North America’s powertrain reality check At the Automotive Manufacturing North America 2025 conference in Detroit in October, Eric Anderson, associate director for Americas Powertrain & Compliance Forecasting at S&P Global Mobility, outlined a data-driven assessment of the region’s outlook. Anushka Dixit
EU carmakers say 2035 CO2 targets unworkable Europe’s leading automotive executives are pressing Brussels to rethink its car and van CO2 rules, warning that rigid 2030 and 2035 targets are no longer realistic amid rising costs, import dependence and trade barriers. Ilkhan Ozsevim
Why range extenders, hybrids, and hydrogen ICEs still matter in the EV era Mahle Powertrain’s Mike Bassett tells AMS how advanced simulation, clean-sheet design, and targeted hybrid integration are driving the development of next generation internal combustion engines for EV platforms. Nick Holt
Renault names François Provost as new group CEO Veteran executive to lead Renault Group through its next phase of industrial evolution, with a strong focus on global partnerships, innovation and manufacturing agility. Ilkhan Ozsevim
Welcome to the new AMS experience We’ve redesigned the AMS website to deliver sharper insight, faster access and a smoother, more intuitive experience at a time when you need it most. Nick Holt
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
Hybrid powertrains will continue to support the transition to vehicle electrification Weak EV demand, critical mineral supply challenges and tariff-driven market uncertainty keeps hybrid vehicles in the big picture for model development and production investments. Ian Henry
GM invests $888M in Tonawanda plant to build next-gen V-8 engines for trucks and SUVs General Motors is reinforcing its commitment to American manufacturing and high-performance engines with a $888m investment in its historic Tonawanda Propulsion plant. The funding supports production of GM’s sixth-generation V-8 engines, powering full-size trucks and SUVs while bridging the gap to an electric future. AMS
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
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
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
As automotive manufacturing digitises, new smart factory roles in AI, data and IIoT are replacing traditional shopfloor jobs and transforming skills requirements As automotive manufacturing becomes more intelligent, connected and software-defined, factory roles are shifting. New digital profiles are emerging, while traditional ones risk becoming obsolete. Chris Löwer
China’s rare earth magnet export ban threatens global EV and automotive manufacturing, as US, European and Asian carmakers scramble to secure critical materials The global automotive sector is facing renewed disruption as China tightens control over exports of heavy rare earths and magnets. With EV powertrains and chips at risk, OEMs are now racing to diversify supply. Ilkhan Ozsevim
Stellantis and Factorial Energy validate breakthrough solid-state batteries with fast-charging FEST technology and target 2026 EV demonstration fleet integration Stellantis and Factorial Energy have validated high-density, fast-charging solid-state battery cells. Their collaboration now aims at optimising battery packs for efficiency and introducing a 2026 EV demonstration fleet. Ilkhan Ozsevim
Honda’s $1bn redevelopment of its Ohio plants sets a global precedent in integrating EV, hybrid and ICE production with smart manufacturing and supplier transformation. Honda North America’s upgraded Ohio operations will be its template for flexible production of ICE, hybrid and electric vehicles on a single line. Project lead Mike Fischer speaks to AMS about the goals, planning and execution behind this major production shift. Nick Holt
Hyundai Motor Group advances hybrid technology with dual-motor transmission and electrification systems for higher efficiency and performance Hyundai Motor Group has revealed its next-generation hybrid system, combining a dual-motor transmission, turbocharged engines and electrification technologies that enhance power, fuel economy and ride refinement across its model range. Ilkhan Ozsevim
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
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. AMS
Lucid acquires Nikola’s former Arizona facilities and offers jobs to over 300 former employees as it scales up EV manufacturing and testing operations Lucid has struck a deal to acquire two former Nikola facilities in Arizona, adding nearly 900,000 sq. ft to its production and testing capacity and offering jobs to over 300 ex-Nikola workers as it scales EV production Ilkhan Ozsevim
Jaguar Land Rover accelerates EV production with hairpin winding machines for high-efficiency electric motors at its Wolverhampton site At its Wolverhampton plant, Jaguar Land Rover is deploying high-speed hairpin winding machines to increase electric motor performance while retraining its workforce for a future of electric propulsion. Ilkhan Ozsevim
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
HORSE accelerates digital twin integration at Valladolid to optimise powertrain production, enhance sustainability and redefine EV manufacturing strategies HORSE, the Renault-Geely joint venture, is harnessing digital twins at its Valladolid plant to transform powertrain production, boost flexibility in EV output, reduce emissions and embed data-driven decision-making across its operations. Ilkhan Ozsevim
