Tag: robotics

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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

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

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

Augmented reality, AI, cobots and digital twins are transforming automotive production by enhancing worker training, planning, inspection and collaboration

Human-machine interfaces are becoming central to car production. With AR, cobots, AI inspection and digital twins, OEMs like Ford, Volvo, GM and Mercedes are reshaping the way people and machines interact.

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

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

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

Ilkhan Ozsevim

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

Volvo Cars begins EX30 electric SUV production at Ghent, adding jobs and capacity to meet high demand across Europe

Volvo Cars has started building its best-selling EX30 EV at its Ghent plant, investing €200m ($227m) to expand flexible production, create hundreds of new jobs and align output more closely with growing European demand.

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

How Mercedes-Benz Bremen manages combustion, hybrid and EV builds while preparing for Maybach and AI-driven smart production without going fully electric

In an interview with Timo Gilgen, the Bremen plant manager talks about his understanding of leadership, identifies the challenges facing the location, and explains how the north manages to build ten different models simultaneously and why a purely electric plant is not an option.

Timo Gilgen

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

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.

Audi pioneers virtual control systems with Siemens and Broadcom to transform production efficiency and digital automation in its Böllinger Höfe bodyshop

Audi is rolling out virtual programmable logic controllers at its Böllinger Höfe site with Siemens, Broadcom and Cisco, replacing hardware with cloud-based automation to enhance agility, scalability and environmental efficiency

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

JLR expands EV production with 150 new UK roles supporting Range Rover Electric and next-generation electric vehicle manufacturing

JLR is expanding its UK workforce with 150 new maintenance roles to support EV production. With Solihull and Wolverhampton at the heart of its transformation, the company is investing in people, technology and electrification.

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

Henkel’s Bergquist Liqui Form TLF 6500 CGel-SF enhances ADAS thermal performance, ensuring reliability, efficiency, and sustainability in next-generation automotive electronics

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with HenkelADAS technology demands high-performance computing, generating heat that risks system efficiency and longevity. Henkel’s Bergquist Liqui Form TLF 6500 CGel-SF provides advanced thermal management, reducing stress on components and enhancing sustainability in production.

AMS

Honda upgrades production with advanced processes for 2026 Passport models

Innovative manufacturing enhances efficiency, quality, and ergonomics at Alabama Auto Plant.

Nick Holt

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

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

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

Audi is transforming vehicle production with AI-powered image processing, eliminating errors and setting new standards for quality control and smart factory innovation

Artificial intelligence is accelerating transformation in automotive production. Audi’s Industrial Computer Vision is proving how AI-driven image processing enhances quality control, minimises defects and paves the way for scalable smart factory innovation.

Ronja Schmiedchen

How AI-powered humanoid robots are changing auto manufacturing at BMW, Tesla, and Mercedes-Benz

Humanoid robots powered by AI and advanced robotics could transform automotive manufacturing and production processes. Companies like BMW, Tesla, and Mercedes-Benz are preparing for a wider deployment of these robots to enhance efficiency, address labour shortages, and improve factory automation with capabilities like adaptive learning, human-robot collaboration, and real-time decision-making.

Anushka Dixit

How AI is transforming automotive manufacturing: A deep dive into key technologies, optimisations and efficiency gains

Automotive production is undergoing a seismic transformation with Artificial Intelligence driving unprecedented innovation. From predictive maintenance to autonomous robotics and generative design, here’s how AI is enhancing precision, adaptability and efficiency.

Anushka Dixit

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

JLR’s Rudy the Robot will be hard at work this Christmas in Gaydon

JLR will be using an automated robot over Christmas to carry out a lifetime of door usage checks within 12 weeks, completing 84,000 door shuts.

Megan Kelly

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

BMW conquers Mexico with sustainable production at San Luis Potosí: "It's about more than cars"

The BMW factory canteen in San Luis Potosí serves cactus salad made from nopal leaves – harvested in the gardens on the factory premises. An example of the site philosophy: using local resources, promoting sustainability and delivering the highest quality.

By Andrea Hoffmann-Topp

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

Watch now: How to maximise efficiency in battery tray manufacturing and integration

This webinar showcased innovative, cost-efficient quality processes to assure 100% quality in battery manufacturing. New quality solutions from Hexagon enable automakers to detect defects efficiently and ensure a perfect fit into the underbody of the car.

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

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

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

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

Watch Now: Next-Gen Gapfillers: Henkel’s Blueprint for Automotive Electronics

This webinar explored Henkel’s latest innovations in thermal gap fillers, designed specifically for automotive electronics.

Global IT outage affects Mercedes-Benz production

The global IT outage that hit industries across the world today has affected automotive manufacturing across the world, causing problems for the automotive manufacturing industry globally.

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

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

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

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

Comau’s Innovations and Solutions in Battery Manufacturing

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with ComauComau offers complete battery manufacturing solutions, from assembly and testing of battery packs to integration into vehicles.

