Tag: editors pick

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Francesco Ciancia returns to lead Stellantis global production

Stellantis has appointed Francesco Ciancia as Global Head of Manufacturing, reuniting with an executive whose international experience in lean production and transformation will shape its future operations.

Ilkhan Ozsevim

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

Novelis hot mill fire risks $1bn hit to Ford F-150 output, exposing heavy reliance on aluminium body-in-white

A fire at Novelis’ aluminium rolling and recycling plant in New York is set to disrupt Ford’s supply of aluminium for its F-150, with analysts warning the production impact could cost the carmaker as much as $1 billion.

James McLoughlin

Ilkhan Ozsevim

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

BYD’s 880% UK surge exposes gaps in the region’s EV strategy

BYD’s record UK sales in September, despite being shut out of subsidy schemes, underline a wider reckoning for UK auto manufacturing strategy. An industry built on incentives and protection needs fresh foundations in design, export and resilience.

Ilkhan Ozsevim

JLR begins phased restart after six-week cyber siege

British luxury carmaker initiates controlled manufacturing resumption following devastating cyberattack, whilst government underwrites £1.5 billion ($2 billion) loan to stabilise supply chain. Economist warns crisis reveals industry vulnerability.

Ilkhan Ozsevim

Stellantis reverses course on US stance with $10bn manufacturing investment

New chief executive Antonio Filosa charts dramatic reversal from predecessor's low-cost country strategy, refocusing capital on North American manufacturing as European operations face mounting overcapacity challenges

Ilkhan Ozsevim

German auto giants face major job cuts

Bosch and ZF Friedrichshafen announce over 20,000 job reductions amid market challenges and global competition.

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

Carmakers and regulators rethink EV timelines as ICE makes a comeback in Europe

Electric vehicle momentum is slowing across Europe as automakers delay EV launches, extend hybrid and ICE models, and push for regulatory flexibility. The EU is under pressure to revise zero-emission targets and support its own supply base.

Ian Henry

Washington's new tariffs disrupt heavy truck production networks

President Trump's 25% levy on imported heavy trucks threatens to reshape North American manufacturing strategies, forcing OEMs to recalculate production footprints whilst grappling with already elevated input costs and weakening demand.

Ilkhan Ozsevim

The paradox of Sustainable Production: Why less might mean more

Automotive manufacturers chase complex technologies for greener production, yet the most effective sustainability gains come from fundamental simplicity: making less, wasting less, and questioning whether volume growth remains viable.

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

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

Digital shopfloors: PdM powers manufacturing uptime

Automotive manufacturers are integrating predictive maintenance systems to boost shopfloor productivity and reduce downtime. Waites' Bill Kilbey explains how digital tools transform equipment reliability across OEM and supplier operations.

Ilkhan Ozsevim

iFactory flourishes at BMW Debrecen

BMW’s Debrecen plant combines fossil-free energy, onsite battery assembly, and digital twins to produce the New Class. Designed as a scalable iFactory blueprint, it aligns product, factory, and process for an electric future.

Andrea Hofmann-Topp

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

Toyota Burnaston brings circular production to life

Toyota's new dismantling plant at Burnaston uses Toyota Production System principles to process up to 10,000 end-of-life vehicles a year. This initiative is aimed at recovering materials and parts to improve sustainability.

Ilkhan Ozsevim

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

US immigration officials raid $7.5bn Hyundai–LG plant, repatriation deal struck after 300+ South Koreans workers detained

The battery facility, part of the broader $7.5 billion Hyundai Motor Group Metaplant America complex, is a joint venture aimed at building cells to power Hyundai, Kia, and Genesis electric vehicles produced in the U.S.

Anushka Dixit

Marcus Williams

JLR shuts IT systems, halts UK plant production after cyberattack

Production at Solihull and Halewood have been suspended. JLR said it had taken “immediate action to mitigate” the impact and that it continues to investigate the source and scope of the incident.

Anushka Dixit

Tariffs, trade shifts, and EV turbulence: How Trump’s second term is reshaping North American auto manufacturing

North American vehicle manufacturing is undergoing major changes. These are in response to political actions, wider market factors and some interesting decisions by major vehicle companies

Ian Henry

EU carmakers say 2035 CO2 targets unworkable

Europe’s leading automotive executives are pressing Brussels to rethink its car and van CO2 rules, warning that rigid 2030 and 2035 targets are no longer realistic amid rising costs, import dependence and trade barriers.

Ilkhan Ozsevim

Megacasting maestro Bühleron the complexities of simplicity

The shift from traditional body-in-white assembly to integrated structural castings is profoundly changing automotive manufacturing. Bühler, a leader in die casting, discusses how it, and other OEMs can successfully navigate the transformation.

Ilkhan Ozsevim

Production minimalism: How Megacasting is reshaping automotive manufacturing

Single aluminium components replace hundreds of welded parts as Tesla's gigacasting revolution spreads to Volvo, Toyota and Chinese manufacturers, promising dramatic cost cuts but demanding massive capital investment.

