Tag: automation

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Inside BMW’s smart logistics strategy at Debrecen

BMW is redefining automotive logistics with direct delivery systems, real-time tracking, digital twins, and autonomous transport at its Debrecen plant. The OEM’s tech-driven approach integrates production, quality, and sustainability – setting a new standard for next-gen vehicle manufacturing.

Nick Holt

Toyota's Burnaston academy redefines industrial training with Rockwell

As global manufacturing confronts a looming skills crisis, Toyota Motor Manufacturing UK, with help of Rockwell, has created a training model that could reshape how the industry develops its workforce

Ilkhan Ozsevim

The flexible assembly line: How vehicle production learned to hedge its bets

Market uncertainty has forced manufacturers to abandon fixed production lines. Honda, BMW and Volkswagen are investing billions in systems that can switch between combustion, hybrid and electric vehicles by the hour.

Ilkhan Ozsevim

Human-centric digitalisation: Empowering the shopfloor with smarter tools

As automotive manufacturing becomes more automated and data-driven, digitalisation must be designed to empower, not replace, shopfloor workers. With intuitive tools, connected systems and real-time insights, OEMs and suppliers are rethinking how humans and machines interact in production environments.

Ilkhan Ozsevim

Anushka Dixit

Hyundai ups US bet to $26bn

Despite an immigration raid at its Georgia plant, Hyundai Motor Group boosts US investment to $26bn, including a $2.7bn EV expansion, to counter tariffs and leverage EV incentives, spotlighting labour reliance issues.

Ilkhan Ozsevim

Gestamp’s digital pathway to flexible, efficient manufacturing

Jorge Vázquez Cancela, I4.0 Virtual Factory Project Management at Gestamp, discusses how the company has been developing its approach to Industry 4.0 principles and the integration of digital tools into production operations to boost efficiency and flexibility

Nick Holt

Lear’s “lights-out” vehicle production launches in Michigan

Lear is opening an advanced centre in Michigan to demonstrate lights-out manufacturing and deepen its automation push, building on its Palantir-backed digital strategy.

Ilkhan Ozsevim

BMW’s Debrecen plant showcases iFactory concept in action

As BMW ramps up to start series production at its Debrecen plant, Plant Director Hans-Peter Kemser and Member of the Board of Management of BMW AG, Production, Milan Nedeljković share insights into a new era of manufacturing for the carmaker

Nick Holt

The new battleground of human capital: An interview with Julien Matalou, ManpowerGroup VP

With the automotive industry's rapid transformation, automakers are facing complex pressures. In this exclusive interview with ManpowerGroup's Global VP, Julien Matalou, AMS discerns ways to bridge the skills gap, embrace automation, and build a more resilient workforce.

Ilkhan Ozsevim

Shopfloor tools: Human-centric digitalisation in production

In this AMS livestream, we explored trends and opportunities in manufacturing user technologies - including AR/VR, cobots, IoT, exoskeletons, computer vision and AGVs - and how they’re reshaping daily operations, enabling smarter decisions, and strengthening the human-machine relationship.

Driving quality forward: Why digitalisation is transforming automotive manufacturing

In this AMS webinar, we’ll explore how digitalisation and automation are redefining quality in automotive manufacturing — from digital measurement to embedding quality directly into production lines.

A new generation of automation at Mercedes-Benz’s Düsseldorf plant

Blending AI and automation, Mercedes-Benz's Düsseldorf van plant is taking a major step in automation with the deployment of a four-legged robotic assistant – Aris

Nick Holt

Automotive industry faces workforce upheaval in 2025, reshapes jobs amid shifting tech

Electric vehicle adoption, automation and shifting trade rules are forcing automakers to rethink workforce strategies as they confront skills shortages and a slowing global economy.

Ilkhan Ozsevim

Modular manufacturing moves automotive production into the future

Automotive manufacturers embrace modular platforms to achieve unprecedented flexibility whilst maintaining efficiency gains, transforming traditional production paradigms for electric and conventional vehicles.

Ilkhan Ozsevim

Electrified production: Scaling EV and battery output

This AMS livestream investigates how automotive manufacturers and suppliers are adapting existing and new factories to produce EVs and electrified vehicles.

Streamlining engineering change orders management in complex harness designs

Learn how Siemens Capital Software enables smarter ECO management for complex harness designs. Gain full visibility, eliminate errors, and accelerate updates through intelligent automation and impact analysis.

Next steps for automating wire harness assembly

The wire harness assembly process has long been the most difficult to automate; complex layout, flexible wires, small connectors and tight grouping all conspire keep this job as a manual operation, until now.

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

Automating complexity: How JLR Is futureproofing production and skills

From goods-to-person automation and modular design strategies to technical training and career paths, Loretta Dittrich, logistics director for global manufacturing engineering explains how the OEM is reshaping both systems and skills to meet the demands of more customised, digitalised vehicle production.

AMS Editorial

JLR deepens electric vehicle manufacturing capabilities with 50 new roles focused on material sourcing, traceability and supply chain risk mitigation

JLR expands EV manufacturing with 50 new roles in material sourcing, traceability and supply‑chain risk

As it transitions to electric vehicle production, JLR has added 50 roles to map material sources, secure battery minerals, and protect manufacturing operations from disruption and compliance risk.

