Benteler starts work on advanced manufacturing plant in Morocco, boosting job creation and integrating Industry 4.0 technologies 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. Ilkhan Ozsevim
Škoda Auto breaks ground on new paint shop to boost flexibility, reduce emissions and support EV-ICE production at Mladá Boleslav by 2029 Škoda Auto has started construction on a next-generation paint shop at its Mladá Boleslav plant. Due to open in 2029, the facility will support EV and ICE models, enhance surface quality, and reduce emissions by 28% Ilkhan Ozsevim
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
ABB PixelPaint revolutionises the automotive paintshop PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with ABB Robotics.The paintshop has always been one of the most expensive and least sustainable areas of any production facility. Joerg Reger, Head of Automotive at ABB Robotics discusses the challenges and how the company has created a revolutionary solution. AMS Editorial
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
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
Skoda expands manufacturing operations with new Vietnam assembly plant Skoda has officially begun local assembly of its Kushaq SUV and Slavia sedan at a newly established facility in Vietnam’s Quang Ninh province. Developed in partnership with Thanh Cong Group, the plant marks a significant step in Skoda’s global expansion, strengthening its foothold in Southeast Asia’s rapidly growing automotive market. Nick Holt
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
Mercedes-Benz introduces new paint finish to improve sustainability at Wörth plant In a move toward reducing the facility’s carbon footprint, the Mercedes-Benz plant in Wörth is rolling out a new painting technology for its truck cabs, which is expected to cut energy consumption by up to 40%. Nick Holt
JLR expands sustainable paint facilities with £65m ($80m) investment to meet soaring demand for personalised luxury vehicle finishes across its brands JLR is expanding its paint operations with a £65m ($80m) investment, meeting soaring demand for bespoke vehicle finishes while cutting energy and water use at key sites in the UK and Slovakia. Ilkhan Ozsevim
Volkswagen de México opens world’s 1st fully electric paintshop at Puebla plant Volkswagen de México has launched the first fully electric paint shop in the automotive industry, eliminating natural gas use and improving sustainability. The Puebla plant’s advanced automation, AI-driven quality control, and renewable energy integration is a step toward carbon-neutral vehicle production. AMS
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
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
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
This is how JLR’s quest for paint perfection is being realised through ostrich feathers and sustainable innovation JLR turns to ostrich feathers for unparalleled paint perfection. Combining sustainability with cutting-edge innovation, these feathers ensure flawless finishes while enhancing eco-friendly manufacturing. Ilkhan Ozsevim
ABB robotics partners with ESS to advance simulation tools for cost savings, efficiency, and emissions reduction in automotive paint shop operations ABB’s collaboration with ESS marks an important step in digitising automotive manufacturing in paintshop. By harnessing advanced simulation technology, the partnership aims to cut paintshop costs by up to 30 percent and reduce emissions significantly, while levelling the digital playing field. Ilkhan Ozsevim
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
“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
Henkel celebrates 100 years of automotive innovation and sustainability PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with HenkelHenkel is celebrating its 100-year anniversary serving the automotive industry. To mark this milestone, the company speaks to AMS about its heritage, its impact on the industry today, and how Henkel will shape the vehicles of the future. AMS
Dürr builds an energy-efficient paintshop for Stellantis’ Kenitra plant Stellantis’ new paintshop to double capacity at Kenitra plant and reuse paint robots from other facilities. Nick Holt
HORSE powertrain continues to expand supply in range extender market HORSE will supply Brazilian EV start-up manufacturer Lecar with its HR10 range extender engine, to be fitted to the Lecar 459 hybrid. Nick Holt
BMW’s Debrecen plant hits fossil-free milestone with gas-free, sustainable Paintshop The Debrecen plant, set to launch pre-series production of the Neue Klasse, boasts a modern paint shop powered by renewable energy. Innovative technologies like power-to-heat, Heat Grid, and eRTO look to achieve maximum resource efficiency and sustainability. Ilkhan Ozsevim
Mahindra & Mahindra to pioneer ABB’s Inkjet paint technology in Indian EV market Mahindra & Mahindra partners with ABB Robotics to implement PixelPaint technology in its new EV line. The innovative system ensures precise paint application with minimal waste; a key step in automotive personalisation and efficiency for the Indian market. Ilkhan Ozsevim
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
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