Mercedes-Benz accelerates AI and robotics at Berlin-Marienfelde, transforming digital production with humanoid robots and next-generation automation technologies At its Berlin-Marienfelde site, Mercedes-Benz is integrating artificial intelligence and humanoid robotics into automotive production. With new digital tools and axial-flux motor technology, the factory is setting new global standards for intelligent manufacturing. Ilkhan Ozsevim
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
BMW plants prepare for a new era with Neue Klasse production As BMW gears up production towards its Neue Klasse electric vehicles, the factories are to remain flexible. Gotz Fuchslocher looks at the strategies the manufacturer is pursuing as it prepares to launch production of the new models. Götz Fuchslocher
Evolution of EV platforms: Innovations in design, manufacturing, and scalability Electric vehicle architectures must be adaptable, scalable, and cost-effective, but evolving battery technologies, crash protection, and manufacturing processes add complexity. While the skateboard design has become standard, innovations like gigacasting and hybrid adaptability are reshaping the industry. Automakers are racing to refine EV platforms, balancing speed to market with efficiency and safety in an increasingly competitive landscape. Nick Holt Anushka Dixit
BMW’s Neue Klasse redefines electric mobility with advanced Software-Defined Architecture and high-performance energy management BMW’s Neue Klasse redefines electric mobility with a software-centric vehicle platform, high-voltage 800V battery technology and four advanced computing modules. A new era of efficiency, flexibility, dynamic performance and seamless energy management is emerging? By Andrea Hoffmann-Topp
EU invests in AI to transform automotive manufacturing with ‘AI smart factories’, automation and next-generation production technologies The EU’s new InvestAI fund will inject €200 billion ($208.4bn) into AI, transforming European automotive manufacturing. With AI gigafactories and smart factory technology, this initiative aims to drive automation, digitalisation and next-generation production systems. Ilkhan Ozsevim
Honda North America’s big investment in flexible manufacturing for EVs, hybrid and ICE vehicles Honda invests $1 billion in retooling its Ohio manufacturing plants to build ICE, hybrid, and EV models on same production line. New technologies being introduced include megacasting, CDC and friction stir welding. Nick Holt
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
AAM’s $1.4bn acquisition of GKN Automotive could mark a major shift in automotive manufacturing, strengthening its position in driveline systems and electrified vehicle production American Axle & Manufacturing’s $1.4 billion acquisition of GKN Automotive is set to reshape global automotive manufacturing, strengthening its position in driveline systems and EV production as the industry moves towards electrification Ilkhan Ozsevim
HORSE launches new high-performance eMotor production at Aveiro, Portugal, for hybrid and plug-in hybrid vehicles, enhancing automotive electrification HORSE, a leader in hybrid and combustion powertrain solutions, has started producing its high-performance eMotor at Aveiro, Portugal. Designed for hybrid and plug-in hybrid vehicles, the motor delivers 49kW and 212Nm torque, with a capacity of 160,000 units annually. Ilkhan Ozsevim
Coventry and Warwick Gigapark aims to transform UK EV battery production amid competition and policy pressure The Coventry and Warwick Gigapark seeks to anchor the UK’s position in Electric Vehicle (EV) battery Production. With 5.7m sq.f of industrial space, incentives, and a central location, it’s a critical response to ZEV mandates and global competition. Ilkhan Ozsevim
BMW Group strengthens circular economy through SK tes battery recycling, advancing sustainability in Europe and beyond The BMW Group has launched a partnership with SK tes to recycle high-voltage batteries across Europe. This closed-loop process reclaims critical materials such as cobalt, nickel, and lithium, boosting sustainability and reducing supply chain risks. Ilkhan Ozsevim
BMW’s San Luis Potosí plant in Mexico is driving global sustainability with solar power, water reuse, and AI-driven carbon reduction BMW’s San Luis Potosí facility in Mexico exemplifies sustainability in action. From solar energy to water recycling and AI-driven efficiency, the plant demonstrates how local, effective green innovation can reshape automotive production on a global scale. Following a site visit, AMS delves into the facility’s world-leading sustainability intiatives. Ilkhan Ozsevim reports. Ilkhan Ozsevim
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
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. Megan Kelly
Ford’s Halewood facility begins production of electric drive units strengthening the UK’s role in EV manufacturing The electrification of Ford’s Halewood plant is more than just a strategic pivot; it’s a testament to the company’s vision for sustainable automotive manufacturing. By producing over 420,000 electric drive units annually, the plant will power Ford’s top-selling EV models and support Europe’s transition to zero-emission vehicles. Ilkhan Ozsevim
