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
Europe’s EV industry faces china threat, recycling gaps and tariffs, warns SSAB PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with SSAB.SSAB’s Erik Nymann warns Europe’s BEV industry must move faster to counter China’s battery dominance, US tariffs, and a widening gap in recycling and infrastructure warned that Europe’s electric vehicle industry faces mounting pressure from geopolitical shifts, battery imports, and weak recycling systems. Michael Nash reports. AMS
How circular economy targets are driving new strategies in automotive design, sourcing and supply chain integration across EVs, batteries and interiors Leading OEMs and suppliers are no longer treating circularity as an end-of-life concern. Design, sourcing and localisation strategies are being rethought to prioritise reuse, remanufacture and material traceability from day one. Ilkhan Ozsevim
Volvo Cars to use recycled, near zero-emission steel in 2025 models under SSAB deal Volvo Cars has signed an agreement with Swedish steelmaker SSAB to begin using recycled, near zero-emission steel in its manufacturing operations from 2025, reinforcing its goal to reach net-zero emissions by 2040 and increase circularity across its supply chain. AMS
Inside JLR’s circular manufacturing push: How reused tools and digital systems are driving EV production and decarbonisation across its global network Tomasz Jozwiak explains how Jaguar Land Rover is driving circularity across its operations by reusing and refurbishing manufacturing assets, cutting emissions, saving millions, and supporting electrification. Ilkhan Ozsevim
Volkswagen appoints Dr. Werner Tietz as new head of Group Research and Development Volkswagen Group has announced that Dr. Werner Tietz, currently the Executive Board Member for Research and Development at SEAT S.A., will take on the additional role of Head of Group Research and Development at Volkswagen Group, effective July 1, 2025. AMS
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
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.
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
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
EU allows automakers flexibility for 2025 emissions targets to be averaged over 2025-2027, easing regulatory pressure The European Commission has eased 2025 CO2 targets, averaging them over 2025-2027. While this relieves short-term pressure, it raises concerns over Europe’s ability to stay competitive with China in the EV race. 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
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
BMW i Ventures backs Phoenix Tailings to reshape rare earth metal refining, securing a sustainable and ethical US supply chain for clean energy and manufacturing Phoenix Tailings secures funding from BMW i Ventures to scale its innovative rare earth metal refining. The milestone supports a zero-waste, zero-emission automotive future while fortifying US supply chains for clean energy and automotive production Ilkhan Ozsevim
How algae can turn CO2 emissions into sustainable carbon fibres CO2 to carbon? Yes, it’s possible! Researchers at the Technical University of Munich are binding carbon dioxide using algae and using it to produce high-quality carbon fibers. The process works, there’s just one hurdle. Chris Löwer
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
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
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
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
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
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
How BMW is ‘Designing for Circularity’ to become a sustainability leader in automotive production BMW’s Roberto Rossetti, Total Vehicle Life Cycle Development, elucidates BMW’s innovative ’Design for Circularity’ approach. From using recycled materials to optimising vehicle disassembly, BMW is redefining how vehicles are produced and consumed. Ilkhan Ozsevim
Northvolt slashes workforce by 1,600 as Europe’s largest EV battery manufacturer stumbles with slow demand, scaling issues, and Chinese competition, pausing major expansion plans Northvolt, once the great hope for Europe’s EV battery industry, is shedding 1,600 jobs and shelving expansion plans. With slow market demand and fierce Chinese competition, Europe’s green ambitions face a critical test, leaving Northvolt to recalibrate its strategy. Ilkhan Ozsevim
Stellantis invests $406M in three Michigan plants for EV and multi-energy strategy Stellantis commits over $406M to three Michigan facilities to ramp up production of electric vehicles, including the Ram 1500 REV and electrified Jeep Wagoneer, in line with its Dare Forward 2030 strategy for sustainable mobility. Ilkhan Ozsevim
Lowering costs through sustainable manufacturing Sophisticated and complex technologies could be used to reduce costs and make manufacturing more eco-friendly, but simple solutions might be the most effective Michael Nash
Reinventing the wheel: the race towards sustainable tyre production Nokian Tyres is building the world’s first zero-carbon tyre factory, with Michelin, Continental, Bridgestone, and Pirelli leading the charge with recycled materials, bio-based components, and innovative sustainable production methods. Ilkhan Ozsevim
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
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
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
Gestamp signs agreement with Acciaieria Arvedi for the supply of low-emissions steel Gestamp will return high-quality steel scrap from stamping parts production to Acciaieria Arvedi, who will reprocess and reintroduce it into the production cycle. Nick Holt
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
BeyonCa sets stage for Hong Kong’s automotive jump with new EV assembly plant Renault (and Dongfeng)-backed BeyonCa plans to transform Hong Kong’s automotive sector with its first EV brand and assembly plant in Tseung Kwan O, potentially shifting towards high-tech production post-2019 protests and COVID-19 challenges. 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
The Sustainable Steel Automotive Manufacturing Survey 2024 Webinar looks at issues of definition, recycling and cost Thomas Hörnfeldt, VP of Sustainable Business at SSAB spoke to Nick Holt and Daniel Harrison of AMS on the survey findings. Do terminological issues serve as barriers to sustainable steel? Ilkhan Ozsevim
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
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
APK 2024 – Increasing circularity in automotive production Circular economy programmes are becoming a key part of automotive manufacturing sustainability strategies, but these should be more ambitious says Dr Michael Riesener, speaking at this year’s Automobil Produktion Kongress. Nick Holt
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
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
BMW builds gigafactory for Neue Klasse in Mexico BMW Group is taking its ‘local for local’ approach to manufacturing and supply chain to Mexico, and has started construction on an 80,000 sq.m battery manufacturing facility next to its assembly plant in San Luis Potosi. The plant is due to start making the Neue Klasse electric sports activity vehicle there from 2027. Marcus Williams
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
Watch on demand: Sustainable Steel Automotive Manufacturing Survey 2024 Webinar Discover the latest insights from a cutting-edge discussion featuring AMS and SSAB on the key challenges faced by automotive OEMs, tier suppliers and other stakeholders in transitioning to sustainable steel.