Ilkhan Ozsevim

Tesla's Nevada Semi surge gathers pace

With a colossal stamping press now in place at Gigafactory Nevada, Tesla primes its all-electric heavy-duty truck for broader output, challenging diesel dominance in a sector ripe for decarbonisation.

Ilkhan Ozsevim

Ford reshapes EV manufacturing with new platform

Ford’s $5 billion EV platform and factory investment

Ford has committed $5 billion to its Universal EV Platform and Production System, overhauling production at Louisville and BlueOval Battery Park Michigan. The new approach introduces parallel assembly, structural batteries, supplier integration and workforce transition.

Charlie Blackie-Kelly

Emily Uwemedimo

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

Europe: Chinese brand’s sales and localised production on the increase

Despite steep EU tariffs, Chinese automakers are rapidly expanding their footprint across Europe – doubling market share. With hybrid models gaining traction and production scaling locally, their momentum shows no signs of slowing.

Ian Henry

Europe: EV investment continues but managing capacity is an issue

Despite billions invested in electric vehicle production and battery supply chains, many European plants are grappling with low utilisation, underwhelming EV sales, and structural overcapacity. Can Europe's auto industry recalibrate to remain competitive?

Ian Henry

Mercedes Chairman urges EV "reality check" on EU 2035 car ban lest region “collapse”

Mercedes-Benz’s Ola Källenius warns Europe’s automotive industry could collapse under a rigid petrol and diesel ban by 2035, urging a technology-neutral and economically sustainable path.

Ilkhan Ozsevim

Daimler, Volvo, Paccar and Traton challenge California clean-air deal in court

Truckmakers are suing to exit California’s Clean Truck Partnership, citing federal pressure. Critics say it undermines market certainty, innovation and the future of electric truck manufacturing.

Ilkhan Ozsevim

Bosch bolsters North American production through cross-functional collaboration

Dr Hanns Bernd Ketteler on bolstering Bosch's North American production through cross-functional collaboration

Ahead of speaking at Automotive Manufacturing North America 2025 in October, Bosch Mobility Americas’ top executive for operations explains how greater collaboration across departments, simultaneous engineering and digital tools are helping the automotive supplier stay competitive in fast-changing times.

Ilkhan Ozsevim

Christopher Ludwig

Tata veteran Balaji to lead JLR as Mardell steps down

Indian automotive giant promotes longtime CFO to lead British luxury brands through electrification push as retiring CEO delivers record financial performance

Ilkhan Ozsevim

Visibility through invisible connections: How 5G is weaving a new automotive network

Automotive OEMs are embracing private 5G networks to drive digital twins, automation and AI. This shift enables safer, smarter and faster factories built on low-latency, high-security wireless connectivity.

Ilkhan Ozsevim

UK automotive output slumps amid EV and cost challenges

UK automotive manufacturing faces its toughest half-year since 1953 outside the pandemic. While EV output grows, cost pressures, unclear incentives and supply shortages threaten recovery plans.

Megan Kelly

Ilkhan Ozsevim

Report: Regional resilience despite volatility for automotive production

The S&P Global Mobility July 2025 forecast highlights regional resilience and challenges in light vehicle production. Despite volatile trade, North America and Greater China show surprising strength, as other regions seek to recalibrate.

Ilkhan Ozsevim

Honda’s Ohio Anna engine plant turns 40 with EV ambitions

Honda celebrates 40 years at its Ohio engine plant as it scales flexible manufacturing, invests in megacasting and prepares for EV battery case production from 2026.

Ilkhan Ozsevim

Washington’s tariff gambit upends vehicle production map

Fresh US tariffs are upending EV strategies, accelerating reshoring, stalling imports and forcing automakers to overhaul production footprints and future investment plans.

Ilkhan Ozsevim

5G, AI, IIoT and the race for real-time visibility in auto manufacturing

As automotive plants grow more complex and dynamic, real-time visibility is becoming the foundation of smarter, more responsive manufacturing. From 5G networks and AI-powered inspections, to digital twins and predictive maintenance, leading OEMs are unlocking next-generation transparency and control on the factory floor.

Ilkhan Ozsevim

Anushka Dixit

Inside Toyota’s 2025 Lean(er) Manufacturing System

Toyota’s lean production system enters a new phase in 2025. Combining its founding pillars of Jidoka and Just-in-Time with digital tools and tighter regional roles, the updated model aims to sharpen EV readiness and operational agility.

Ilkhan Ozsevim

European vehicle makers navigate the challenging US tariffs

The European vehicle manufacturing sector faces a multitude of challenges including tariffs imposed by President Trump. OEMs are now reviewing their export strategies and manufacturing networks.

Ian Henry

Polestar expands European production with new Polestar 7 in Slovakia

Polestar is advancing its production strategy with a new European manufacturing footprint, shared platforms with Volvo Cars, and the forthcoming Polestar 7 SUV set to launch from new Slovakia plant in 2028.

