Tag: process improvement

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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

Key steps to building flexibility into production operations

The need for agility and flexibility in automotive manufacturing operations is greater than ever. AMS spoke with Trent Randles, Engineering Manager - Transfer Case Assembly & Operational Excellence at BorgWarner, about key steps towards developing agile production processes.

Nick Holt

Volvo announces 3,000 job cuts as EV sales drop and projects react

Volvo Cars is reducing its workforce by 3,000, primarily in Sweden, as part of a $1.9 billion cost-cutting plan. The move follows a significant decline in electric vehicle sales and a strategic shift in the company’s electrification goals.

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

5G networking: How JLR is building smarter factories

As manufacturing operations become more data-driven, traditional network technologies are struggling to keep up. Steve Mason, JLR’s Advanced Digital Technologies Manager for Global Industrial Operations speaks to AMS about the integration of 5G networks into factory environments.

Nick Holt

Edge computing and AI: Transforming manufacturing at the source

In modern manufacturing, edge computing is becoming a game changer, enabling faster, more secure, and more efficient operations. Steve Mustard, an expert with the International Society of Automation (ISA), spoke with AMS on how this technology is shifting traditional processes and how it’s set to evolve with artificial intelligence.

Nick Holt

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

New whitepaper: BASF and Catena-X: Creating a more connected and efficient automotive industry

This whitepaper provides an in-depth look at how BASF, as a top 30 global automotive supplier, is leveraging Catena-X to enhance supply chain transparency, ensure regulatory compliance, and drive efficiency.

Future-ready: BMW’s digital transformation of its Munich plant and beyond

As the global automotive market pivots toward sustainability and electrification, BMW isn’t just adapting its product portfolio it’s reengineering the entire production operation, prioritising flexibility, digitalisation, and long-term operational efficiency. Plant Munich director, Peter Weber discusses the company’s approach to digitalising production.

Nick Holt

Digital twin technology is bridging the physical and digital worlds in automotive manufacturing

OEMs and Tier suppliers are actively deploying digital twin solutions to enhance their manufacturing capabilities. This article explores the latest trends, ongoing developments, key challenges, and critical steps in deploying digital twins in the automotive industry.

Nick Holt

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

hofer powertrain and Pollmann International accelerate EV powertrain manufacturing

hofer Powertrain and Pollmann International have teamed up to accelerate the industrialisation of next-generation electric powertrain solutions. The partnership aims to bring advanced EV powertrain technologies to market faster.

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

Solving EV battery pack development, cost and production challenges

James Eaton, CEO of IONETIC, discusses the evolving landscape of EV battery pack development and production, focusing on the challenges facing low-volume manufacturers. Eaton shares insights into the importance of cost optimisation, flexible manufacturing, and overcoming the unique challenges of electrifying commercial vehicles such as buses.

Nick Holt

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

Rolls-Royce invests £300m to extend Goodwood manufacturing facility

The £300m site extension will expand Bespoke and Coachbuild capabilities, driven by a 10% increase in Bespoke content value per motor car year-on-year, and support future EV production.

Nick Holt

Thomas Dose discusses leadership, diversity, and challenges at BMW’s Chennai Plant

How do you go from being a consultant to being a plant manager? Thomas Dose, managing director of the BMW plant in Chennai, India, talks in an interview about his path, the challenges and opportunities in India and the importance of diversity and sustainability.

Ronja Schmiedchen

Automotive OEMs and suppliers look to continued development of smart factories and the deployment of digital tools to optimise production operations

The concept of the smart factory offers highly efficient, optimised production operations. Ford, ZF and PPG reveal how they are working to realise this potential.

AMS

Hyundai Motor and Kia Introduce X-ble Shoulder to boost industrial efficiency and worker safety

Hyundai Motor and Kia have revealed the X-ble Shoulder, a wearable robot aimed at transforming industrial efficiency and reducing workplace injuries. With plans for global expansion and a broader product lineup, the companies are leading innovation in wearable robotics.

Ilkhan Ozsevim

Gestamp employs gigastamping and advanced material solutions to drive lightweighting and sustainability

The Spanish supplier believes it is well prepared for the transformation of the automotive industry. Innovations from a wide range of areas are intended to help. The company presented some of these at the IZB in Wolfsburg.