AMS

Sames solves for BMW & Mercedes: Adhesive tech in bodyshop & glazing

Sames’ innovations support high-quality adhesive bonding in automotive manufacturing, optimising efficiency and standardisation across bodyshop and glazing processes.

SAMES

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

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

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

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

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

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

DESIGN4PRODUCTION brings together leaders in automotive production, design, and engineering

Explore the future of automotive design and manufacturing at Design4Production in Munich on 15 May and join leading designers, engineers and production leaders on Automotive design and manufacturing experts as they discuss how to accelerate innovation, efficiency and sustainability.

AMS

Magna has landed a major eDrive system contract for a niche, high-end vehicle Original Equipment Manufacturer in North America

Magna has landed a crucial contract to provide a specialised eDrive system for a well-known North America-based OEM, marking a pivotal step in the automotive industry’s shift towards electric mobility

Ilkhan Ozsevim

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

Rising labour costs become biggest concern for automotive manufacturing

Rising labour costs and skills shortages are the biggest concern for the automotive manufacturing industry this year, according to the latest AMS & ABB Automotive Manufacturing Outlook Survey 2023.

AMS

Watch Now: Shaping the future: How electric vehicles are driving manufacturing decisions

Dive into the intricacies of EV platform design with industry experts from Gestamp and ArcelorMittal. Looking at how current trends are influencing manufacturing processes and the balance between innovation, sustainability, and efficiency.

AMS & ABB Automotive Manufacturing Outlook Survey 2023 results: A positive outlook despite evolving challenges

Download our latest global survey results to gain expert insight into automotive manufacturing trends, gauge the current sentiment across the automotive sector and learn about the broader industry outlook for 2024 and beyond.

AMS

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

Henkel supports innovation with 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, has opened its revolutionary Battery Engineering Center within its Inspiration Center in Duesseldorf, to address the need to improve safety, performance, quality and price of EV batteries.

AMS

The state and stipulation of automotive production: Retrospect 2023 to prospect 2024

Using 2023 as a launchpad into the coming trends of 2024, we take a dive into the coming automotive production trends set to shape the industry

Ilkhan Ozsevim

AMS Winter 2023/24 – BMW’s battery boost

Our Winter digital edition takes an in-depth look at how OEMs are getting to grips with developing and manufacturing new electric vehicles and powertrains

AMS

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

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

Ilkhan Ozsevim

Ford’s Paul Stephens on EV opportunities and greenfield sites

Following the ‘Greenfield of Dreams: Building the Future of Automotive Production’ keynote and panel discussion at AMS Automotive Evolution North America, AMS was eager to catch up with Paul Stephens, Manufacturing Transformation Lead for Ford Motor Company, to learn more.

How digitalisation is ramping up battery cell production for EVs

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

Megan Kelly

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

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

Ilkhan Ozsevim

The future of Ford in a flash of lightning

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

Christopher Ludwig

AMS Autumn 2023 – Continental Shift

In this latest AMS digital edition we have a special focus on the North American automotive industry as the region’s OEMs make big investments in electric vehicle and battery production

AMS

Battery production and design need to be optimised together, says Volvo Trucks and ABB

Václav Švub from ABB Robotics and Wenting Hu from Volvo Trucks pointed to the benefits of aligning battery engineering and production processes in an exclusive AMS livestream, including opportunities in automation, new materials and production processes.

Ilkhan Ozsevim

How Vitronic’s Weldloop software reimagines the welding process

Find out how Weldloop’s technology achieves quality enhancements in automotive welding through machine vision technology.

Ilkhan Ozsevim

Rising EV production boosts demand for more advanced automation

The increase in EV demand and production is causing OEMs to look for more advanced automation, as new equipment, systems and manufacturing processes add challenges to already complex production networks, according to experts at electrification and automation supplier ABB.

Megan Kelly

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.

Technical partnerships – AMS Expert Interview with Magswitch

As the automotive industry seeks to reduce costs and improve efficiencies and productivity, we are seeing an increasing number of partnerships being formed. It’s nothing new to this industry but these new relationships are proving much more necessary and beneficial than previously

Nick Holt

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

Ready for the next generation in Spartanburg

As BMW prepares to build EVs and batteries in Spartanburg, it has expanded training programmes, with emphasis on safety, change management and youth outreach. The head of talent and training, Paul Sinanian, is focused on preparing for the decades ahead.

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

Automatica 2023: Revealing key trends shaping the automotive manufacturing industry

The Automatica exhibition 2023 focused on smart automation and robotics, with 650 exhibitors and 40,000 attendees from 88 countries. AMS speaks to leading experts who were there on the main takeaways from the show.

Ilkhan Ozsevim

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

Joining forces – technical partnerships supporting vehicle manufacturers

As the automotive industry seeks to reduce costs and improve efficiencies and productivity, there are a growing number of new partnerships being formed. Experts from automation specialist Magswitch discusses how these new relationships are proving more necessary and beneficial than previously.

Nick Holt

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