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. Anushka Dixit
JLR expands EV manufacturing with 50 new roles in material sourcing, traceability and supply‑chain risk As it transitions to electric vehicle production, JLR has added 50 roles to map material sources, secure battery minerals, and protect manufacturing operations from disruption and compliance risk. Ilkhan Ozsevim
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
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. Christopher Ludwig
Automotive expert Tunç Kip: Human-machine interfaces essential in boosting flexibility, quality, and performance in global manufacturing From the factory floor to upstream design, digital human-machine interfaces are enabling smarter, leaner, and more flexible vehicle production - but humans need to be at the centre of gravity for it to work. Ilkhan Ozsevim
How Arno Güllering wants DRÄXLMAIER Group to harness shopfloor visualisation and genAI in production and maintenance The tier-1 supplier has established a highly connected production and logistics network, with a strong emphasis on data visualisation and a roadmap for AI. But to stay competitive and resilient, COO Arno Güllering wants to ensure both plants and HQ have a mindset ready to embrace change. Christopher Ludwig
Mercedes-Benz blends AI, humanoid robots and craftspeople at its Digital Factory Campus to redefine the boundaries of human-machine collaboration in vehicle production At its Digital Factory Campus in Berlin, Mercedes-Benz is pioneering new forms of human-machine interaction, from generative AI agents to humanoid robots, blending physical and digital intelligence in its production system. Ilkhan Ozsevim
Toyota reorganises North American manufacturing into three pillars and seven regions as part of its long-term production and logistics strategy Toyota has unveiled a sweeping reorganisation of its North American manufacturing, dividing operations into three strategic pillars and seven regions, alongside executive changes aimed at EV growth and production agility. 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
How Mercedes-Benz, BMW and Dräxlmaier are using digitalisation, automation and AI to transform production, logistics and sustainability across their global manufacturing networks European automotive manufacturers are building digitally integrated production systems across their global operations to increase resilience, reduce emissions and prepare for new vehicle architectures and future technologies Götz Fuchslocher
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
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
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
Hyundai Motor Group to invest $21bn in US vehicle production, future tech, energy infrastructure and supply chains, targeting 1.2m unit capacity and 100,000 new jobs by 2028 Hyundai Motor Group is deepening its US manufacturing footprint with a $21bn investment through 2028. The Group is scaling production, localising components and developing future mobility and energy technologies to strengthen industrial resilience. Ilkhan Ozsevim
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
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
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
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. Ilkhan Ozsevim
BMW drives CO2 reduction with workforce engagement: Transformation only succeeds with head and heart The BMW Group is driving forward decarbonisation, digitalisation and modern leadership with ambitious CO2 targets and a clear strategy. Human Resources Board Member Ilka Horstmeier outlines the economic policy opportunities and challenges in this Q&A. By Andrea Hoffmann-Topp
How OEMs such as BMW, Toyota and Ford are harnessing data-driven decision making drive sustainability in automotive manufacturing Leading automotive OEMs and tier-suppliers are deploying cutting-edge data tools to transform their operations. This article explores how they are using AI and big data to enhance resource efficiency, reduce emissions, and pave the way for a greener future in manufacturing. 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
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. Timo Gilgen
BMW group plant Regensburg integrates hydrogen to reshape production logistics by 2030 The Regensburg plant is transitioning its logistics fleet from electric to hydrogen power. With hydrogen filling stations and efficient refuelling, this shift aligns with the bmw iFACTORY vision of a digital, sustainable production future. Ilkhan Ozsevim
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
“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
In Emden, Volkswagen wants to leave the Passat behind Volkswagen’s Emden plant has existed in northwest Lower Saxony for decades. Nowhere else is the change to electric drives so noticeable. With new logistics, new assembly and the new ID.7, a new era begins. Timo Gilgen
Virtual production networks are able to solve multi-level complexities across automotive manufacturing Virtual production networks provide automotive manufacturing with myriad solutions like advanced time- and cost-saving simulations, global collaboration capabilities, and innovative tools like digital twins to harness untapped production flexibility. Ilkhan Ozsevim
Toyota Motor Europe shuffles manufacturing leadership Toyota Motor Europe has made a series of changes to its manufacturing team leadership, including appointing a new vice-president. Megan Kelly
Porsche powers production with digital MHP FleetExecuter at Zuffenhausen as it expands it digital and automated ecosystem The Zuffenhausen plant is reaping the benefits of a digital ecosystem with Automated Guided Vehicles streamlining its production processes and preparing for wider deployment Ilkhan Ozsevim
Porsche plant in Leipzig wins Factory of the Year The Porsche factory in Leipzig, germany has won the ‘Factory of the Year’ award, presented by consulting firm Kearney and Automobil Produktion, a sister publication of AMS. AMS