Timo Gilgen

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’ 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

Nissan to cut 9,000 jobs globally, reduce Mitsubishi stake and bolster US and China EV plans as profits continue to decline

With profits down 85 per cent year-on-year, Nissan is moving to align production with sales projections and reduce its Mitsubishi stake, while accelerating its EV push to compete in critical markets. The automaker’s revised strategy includes job cuts, cost reductions, and renewed alliances as part of its Arc turnaround plan.

Ilkhan Ozsevim

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

Mercedes-Benz Trucks Mannheim plant to start production of eActros 600 components

Series production of the eActros 600 will start at the end of November this year at the Mercedes-Benz plant in Wörth supported by components produced at Mannheim.

Nick Holt

Smart manufacturing: Data, AI, and digital transformation

The process of digitalising manufacturing operations continues to change rapidly with new software and hardware developments and the growing application of artificial intelligence, but challenges remain in optimising these opportunities.

Nick Holt

Mercedes-Benz opens battery recycling facility to create a closed loop system

The new recycling facility, located in Kuppenheim, Germany, will utilise an integrated mechanical-hydrometallurgical process.

Nick Holt

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

GM Ventures invests $10m in Forge Nano to improve EV battery performance and reduce costs

General Motors drops the Ulitum brand and shifts from single chemistry approach. The OEM has also entered into a strategic partnership agreement with Forge Nano to collaborate on atomic layer deposition applications for GM’s electric vehicle batteries.

Nick Holt

EV batteries – Increasing quality and reducing costs

A new eBook from Hexagon examines how AI and smart factories are revolutionising EV battery manufacturing, helping Europe and North America catch up with China.

Hexagon Manufacturing Intelligence

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

Honda expands new energy vehicle manufacturing in China with new Wuhan plant

Honda opens its first dedicated new energy vehicle (NEV) production plant in Wuhan, China, boosting its electric vehicle production capabilities with advanced automation and eco-friendly technology.

Nick Holt

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

EV transition slowdown and domestic politics challenge the US Big Three in new and unexpected ways

US automakers face a tangled web of tariffs, union issues, and a slowing EV market. The threat of Chinese competition looms large, while the IRA’s complex rules create new challenges. Ford, GM, and Stellantis are each fighting to navigate these obstacles.

Ian Henry

How cobots can support automotive production

Cobots enrich the industry with their ability to complete tasks in close cooperation with humans and are becoming increasingly intelligent thanks to modern technologies. This article takes a look at the different types of robots, and their benefits to the industry.

Ronja Schmiedchen

Werner Beutnagel

Megacasting: a new frontier or unfounded flare-up for automotive production?

From Tesla to Volvo, Megacasting is gaining traction. While it offers efficiency and sustainability benefits, challenges remain. Stellantis, however, remains unconvinced.

Ilkhan Ozsevim

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

EV battery testing – new software supports testing rapidly changing battery technologies

New battery technology is being developed, and testing companies are focused on the same old parameters. But change could be on the horizon with new software.

Michael Nash

Skoda builds updated Octavia at Kvasiny

Skoda shuffles production to add Octavia to Kvasiny and free up capacity at Mlada Bolslav for Enyaq and Elroq models.

Nick Holt

GM continues path towards 2040 carbon neutral target

General Motors (GM) boosts renewable energy sourcing and reduces natural gas consumption to support sustainability targets.

Nick Holt

Antolin, Gestamp and Fersa using AI to improve production operations

Autoparts from Spain, a collaborative digital project among automotive suppliers that provides intelligence on the automotive equipment and components industry, reports that the radical transformation of the industry supported by artificial intelligence (AI), is providing opportunities for tier suppliers, with benefits already registered by members Antolin, Fersa Bearings and Gestamp.

Marcus Williams

Poor financial results and slow EV transition forces Nissan to rethink plans

Nissan looks to cut production costs and rebalance production operations in the face of poor financial results.

Ian Henry

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

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

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

Designing manufacturing systems for flexibility and scalability

Comau discusses assembling e-drives, developing battery manufacturing solutions, and collaborations with universities for next-generation cells.

AMS

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

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

Quality data drives F1 peak performance

Formula one cars represent the pinnacle of automotive engineering and behind the scenes, high quality components and manufacturing data are key to on-track success. Oracle Red Bull Racing offered AMS a glimpse of its championship winning engineering operations.