PPG to build new paint and coatings manufacturing facility in the US PPG plans to build a new paint and coatings manufacturing facility in Tennessee as part of $300m investment in advanced manufacturing in North America. Nick Holt
Ford Otosan manufacturing for an economy in transition Ford Otosan has upgraded its manufacturing facilities in Turkey to ensure the Transit is ready for an electrified future Mark Smyth
Perfecting paint transfer by focusing on improving efficiency in vehicle exterior paint application The paintshop is an area of the production process where throughput, quality and sustainability need to be carefully balanced. Paint application specialist, Sames, looks at key areas where efficiencies can be made. SAMES
Bentley prepares electric future with groundbreaking for new paintshop as part of £2.5 bn investment program As part of Bentley’s ambitious Beyond100 strategy, a state-of-the-art paintshop breaks ground in Crewe, signifying a leap towards Battery-Powered Electric Vehicle (BEV) production and a commitment to sustainability, innovation and digital manufacturing Ilkhan Ozsevim
AI + I = Enhanced Automotive Surface Inspection AI and automation are becoming key technologies for surface inspection in the paintshop, but human workers are still providing the finishing touches. Report by Michael Nash. Michael Nash
Audi’s Brussels revolutionises sustainability with freshwater reduction initiative To reduce waste and energy consumption paintshops are deploying a range of strategies, innovative processes and materials to meet new sustainability targets. Report by Mike Farish Mike Farish
How the Audi Q6 e-tron series is proof of the OEMs flexible and sustainable vehicle production ecosystem Audi’s Ingolstadt plant pioneers sustainable manufacturing with net-zero emissions, showcasing flexible integration and cutting-edge technology: Q6 e-tron leads the way Ilkhan Ozsevim
Artificial intelligence – New developments in surface inspection AI and automation are becoming key technologies for surface inspection in the paintshop, but human workers are still providing the finishing touches. Michael Nash
“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
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
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
JLR expands EV production to Slovakia JLR has used the fifth anniversary of its plant opening in Nitra, Slovakia to announce that it will develop the plant to produce electric vehicles by 2030. Nick Holt
UAW workers start strike against GM, Ford and Stellantis Members of the United Auto Workers (UAW) union have started a strike against the ‘big three’ Detroit OEMs GM, Ford and Stellantis, after their contracts expired and no agreements were reached. Megan Kelly
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
BMW Batteries blossoming in South Carolina The carmaker’s battery assembly plant in Woodruff will use advanced automation and help set global standards, whilst supporting a local-for-local drivetrain production strategy, says Rich Everly, who is leading battery pack production. Christopher Ludwig
Mercedes and Dürr enter decade-long partnership for sustainable paint shops Mercedes-Benz has entered into a long-term strategic partnership with painting technology group Dürr with the aim of making vehicle painting CO2-free. 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
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
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
Focus on efficiency: new solutions for paintshop improvement Milan-based FIDIA Automotive Engineering Systems has two new patents currently pending that could provide significant savings for carmakers in the form of energy consumption and downtime reduction in paintshops Michael Nash
Electric ovens – sustainable, efficient paintshop technology Climate neutrality, increased costs and uncertainties with the natural gas supply are prompting car manufacturers to intensify their search for alternatives to gas-powered production plants. Dürr discusses how its electric paintshop ovens can significantly reduce CO2 emissions Dürr
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
Painting a brighter day: increasing speed, reducing errors in paintshop Sébastian Salze at SAMES and Robin Kaufmann at FANUC joined the eighth panel at Automotive Evolution Europe to discuss optimising processes and reducing waste in the paintshop. 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
After baptism of fire, BMW plant has room to grow in Mexico Under Harald Gottsche, plant director and CEO of the OEM’s San Luis Potosi facility, BMW has launched new models during the pandemic, navigated supply disruptions, integrated new technology and maintained staff levels – and it’s ready to integrate more production to serve global markets. Christopher Ludwig Peter Murphy
BMW trials pioneering hydrogen burner in Leipzig paint shop The flex-fuel burner can use hydrogen, methane or any mix of the two in paint dryers, one of the biggest sources of energy demand in car making. Peter Murphy
Ford’s e-coating edge for the new Ranger’s chassis frames A key element of a $1bn investment by Ford Motor Company to upgrade operations at its manufacturing plant at Silverton on the outskirts of the South African capital of Pretoria is a completely new e-coating facility for chassis frames Mike Farish