Exclusive: How Henkel is co-developing the EV batteries of the future at its Battery Engineering Center PARTNER CONTENT This content was produced by Automotive Manufacturing Solutions in partnership with Henkel. Henkel, a global leader in adhesives, sealants and functional coatings, inaugurated its revolutionary Battery Engineering Center (BEC) within its Inspiration Center Düsseldorf (ICD) in November last year. Henkel invited AMS as its first visitor, to take a tour of the Battery Application Center (BAC) and Battery Test Center (BTC) within the BEC and the innovations happening inside. AMS
Watch: Henkel invites AMS for an exclusive look inside its Battery Engineering Center PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with HenkelHenkel, a global leader in adhesives, sealants and functional coatings, inaugurated its revolutionary Battery Engineering Center (BEC) within its Inspiration Center Düsseldorf (ICD) in November last year. Henkel invited AMS as its first visitor, to take a tour of the Battery Application Center (BAC) and Battery Test Center (BTC) within the BEC and the innovations happening inside. AMS
Honda sets up a demonstration production line for all-solid-state batteries Honda’s demonstration production line will support development for the mass production of solid-state batteries. Nick Holt
Stellantis launches, new multi-energy platform for body-on-frame trucks and SUVs Stellantis has launched its STLA Frame platform which supports internal combustion, hybrid, hydrogen, battery electric and range-extender electric vehicle powertrains. Nick Holt
BMW reinforces EV production quality with first phase go-ahead for new Wackersdorf battery testing centre in Germany BMW’s Wackersdorf facility, now home to an advanced battery testing centre, highlights the automaker’s push towards sustainability and precision in electric vehicle production. The €100 million ($105.65m) investment underscores BMW’s commitment to innovation. Ilkhan Ozsevim
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… Ilkhan Ozsevim
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. 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
SAMES’ solutions: precise assembly processes for battery packs PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with SamesAs the electric vehicle (EV) market grows, the need for efficient and safe battery pack assembly intensifies. Benoit Batllo from SAMES shares how the company tackles challenges in applying critical materials like dielectric coatings, fire protection coatings, and thermal conductive adhesives (TCAs) AMS
Automotive Manufacturing Solutions Magazine – Issue 2, 2024 Issue 2, 2024 of Automotive Manufacturing Solutions is out now, with a focus on the North American manufacturing sector, EV and battery production projects, hybrid powertrains, and much more. This issue includes insights from BorgWarner, BMW, Ford and Stellantis. Purchase print edition Nick Holt
Oyak Horse celebrates production of 7.5 million engines at its Türkiye plant while expanding its workforce with 100 new jobs and scaling output to meet rising hybrid demand Oyak Horse has achieved the milestone of producing 7.5 million engines at its Bursa, facility, in Türkiye. As hybrid demand grows, the plant adds 100 jobs, expands to a third shift, and increases daily output. The company continues to play a key role in low-emission powertrain solutions for global markets. Ilkhan Ozsevim
Hybrid powertrains – building the bridge to e-mobility The future of internal combustion engines (ICE) is being extended through growing demand for hybrid powertrains as OEMs rebalance EV product line-ups. Nick Holt
Tier suppliers – Adapting to new challenges BorgWarner shares insights into how the company is leveraging existing assets and using mergers and acquisitions to boost electric vehicle component production. Nick Holt
Scania progresses production by integrating remanufactured components on its main assembly line, reducing material use by 50% and cutting carbon emissions by 45% Scania has become the first truck OEM to integrate remanufactured components directly into the main assembly line. The innovative approach aims for a circular economy in vehicle production. Ilkhan Ozsevim
Hyundai and Skoda sign MOU on hydrogen tech collaboration Hyundai and Skoda will work together on hydrogen fuel cell technologies for mobility applications. Nick Holt
Audi’s electric hopes rest on Györ Györ plays a special role in Audi’s production network. Just as important as the approximately 176,000 vehicles produced each year are the almost 1.7 million drives produced. Now Györ must make the transition to electromobility. Werner Beutnagel
Volvo’s 100% EV strategy shift: facing the unavoidable truth Lower-than-expected EV sales continues to have repercussions for production plans, with Volvo the latest vehicle maker to delay 100% EV target. Ian Henry
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
Denso expands electrification-focused inverter line and sustainable digital production Denso is bolstering its position in the electrification market with the launch of inverter production at Denso Fukushima. Simultaneously, the company has unveiled plans for a next-generation, fully automated plant at Zenmyo, set to modernise ECU production with 24-hour unmanned operation and sustainable energy use. Ilkhan Ozsevim