Porsche launches all-electric Macan Porsche has revealed its first native all-electric model, the Macan SUV, using the Premium Platform Electric (PPE). Megan Kelly
How Farasis will bridge the EV battery gap in Europe The Chinese battery manufacturer’s new European general manager, Marcel Brömlage, will lead an evolving strategy in the region including increasing engineering and acquisition capabilities, and targeting automotive as well as non-automotive customers to support the growth strategy for the Siro joint venture and Farasis group. Christopher Ludwig
Design and manufacturing integration key to BMW’s Neue Klasse To realise large cost and emission savings on its EV architecture, BMW is redesigning vehicles and manufacturing in parallel, and rolling out rapid digital solutions. Christopher Ludwig
BMW Munich plant to go full electric with Neue Klasse and revamped, digital production system BMW’s home plant will produce only EVs by 2027, with much of the century-old factory rebuilt to meet new levels of efficiency and digitalisation, without missing a beat of ongoing production. Christopher Ludwig
BMW: ‘Flexibility is in our genes’ BMW, Mini and Rolls Royce are driving a tight electrification course. Nevertheless, the group remains open to drive diversity. In an interview, production director Milan Nedeljković talks about flexibility and the concept of the iFactory. Götz Fuchslocher
Panasonic sparks scalable and sustainable US battery production Abby Chitwood, who leads new product introduction and new factories at Panasonic Energy of North America, discusses maximising output and reducing emissions in battery cell production ahead of the first AMS Evolution North America conference, where she is a speaker. Christopher Ludwig
Gestamp joins Catena-X to push digital and decarbonisation strategies Gestamp has joined the Catena-X data-sharing platform, which is designed to increase visibility in the supply chain and improve the flow of parts and materials. Marcus Williams
McKinsey: Auto Industry’s shift towards EVs and digitisation could pose threat to European automotive manufacturing New McKinsey report judges threat in diminishing European automotive market share driven by innovation; calls for change and sets out roadmap steps to success Ilkhan Ozsevim
Watch: The advance of automation: what next-gen vehicles and batteries mean for robotics OEMs are transforming not only their respective vehicle types, transitioning to electric and connected models, but also the manufacturing operations to build these new vehicles. This creates challenges in integrating new vehicle architectures, powertrains and electronics into existing manufacturing facilities, boosting demand for more advanced automation.
On advanced robotics, skills and training: “Machines can’t do everything” Next-generation vehicles require new production processes, above all in automation, digitalisation and employee qualifications. Carolin Platz from the Auto-Motive Academy and Jörg Reger from automation expert ABB discuss the intersection of major topics in scaling up EV manufacturing. Götz Fuchslocher
Volta Trucks partners with ZF Commercial Vehicle Solutions for core systems for its all-electric urban delivery truck Scandinavian electric vehicle OEM, Volta Trucks, partners with ZF Commercial Vehicle Solutions (CVS) to leverage their expertise and tech, accelerating the advancement of the Volta Zero—a fully electric 16-tonne truck designed for urban deliveries Ilkhan Ozsevim
Audi uses AI for quality control of spot welds Audi is using artificial intelligence (AI) to improve its quality control in spot welds in car body construction. Megan Kelly
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
AMS Summer 2023 – JLR goes electric In our AMS Summer digital edition, we have features on JLR’s plans to transform its end-to-end industrial system, ready for new electric models, Seat’s technical upgrades to production operations and upskilling the workforce and insights into developments at Audi’s Neckarsulm plant, and more. AMS
A culture of quick decisions for Mercedes-Benz production Jörg Burzer, the carmaker’s manufacturing chief, explains how it has reorganised its production network for electric vehicles and powertrains, while speeding up the rollout of digital tools. Now, another phase of change is just ahead. Pascal Nagel
Manufacturing in the metaverse BMW has designed its latest production plant at Debrecen in Hungary entirely using digital tools, virtually simulating every detail, including production processes, robot cells and workstations, even before construction has begun Mike Farish
Ford opens $2bn carbon-neutral EV assembly plant in Cologne Ford has opened the Cologne Electric Vehicle (EV) Center which will produce a new generation of EVs for the European market and will be Ford’s first carbon neutral assembly plant. Megan Kelly
Neckarsulm – Audi’s plant prepares for more electric vehicles Audi’s Neckarsulm plant manager Fred Schulze discusses sustainability and digitalisation, and shares some insights into the transformation of the factory and its importance within the Audi production network Michael Nash
Rising vehicle production could signal ‘tougher’ market in H2, says analyst The manufacturing market could experience a tough second half of the year as output increases, backorders are filled and pricing becomes more competitive, threatening OEM profitability. Megan Kelly
A friend of flexible lines – upgrading JLR production for EVs and more Barbara Bergmeier is driving digitalisation, sustainability and resilience across JLR’s operations. Now she will help ramp up EV and battery output whilst keeping manufacturing flexible Nick Holt Christopher Ludwig
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
BMW to produce Neue Klasse in China from 2026 The BMW Brilliance Automotive (BBA) joint venture has announced it will build the next model generation, Neue Klasse at its production plant in Shenyang Nick Holt