Automotive Manufacturing Solutions Magazine – Issue 1, 2024 Issue 1, 2024 of Automotive Manufacturing Solutions is out now, with a focus on sustainability with insights from JLR and GKN Automotive, and supporting features on manufacturing engineering with BMW and Gestamp Purchase print edition Nick Holt
Toyota invests $1.4B in US manufacturing for new BEV SUV With a focus on sustainability and job creation, Toyota’s investment in its Princeton facility in Indiana aims to solidify its position in the electrification market, adding up to 340 new jobs and bolstering its long-standing partnership with the state Ilkhan Ozsevim
Cost effectiveness key barrier to sustainable steel adoption in automotive production AMS and SSAB’s industry survey reveals a growing prioritisation of sustainability in automotive manufacturing, highlighting challenges in sustainable steel adoption such as cost-effectiveness and gaps in awareness, while underlining the need for innovative solutions and collaboration to drive meaningful change… AMS
Volvo’s Taizhou plant achieves climate neutrality with biogas shift Despite the Taizhou plant’s smaller share in the company’s total emissions, this initiative is critical to Volvo’s goal of climate-neutral manufacturing by 2025 and achieving net-zero greenhouse gas emissions by 2040. AMS and Anushka Dixit
Renault subsidiary, HORSE, kicks off Power Electronics Box production Power Electronics Box (PEB) production at the Aveiro facility in Portugal promises enhanced scalability and efficiency in meeting the rising demand for hybrid vehicle components. Ilkhan Ozsevim
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
How BMW is ramping up its circular production and sustainability principles as it drives towards electrification BMW’s Dr. Irene Feige, Head of Climate Strategy and Circular Economy says that circular economy is becoming central to BMW’s automotive production landscape, part of its wider push for sustainable production and supply chains. Ilkhan Ozsevim
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
Bridgestone commits a European record €207m investment to its Burgos tyre plant in Spain, aiming for BCMA principles and sustainable production The record €207m investment aims at integrating BCMA to streamline production, boost capacity and promoting sustainable manufacturing Ilkhan Ozsevim
“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
The Centre for European Policy Studies (CEPS) publishes suggestions to stimulate demand for green steel The paper argues for stimulating demand for the green steel transition and proposes slowly phasing in ’green premiums’ so as not to upset the consumer base Ilkhan Ozsevim
JLR boosts sustainability with solar power expansion in the UK and drives global ops towards energy independence The carmaker has announced its sustainable energy expansion focusing on solar power expansion for substantial cost savings and reduced grid dependence 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
GKN Automotive – Embedding sustainability in the business GKN Automotive’s director of sustainability, Tom Salisbury discusses the importance of Science Based Targets, managing supply chains and the need to embed sustainability throughout the organisation. Nick Holt
JLR – Putting sustainability at the centre of its strategy Sustainability is a key of JLR’s Reimagine strategy, but this goes beyond developing and manufacturing a new generation of electric vehicles. The OEM’s manufacturing sustainability transformation lead, Garrett Bell, shared some insights in how the business is reducing its carbon footprint across its operations. Nick Holt
Green Revolution: How renewable energy is fuelling sustainable automotive manufacturing Adopting renewable energy in automotive production requires a comprehensive strategy, integrating solar, wind, biogas and electric solutions to drive sustainability and mitigate environmental impact effectively. OEMs, strategies and technologies are converging on different approaches to achieve sustainability goals across regions. Here are some notweworthy projects to keep an eye on… Ilkhan Ozsevim
Investment is main barrier to sustainable automotive manufacturing A lack of capital investment is the main barrier to meeting sustainability targets in automotive manufacturing, according to the latest AMS & ABB Automotive Manufacturing Outlook Survey 2023. Megan Kelly