BMW and Toyota’s mixed powertrain approach sees collaboration to produce Fuel Cell Electric Vehicle options for passenger cars Utilising a fuel cell powertrain, developed in collaboration with Toyota, BMW plans to launch its first-ever series production fuel cell electric vehicle (FCEV) in 2028. Nick Holt
Valmet Automotive’s battery business to become an independent company Valmet Automotive is making its Electric Vehicle Systems business an independent company with its own leadership. The company says it plans to target markets beyond automotive. Marcus Williams
Musk halts Tesla Mexico gigafactory until after US election Tesla has paused its plans to build a new gigafactory in Mexico until after the US presidential election in November, as Donald Trump has pledged to impose a 100% tariff on vehicles made in Mexico. Megan Kelly
Toyota West Virginia starts production of new hybrid transaxle Production of this fifth-generation hybrid transaxle is part of Toyota’s multi-pathway approach to electrification. Nick Holt
Toyota to build EV battery plant for Lexus in Japanese island Toyota Motor is planning to build an EV battery plant for its Lexus brand in the Japanese island of Kyushu, according to Japanese newspaper Nikkei. Megan Kelly
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
European battery production needs greater speed and agility Exhibitors at this year’s Battery Show in Stuttgart shared insights into EV and battery production challenges and how the industry needs to adapt with greater speed. Nick Holt
Ampere supports Renault Group with LFP technology and cell-to-pack solutions Ampere will integrate LFP (Lithium Iron Phosphate) technology to complement NCM batteries (Nickel Cobalt Manganese) and create a European value chain. Nick Holt
GM, Stellantis and Volvo Group to gain $1.7 billion in EV grants The US federal government is set to contribute $1.7 billion in grants to GM, Stellantis, Volvo Group and more to support increased EV production. Megan Kelly
Amplify Cell Technologies begins construction of Mississippi battery cell factory Amplify Cell Technologies’ new plant will have an annual manufacturing capacity of 21GWh for the production of LFP battery cells. Nick Holt
Arno Güllering lands Chief Operating Officer position at Dräxlmaier after ZF Arno Güllering has been appointed Chief Operations Officer (COO) of the Dräxlmaier Group, effective July 1, 2024, for which he will be responsible for the company’s production and logistics functions. Ilkhan Ozsevim
HORSE Powertrain welcomes Aramco as strategic investor, leveraging chemical expertise Aramco invests 10% in HORSE Powertrain Limited, a joint venture by Renault Group and Geely. This partnership will enhance the development of sustainable powertrains and synthetic fuels, driving the future of automotive decarbonisation. Ilkhan Ozsevim
The future may be all electric, but not just yet With demand for battery electric vehicles lower than expected, OEMs are boosting hybrid output and extending ICE production. Ian Henry
Europe’s tariffs on Chinese EV imports stresses importance of local production The European Commission (EC) has decided to impose additional tariffs of up to 38% on Chinese EVs following preliminary results of its anti-subsidy investigation, which found that prices are being distorted by Chinese state support. Megan Kelly
HORSE announces next-generation Range Extender powertrains HORSE has introduced innovative Range Extender powertrains for passenger and light commercial vehicles. Offering a 200km electric range plus an additional 600km from an onboard engine, this technology reduces battery size by over 50%, cutting costs and weight. Ilkhan Ozsevim
GKN Automotive reduces direct CO2e emissions in 2023 GKN Automotive has published its second sustainability report, revealing a 10.5% reduction in CO2e emissions in 2023. Nick Holt
Honda starts production of fuel cell electric vehicles in the US The 2025 CR-V e:FCEV fuel cell electric vehicle is now being produced at Honda’s Performance Manufacturing Center (PMC) in Marysville, Ohio. Nick Holt
ACC halts construction of two European gigafactories Automotive Cells Company (ACC), with its shareholders Stellantis, Mercedes-Benz and TotalEnergies subsidiary Saft, has halted the construction of two of its three planned European gigafactories. Megan Kelly
Vitesco Technologies supplies electric drive system for Honda plug-in fuel cell vehicle Vitesco’s EMR3 axle drive will be integrated into the Honda CR-V e:FCEV and will be the first time this system has been used for a hydrogen fuel cell vehicle. Nick Holt
Volkswagen announces new affordable European EV Volkswagen Group has announced that it will make all-electric entry-level mobility widespread across Europe, with affordable EVs made in the continent, for the European market. Megan Kelly
Q&A with Patrice Haettel: CEO of powertrain technology company HORSE Renault’s powertrain tech company, HORSE, has begun mass-producing the Power Electronics Box (PEB); crucial for HEVs and PHEVs. The redesigned PEB boosts performance by managing Emotors more efficiently. Here’s CEO, Patrice Haettel on electrification and more. Ilkhan Ozsevim
Bosch Ventures invests in battery recycling startups Bosch Group’s venture capital unit, Bosch Ventures, has made significant investments in Cylib and Li Industries, two battery recycling startups. Megan Kelly
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