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

JLR boosts training to build electric cars

JLR says 95% of its global retail partner technician workforce is now EV trained, with further training underway for 11,000 manufacturing colleagues to build BEVs.

Nick Holt

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

Nissan to transition to low-CO2 emission aluminium by 2030

Through sourcing and using low CO2 emission aluminium, Nissan aims to significantly reduce CO2 emissions.

Nick Holt

Exclusive: BMW Group improves efficiency with additive manufacturing gripper

BMW Group has improved the speed, versatility and sustainability of its manufacturing and cut costs by using 3D-printed bionic robot grippers. Automotive Manufacturing Solutions reports on the latest innovations from the BMW Group Additive Manufacturing Campus and manufacturing plant in Munich.

Megan Kelly

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

How Mercedes-Benz and Seat are transforming their plants

Michael Bauer, regional head of production at Mercedes-Benz and Jose Arreche, plant manager at Seat emphasised the importance of data and digitalisation in the transformation of their plants at the Automobil Produktion Kongress 2024, but stressed the evolving role that people will play in production.

Timo Gilgen

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

Quality control: 3D vision inspection systems

LMI Technologies offers insights into current trends in automotive quality control requirements and the technology solutions available.

AMS

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

Danny Auerswald to lead Volkswagen Saxony, bringing global production expertise

Danny Auerswald will assume the position of managing director at VW Saxony starting July, overseeing technology and logistics at the Zwickau, Chemnitz, and Dresden plants. His leadership will guide a fully electric production network. Auerswald succeeds Robert Janssen, who transitions to executive vice-president, overseeing production and product management at SAIC Volkswagen in Shanghai.

Ilkhan Ozsevim

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

Rivian secures $827m funding, plans expansion and brings in Javier Varela as new COO

Rivian secures $827m in public funding from Illinois Department of Commerce & Economic Opportunity despite announcing 10% workforce cuts earlier this year. Javier Varela appoitned new COO ahead of R2 production

Ilkhan Ozsevim

Honda grows its North American EV footprint

Honda is investing heavily in growing its electric vehicle production operations in North America but is also leveraging expertise and capacity for hybrid powertrain production

Nick Holt

Toyota Motor North America announces key production leadership changes

Toyota Motor North America (TMNA) is undergoing significant leadership changes in its manufacturing operations, with the retirement of Jim Zehmer, president of TABC, and Wes Woods, president of Toyota Missouri and Toyota Tennessee, and the appointment of Oscar Villarreal as interim president of TABC and Todd Williams as Woods’ successor, marking a pivotal transition in the company’s manufacturing leadership.

Volvo Cars realigns manufacturing, procurement and supply chain management

The departmental integrations reflect a broader industry shift which recognises a streamlined and holistic approach as key to carmaker successes.

Ilkhan Ozsevim

VW focuses on Chinese market boosting cost competitiveness and local partnerships

VW seeks to strengthen its position in the Chinese automotive market through achieving cost reductions in production and boosting local partnerships

Nick Holt

OEMs jointly develop green battery prototypes with Henkel

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Henkel More OEMs are looking to build their own EV batteries in-house to streamline production and logistics and have more visibility on costs and efficiencies. In a fast-paced competitive market where technologies evolve and overtake one another quickly, carmakers are keen to keep their progress under wraps – particularly when it comes to battery prototypes. But they are making an exception for the purpose of recycling and repair, according to Henkel’s battery sustainability expert, Philipp tho Pesch.

AMS

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

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

Nissan North America announces leadership shakeup

The leadership shakeup involves both interdepertmental and international appointments across production and R&D

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

Nissan launches its new Arc business plan

In line with other vehicle makers, Nissan is adapting its production strategy to rebalance its ICE and electric vehicle output and address rising costs and market fragmentation

Nick Holt

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

Mercedes-Benz has entered into an agreement to explore the use of Apptronik’s humanoid robots for its automotive manufacturing ecosystem

The carmaker partners with Apptronik to integrate Apollo robots, potentially revolutionising production lines with collaborative automation, addressing labour challenges and advancing the future of automotive manufacturing.

Ilkhan Ozsevim

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

Changing dynamics– developing the next generation of vehicle architectures

Building electric vehicles has demanded big changes in OEM production operations and increased support from tier suppliers. Gestamp’s director of R&D North America, Paul Belanger, shares some insights into the company’s development and how it’s managing the engineering challenges around EVs

Nick Holt