Lotus opens new sports car manufacturing facility at Hethel The Chapman Production Centre is already building the Emira, the last petrol-powered car from Lotus and is latest stage of £100m redevelopment of the company’s UK facilities AMS
Ineos prepares for production As Ineos moves towards a second phase of prototypes for production, AMS visited the company’s new automotive manufacturing plant in Hambach, France to see how production of its Grenadier 4x4 is developing ahead of series production launch in August. Mark Smyth
Porsche: Inside the Macan paintshop During our recent AMS Livestream on developing and operating more sustainable, flexible paintshops, Henning Steinborn, head of paintshop and Klaus Koberg, who is head of paintshop Maintenance, both from Porsche’s Leipzig plant, offered some insights into how the premium vehicle maker has developed its paint operations Nick Holt
Innovation drives paintshop performance at Skoda Just over two years after it opened, the new paintshop at Skoda’s Mladá Boleslav plant is fulfilling all the objectives set for it when it first went into operation. Mike Farish
Porsche’s smarter, greener paintshop Hear from leading paintshop experts at Porsche’s Leipzig plant on strategies for improving quality and reducing errors in paintshop, including new automation and processes to reduce overspray waste AMS
AI data analytics for the paintshop The presence of any airborne dust in a paintshop always presents a challenge to creating a high-quality paint finish. Effective filtration is the most basic way to prevent contamination but for BMW that is not enough. Mike Farish reports on how the OEM is using artificial intelligence (AI) and data analytics to develop better preventative measures Mike Farish
A lighter coat: how Porsche and suppliers are reducing waste and errors in paintshop Paintshop leaders from Porsche and Sames Kremlin spoke to AMS in an exclusive livestream and interview regarding innovations in technology and new approaches in the automotive painting process. Jason Dunn Christopher Ludwig
Watch: Paint it green – more sustainable, flexible paintshops When it comes to the future of paintshop, green is the only colour going. This exclusive AMS Livestream features paintshop leaders from Porsche and Sames Kremlin sharing innovations in technology and collaborative approaches to maintain speed and quality whilst reducing energy and waste in automotive painting processes. AMS
GM invests $4 billion to prepare Spring Hill and Detroit-Hamtramck plants for EV production General Motors is moving forward with investments to equip its factories to produce electric vehicles (EVs). The Spring Hill, Tennessee plant gets a $2 billion upgrade to produce the Cadillac Lyriq and the and Detroit-Hamtramck plant will see $2.2 billion invested to produce the recently unveiled GMC Hummer EV. Illya Verpraet
AMS Podcast Episode 07 – Perfecting the paintshop To get some insight into how vehicle makers are adapting their paintshop operations to meet the needs of electric vehicle production and improve the sustainabilty of the paint process, Nick Holt spoke to Dennis Taljan, general manager for PPG’s Automotive OEM services division Nick Holt
Event preview – Surcar North America: Virtual Summit 2020 Automotive coating experts set the scene as networking opportunities reconvene Gareth Price
Toyota sees positives in its electrostatic paint atomiser innovation Across the group, the OEM anticipates lower consumption and more compact paintshop design as a result of deploying the new technology AMS
New recycle system at Bentley puts waste water to work A paintshop water treatment innovation is helping Bentley achieve sustainability targets and reduce consumption Gareth Price
Production records set at Skoda’s domestic plants As it marks the 125th anniversary of the company, Skoda is chalking up record-breaking output Gareth Price Ian Henry
GM Arlington: expansion and inspection on the Texas SUV lines Upgrades at the home of GM’s full-size SUV production help to launch the new Chevrolet Tahoe and Suburban models for 2020 Gareth Price
Nissan lines up its next-gen factory technology In preparation for its next generation of electrified, intelligent and connected vehicles, Nissan is introducing a programme of major advancements in its production operations Gareth Price
Painting sideways With its new paintshop at Mladá Boleslav, Skoda is bringing some unique approaches to conveying and curing Mike Farish
Lamborghini puts the AI in paint Lamborghini’s chief manufacturing officer Ranieri Niccoli speaks to AMS about the key features of the company’s new paintshop in Sant’Agata Bolognese Mike Farish
Two become one in the Audi paintshop Saving time, resources and environment impact, the OEM has introduced new overspray-free paintshop technology that can apply two colours in one process Gareth Price
Success for Seat Spain’s biggest exporter has turned its finances around and looks to have a bright future Ian Henry
A two-tone finish Bi-colour coats and enhanced quality assurance are high on the agenda in the paintshop at SEAT’s Martorell factory. Michael Nash gets an inside look Michael Nash and Bi-colour coats and enhanced quality assurance are high on the agenda in the paintshop at SEAT’s Martorell factory. Michael Nash gets an inside look
The clean machines Paintshop cleanliness is a vital aspect of the coating application process. Mike Farish finds out what it takes to keep the paint finish blemish-free Mike Farish