Ilkhan Ozsevim

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

BMW’s digital brain: Dr. Michael Nikolaides on AI, robotics and resilience in a complex global supply chain

BMW’s Dr. Michael Nikolaides discusses how the OEM is leading with intelligent intralogistics, AI-powered automation, and data-driven decision-making. From real-time reallocation to humanoid robotics, BMW is future-proofing its production network in a volatile global landscape.

Christopher Ludwig

Inside Dräxlmaier’s digital drive: COO Arno Güllering on AI, mindset shifts and global smart factory strategy

In a revealing interview at the Automobil Produktion Kongress in Munich, Arno Güllering, chief operating officer of Dräxlmaier Group, shares how the global supplier is accelerating its smart factory transformation. From unexpected digital frontrunners like Tunisia to the growing role of generative AI in maintenance, Güllering discusses his first-year priorities and why a shift in mindset is just as critical as technology.

Christopher Ludwig

How Arno Güllering wants DRÄXLMAIER Group to harness shopfloor visualisation and genAI in production and maintenance

The tier-1 supplier has established a highly connected production and logistics network, with a strong emphasis on data visualisation and a roadmap for AI. But to stay competitive and resilient, COO Arno Güllering wants to ensure both plants and HQ have a mindset ready to embrace change.

Christopher Ludwig

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

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

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

Sterling Anderson joins GM as executive vice-president and chief product officer to drive innovation across electric and petrol vehicles, software, services and user experience

General Motors has appointed Sterling Anderson, co-founder of Aurora and former Tesla executive, to lead product development across its portfolio, as the carmaker seeks to unite software, hardware and user experience under a single innovation strategy.

Ilkhan Ozsevim

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

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

As VW cuts back in Germany, Slovakia and Spain emerge as new pillars of cost-effective and future-focused production across Europe

As VW’s traditional German plants face uncertainty, its long-established facilities in Bratislava and Pamplona are stepping into the spotlight—producing top-selling models and gearing up for a new era of electric vehicles.

Timo Gilgen

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

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

BMW ramps up Debrecen plant with cutting-edge modular assembly to lead Neue Klasse electric vehicle production from late 2025

BMW’s all-electric plant in Debrecen enters its final phase before full production. With modular systems, digital twin planning and just-in-sequence delivery, the site signals the future of scalable, fossil-free manufacturing.

Ilkhan Ozsevim

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

JAC Motors expands production in Mexico to increase capacity by 30% and assemble electric and combustion SUVs, pickups, trucks and LCVs for future domestic growth

JAC Motors is scaling up production at its plant in Ciudad Sahagún, Hidalgo, with a 30% capacity boost and new flexible lines to assemble electric and combustion SUVs, pickups, LCVs and trucks for Mexico’s evolving market

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

How China’s BYD surpassed Tesla with production and battery tech - reshaping the global EV market

BYD has surged onto the global stage, challenging industry giants like Tesla with its aggressive expansion and pioneering battery technology. BYD’s production soared from half a million to over 4 million vehicles. As the company celebrates its 30th anniversary, its blend of vertical integration, cutting-edge automation, and global supply chain mastery has redefined the EV landscape.

Anushka Dixit

Why global automotive innovators must embrace Design For Manufacture to power production in an environment of increasing complexity and fierce foreign competition

Automotive manufacturers are streamlining production with Design for Manufacture (DFM), cutting complexity, reducing costs and driving EV innovation. In In this article, experts reveal the key strategies and digital tools that are reshaping vehicle production.

Ilkhan Ozsevim

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

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

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

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 OEMs such as BMW, Toyota and Ford are harnessing data-driven decision making drive sustainability in automotive manufacturing

Leading automotive OEMs and tier-suppliers are deploying cutting-edge data tools to transform their operations. This article explores how they are using AI and big data to enhance resource efficiency, reduce emissions, and pave the way for a greener future in manufacturing.

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 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

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

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

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

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

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

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

MD ELEKTRONIK shows how automation is reforming automotive cable assembly and the solutions that come with the change

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with MD ELEKTRONIKMD ELEKTRONIK demonstrates why top quality and competitive pricing are critical to automotive production and supply

AMS

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

Holon seeks to transforms urban mobility with new Florida autonomous shuttle vehicle plant

Holon, a subsidiary of Benteler, has unveiled plans to modernise the future of transportation with its first autonomous shuttle vehicle manufacturing facility in Jacksonville, Florida. The plant is expected to produce up to 5,000 autonomous movers annually.

Ilkhan Ozsevim

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

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

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

Balancing digitalisation with production output

The focus of the Automobil Produktion Kongress 2024 was on sustainable, efficient and digital production methods. Industry experts from car manufacturers and suppliers discussed the future of smart production.

Werner Beutnagel

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

Ford Otosan in Kocaeli, Turkey, demonstrates how automation is driving Ford Transit production

The Ford Otosan Plant in Kocaeli, Turkey relies on automation to deal with a very complex number of powertrains and derivatives. Plant Leader, Aysan Hosver, takes us on a tour of one of the most advanced production facilities in the world. With more than 1,200 robots throughout the site, this is how complexity

Mark Smyth

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