMTE Power and Henkel, discussed the fast-changing production requirements as cell manufacturers and OEMs ramp up Gigafactories and battery pack assembly.

Nick Holt

Mercedes will use VAN.EA architecture for its next generation of midsize and large vans

Mercedes says starting 2026, all newly developed midsize and large vans will be built on VAN.EA, using three modules to allow for a clear differentiation between private luxury vans and premium commercial vans

Nick Holt

Shaping the future – Developing electric vehicle architectures

In our AMS Evolution Livestream experts from ArcelorMittal and Gestamp tackle EV production challenges and explain how digital tools, new technologies, processes and materials innovations could help solve some key issues

Michael Nash

Watch: EcoDryScrubber – paint booth efficiency through dry separation

The EcoDryScrubber separates paint overspray using finely ground limestone powder and highly efficient HEPA12 filters in just one filter stage – sustainable and without chemicals

By Dürr, sponsor partner

Form and function: Developing production processes and structures for electric vehicle architectures

As much as we read about battery cell development and production, in parallel the new electric vehicle architectures are also continuing to evolve as vehicle makers strive to find the optimum balance between platform flexibility to meet changing market demands for new models, while also being viable for high-volume production. To get some insights in to this ongoing process AMS spoke with Paul Belanger, Gestamp’s R&D Director for North America

Nick Holt

Christopher Ludwig

Developing EV architectures optimised for manufacturing

There’s more to electrification than batteries. We look at some of the developments and trends in designing and manufacturing electric vehicle platforms ahead our exclusive livestream featuring Gestamp and ArcelorMittal

Nick Holt

Renault 5 EV prototypes begin endurance testing and fine-tuning

Renault tests its new CMF-B EV platform, which will underpin the new Renault 5 model, due for launch in 2024

Nick Holt

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.

Christopher Ludwig

Renault-Nissan-Mitsubishi Alliance rebalances partnership

Revised partnership will see high-value-creation operational projects in Latin America, India and Europe including further platform sharing

AMS

Watch: The Paint Shop of the Future: flexible, scalable, efficient

Welcome to a whole new world of painting: Dürr‘s Paint Shop of the Future is flexible and scalable and offers efficiency across all the processes

By Dürr, sponsor partner

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

AMS

Honda Alabama starts production of all-new Pilot

Honda’s Alabama plant requires substantial production changes to build all-new Pilot SUV

AMS

Welcome to Automotive Evolution Europe 2022!

The 1st Automotive Evolution Europe took place December 6-7 in Munich. We welcomed colleagues and industry peers before the conference at the SZ Tower’s Panorama Lounge followed by a full day of back-to-back discussions with leading experts across Europe and more.

Christopher Ludwig

Future-proof Plant Munich - interview with Peter Weber, BMW

Christopher Ludwig caught up with Peter Weber, Director Plant Munich, BMW Group following the closing session of AMS Automotive Evolution Europe 2022.

Christopher Ludwig

Blossoming brownfields: rejuvenating Europe’s car plants

Peter Weber at BMW and Kjell Walöen at Volta Trucks joined the closing panel discussion at Automotive Evolution Europe to discuss how Europe is revamping production plants and ensuring their existing production plants can be as flexible and efficient as any greenfield.

Christopher Ludwig

Tier-1 transformation: fast-changing production for automotive suppliers

Arno Güllering at ZF and Stephen C. Nunn at Hardinge joined the sixth panel at Automotive Evolution Europe to discuss how to better understand what electrification means for tier-1 suppliers.

Christopher Ludwig

Material matters: body, forming and process transformation

Michel Peña at Teknia, Jesse Paegle at ArcelorMittal and Jonas Adolfsson at SSAB joined the seventh panel at Automotive Evolution Europe to discuss how new technology and materials are ushering in new innovations in manufacturing.

Christopher Ludwig

Managing an uncertain future in manufacturing

S&P Global Mobility, Magswitch and Next e.GO Mobile joined the fourth panel at Automotive Evolution Europe to discuss the volatile production environment, to which OEMs and suppliers must respond to mitigate disruption to production.

Christopher Ludwig

A tipping point: European automotive manufacturing outlook

Henner Lehne at S&P Global Mobility joined the third session with an in-depth presentation on the latest analysis and forecast for the European sector, including volume, regulations and OEM strategies in the face of disruption and changing business models.

Christopher Ludwig

Scaling up battery production in Europe

The second session of Automotive Evolution Europe was joined by Matthias Zentgraf at CATL, Francisco Carranza at Basquevolt and Lars Carlstrom at Italvolt to discuss production strategies, constraints and opportunities in ramping up output of EV batteries in Europe.

Christopher Ludwig

Data at the heart of Europe’s manufacturing evolution

Rüdiger Eck at Audi, Timothy McGrath, at BMW and Karthik Krishnamurthy at AWS joined the opening session of Automotive Evolution Europe which focused on opportunities in data analytics, artificial intelligence, digital simulation, cloud services and the digital tools that support them.

Christopher Ludwig