Manufacturers integrate digital tools and teamwork to futureproof flexible production across ICE, EV and hybrid assembly lines Leading manufacturers reveal how cross-functional collaboration, real-time data and advanced automation are strengthening agility and flexibility across assembly lines, with lessons from Bosch, BorgWarner and Renishaw 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
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
Will Volkswagen’s surplus German plants become Chinese production operations? As European vehicle makers continue to face challenging global markets and increased costs, many are having to make difficult decisions around underutilised production operations. Ian Henry looks at how Chinese OEMs could potentially buy or utilise some of Volkswagen’s production sites. Ian Henry
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
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
Shifting gears – Electrifying the driveline GKN Automotive has a long history as a driveline component and system developer, and manufacturer. Like many of the leading tier suppliers in this segment, the company has now added a range of products for electric powertrains to its range. Jorge Beja, VP of Operations Systems shares some insights into production at the company’s centre for excellence for eDrive systems, at Bruneck, Italy. 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
AlixPartners reveals 60% of automotive executives are struggling to prioritise disruptions in the shift towards EVs and software Automotive production facing significant disruptions from EVs and software shift, global consulting firm AlixPartners’ 2024 Disruption Index (ADI) reveals. 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
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
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
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
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
Stellantis and Samsung SDI choose Indiana for second US Gigafactory Stellantis and Samsung SDI have announced that their joint venture StarPlus Energy will build its second US gigafactory in Kokomo, Indiana. Megan Kelly
BMW’s aspirations to the X degree in Spartanburg: Special series The carmaker is investing in capacity, suppliers and people to prepare for EV production in South Carolina, with a focus on flexibility, resiliency and sustainability. Interviews with the plant CEO, Dr Robert Engelhorn, and key leaders in battery, logistics and training outline BMW’s huge ambitions in the region. Christopher Ludwig
Chipmaker JV to build €10 bn semiconductor plant in Germany Semiconductor manufacturers Robert Bosch, Taiwan Semiconductor Manufacturing Company (TSMC), Infineon Technologies and NXP have established a plan for a joint venture to invest in a new semiconductor plant in Dresden, Germany. Megan Kelly
Ford restarts electric F-150 Lightning production in Dearborn following retooling and expansion The OEM has retooled its Rouge Electric Vehicle Center to build 150,000 units per year at, and is increasing manufacturing capabilities to produce more trim options. Ilkhan Ozsevim
Adopting circular economy principles in car production As the automotive industry looks at how to be more eco-friendly, car companies are taking various approaches to lower emissions across their manufacturing operations. Experts at Stellantis and Mazda speak about the implementation of circular economy principles in vehicle production Michael Nash
Going green: Self-generating electricity on-site When it comes to production in the automotive industry, companies including Ford and Audi are increasingly looking at how they can source the energy they use in a more environmentally efficient way. One way to do this is by generating electricity on-site Mike Farish
Renault advances circular economy reuse, remake, recycle business The pioneering initiative will reduce the resource, energy and emissions intensity of a car’s lifecycle since some components can have a second life as used, reconditioned parts. Peter Murphy
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
Renault Trucks to recover, resell parts from used vehicles in circular economy push The recovery of used parts suitable for re-sale builds on the company’s existing initiative to refurbish and modernise second-hand trucks. Peter Murphy
Fast fashion – how Tata is keeping up with changing tastes in India’s car market Consumers in this populous Asian market are showing willingness to spend more for fresh products and extra features. Peter Murphy
An exclusive focus on flexibility as OEMs look to modular-based manufacturing Modular production in automotive manufacturing is rapidly becoming more innovative and flexible with the ability to multitask. As a result, OEMs are increasingly rethinking their methods and working closely with technology providers to make flexible manufacturing hegemonic. Jason Dunn
Audi introduces closed-loop systems for aluminium, wastewater and plastic Audi has detailed how it is introducing closed-loop systems to its plants as part of its goal to make all its five plants carbon-neutral by 2025. This includes aluminium, wastewater and a pilot project for chemical recycling of plastics. Illya Verpraet
People get ready: recruitment and retention in a complex automotive industry With contributions from Volkswagen, Toyota, BMW and Audi, AMS looks at some of the strategies OEMs are using to attract and retain employees with the skills needed to work in modern digitalised workplaces – and to adapt to cutting-edge developments in hybrid, electric and autonomous vehicles … Abigail Williams
A proactive approach Predictive maintenance offers big gains in production efficiency. Mike Farish looks at some examples of how these systems have been developed and applied Mike Farish
Made in Wales Nick Gibbs reports on the opening of Aston Martin’s SUV plant in South Wales, all set to build the new DBX Nick Gibbs