Powering up: AMTE ramps up cell production volume AMTE CEO Alan Hollis discusses ramping up cell production, establishing a new Gigafactory and developing a flexible, sustainable manufacturing approach Nick Holt
Seat: Digital tools, shopfloor innovations and multi-brand manufacturing After stints at Volkswagen in Portugal and Spain, Markus Haupt has returned to his professional roots in Barcelona. As the board member in charge of production and logistics, he now has the fortunes of Seat’s manufacturing operations in his hands. Here, he talks about the special aspects of the Iberian Peninsula, good ideas from the shop floor, and the logistical challenges of the recent past Pascal Nagel
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
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 Siemens
Kia starts building facility for electric purpose-built vehicle (PBV) production The new plant will be dedicated to production of Kia’s electric PBVs, with planned annual capacity of 150,000 units Nick Holt
Re-evaluating recycled materials Carmakers are increasingly looking into ways of reducing the environmental impact of their vehicle manufacture – and one way to do this is by using more recycled materials in their cars. But how can they go about this? James Bakewell
Operators, cobots and mobile robots work in harmony How introducing autonomous mobile robots and collaborative robots, manufactured and supplied by Omron, can help achieve a modernised and more sustainable factory Omron
Virtual production underway in BMW Group’s future plant Debrecen NVIDIA Omniverse is enabling virtual production in the plant more than two years before actual series production is launched Rebecca Morley
VW Group and PowerCo to establish battery cell gigafactory in Canada The plant will be located in St. Thomas, with production set to begin in 2027 Rebecca Morley
VW-backed Scout Motors to establish manufacturing plant in South Carolina The plant will build next-generation trucks and rugged SUVs, harkening back to Scout vehicles produced from 1960 to 1980 Rebecca Morley
Mercedes-Benz’s groundbreaking ceremony for new Kuppenheim battery recycling factory Mercedes-Benz says it is investing a ‘double-digit million euro amount’ in the construction of the balance sheet CO2-neutral plant Rebecca Morley
BMW Group’s Leipzig plant prepares production of electric Mini Countryman The company says this will be the first time that a Mini model is produced entirely in Germany Rebecca Morley
Britishvolt bought by Australian company Recharge Industries According to the BBC, Recharge Industries intends to start by focusing on batteries for energy storage and hopes to have those products available by the end of 2025. It then intends to produce batteries for high-performance sports cars. Marcus Williams Rebecca Morley
Seat’s Martorell site celebrates 30th anniversary The Martorell, Spain, factory has built more than 12m units of 45 car models in the past 30 years Rebecca Morley
BMW’s San Luis Potosí plant to build EVs based on Neue Klasse platform BMW is investing €800m in its Mexican production site to integrate production of the full-electric Neue Klasse models and construction of local high-voltage battery assembly AMS
Dacia – building on a successful formula Speaking to AMS, Carlos Carrinho, General Manager Dacia Vehicle plant Mioveni, discusses the factory’s unique position within the realm of European car manufacturing and how it has been continuously developing to meet future production challenges Michael Nash
Microvast to supply battery packs for REE Automotive commercial EV platforms Microvast’s MV-C Gen 4 lithium-ion battery packs to power REE’s P7 commercial EV platforms with REEcorner technology AMS
Britishvolt collapse a shock to UK’s electric vehicle goals The collapse of Britishvolt’s battery manufacturing ambitions in the UK, which was announced last week, is a setback for the UK automotive sector as it strives to become a competitive market for electric vehicle production. Marcus Williams
Multi part integrated BIW solutions and advanced steel grades support EV production PARTNER CONTENTThis content was paid for by ArcelorMittal and produced in partnership with Automotive Manufacturing SolutionsArcelorMittal Global R&D Head of Automotive Steel Solutions, Jérôme Favero discusses how the company’s Multi Part Integration solution is an innovation that has been driven by the challenging context of Battery Electric Vehicle production ArcelorMittal
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
AMS Automotive Evolution Europe – a review from Munich 2022 The first AMS Evolution Europe Summit explored how the region’s automotive industry is transitioning away from internal combustion engine vehicles, with experts from BMW, Audi, ZF CATL and more discussing speeding time to market, greater agility in production, factory conversion and boosting battery cell manufacturing in the region Michael Nash
More than moving parts – autonomous mobile robots The fundamental changes in the type of vehicles emerging from automotive manufacturing plants worldwide most obviously the increasing proportion of electric vehicles (EVs) are also having repercussions for the development of another type of vehicle – autonomous mobile robots Mike Farish
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
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
Ford upgrades its Cologne plant to be the European Electrification Centre Next year, Ford’s first fully electric volume model in Europe will roll off the production line in Cologne, and the site will become the first Ford Electrification Centre in Europe. AMS spoke with Rene Wolf, Director of Manufacturing Vehicle Operations at Ford of Europe and member of the Management Board of Ford-Werke GmbH. He describes the changes that will take place as the plant gears up for this new era of electrification Michael Nash