AMS Editorial

Nick Holt

Key insights from Daimler Truck’s Twin4Trucks project

Daimler Truck’s Twin4Trucks project has provided significant insights into AI-driven data consistency in truck production. Discover how its successes and challenges in AI, 5G, and local solutions are shaping the company’s roadmap for future manufacturing advancements.

Yannick Tiedemann

BMW’s Factory Genius: How AI is transforming global automotive production

BMW’s AI-driven Factory Genius is cutting troubleshooting times and streamlining production across global plants. As part of its broader iFactory and AIonic strategy, BMW is reimagining shop floor intelligence through real-time data, machine learning, and generative AI.

Nick Holt

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 smart material transportation can support flexibility in automotive production operations

As the automotive industry faces multiple economic and geopolitical challenges, impacting costs, market demand and supply chains, developing agile, flexible production lines becomes a necessity.

AMS Editorial

Welcome to the new AMS experience

We’ve redesigned the AMS website to deliver sharper insight, faster access and a smoother, more intuitive experience at a time when you need it most.

Nick Holt

Tariffs, competition and challenging markets put European OEMs under more pressure

The European vehicle manufacturing sector faces major challenges amidst ongoing geopolitical and economic turmoil. This review looks at US tariffs, the slower adoption of electric vehicles (EVs), low factory utilisation, and the rising competition from the Chinese vehicle manufacturers.

Ian Henry

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

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

The rise of HMI: Human-machine synergy in smart manufacturing

Human-Machine Interfaces (HMIs) are no longer simple control panels; they are intelligent, connected systems that empower operators with real-time insights, intuitive workflows and predictive guidance. As HMI technology evolves, it is reshaping how workers interact with automation, improving ergonomics, safety and efficiency, while bridging the gap between cyber-physical systems and human expertise.

Anushka Dixit

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

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

India targets $500bn in EV investment as government boosts manufacturing incentives and new players like Tesla, VinFast prepare entry

Significant investments are now under way at domestic and international vehicle companies in India, in component production, electric and hybrid vehicle production for the domestic market, and to facilitate rising exports across the world. This is being encouraged under the government’s strapline of “Make in India for the world.”

Ian Henry

Evolution of EV platforms: Innovations in design, manufacturing, and scalability

Electric vehicle architectures must be adaptable, scalable, and cost-effective, but evolving battery technologies, crash protection, and manufacturing processes add complexity. While the skateboard design has become standard, innovations like gigacasting and hybrid adaptability are reshaping the industry. Automakers are racing to refine EV platforms, balancing speed to market with efficiency and safety in an increasingly competitive landscape.

Nick Holt

Anushka Dixit

Honda upgrades production with advanced processes for 2026 Passport models

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

Nick Holt

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

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

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

JLR and partners push seat foam circularity forward through digital tools and collaboration, accelerating sustainable material reuse in luxury vehicle production

JLR’s breakthrough in seat foam circularity is powered by digital tools, data-driven traceability and production/supply chain collaboration. The Circularity Lab’s ‘learn through doing’ approach is setting new industry benchmarks for material reuse and sustainable innovation. Ilkhan Ozsevim reports.

Ilkhan Ozsevim

US tariffs on Mexico and Canada threaten North American auto production and supply chains, raising costs for manufacturers

The US is threatening to impose tariffs on automotive imports from Canada and Mexico, testing the resilience of North American manufacturing. The move could drive up costs, disrupt supply chains, and challenge the stability of the US-Mexico-Canada Agreement (USMCA), just as the industry navigates nearshoring, investment shifts, and electrification.

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

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

Jaguar Land Rover Industrial Operations Chief departs as Nigel Blenkinsop takes over manufacturing leadership

Jaguar Land Rover is undergoing a leadership transition as Barbara Bergmeier steps down from her role as executive director of industrial operations. Nigel Blenkinsop, a seasoned JLR executive, will take over as the company navigates an evolving automotive landscape.

Ilkhan Ozsevim

AI: Enhancing predictive maintenance in production lines

Unplanned downtime is costly and something that the automotive industry has been working hard to reduce through predictive maintenance strategies. AI now offers a significant step forward in real-time monitoring and data gathering and analysis.

Nick Holt

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

Volkswagen de México opens world’s 1st fully electric paintshop at Puebla plant

Volkswagen de México has launched the first fully electric paint shop in the automotive industry, eliminating natural gas use and improving sustainability. The Puebla plant’s advanced automation, AI-driven quality control, and renewable energy integration is a step toward carbon-neutral vehicle production.

AMS

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

Shape the Future: Join the 2025 Survey on Digital Transformation in North American Automotive Manufacturing and Win Exciting Prizes

The North American Automotive Manufacturing Digital Transformation Survey 2025, in partnership with Kyndryl, explores AI, IoT, and automation in production. Join the survey, win prizes, and access vital insights on sustainability, nearshoring, and workforce evolution.

AMS

Stellantis to reopen Belvidere plant, build new pickup truck and dodge durango, investing $5bn in US production amid strategic reshuffle

Stellantis commits $5bn to US auto manufacturing, reopening the Belvidere plant, building a midsize pickup, and producing the next-generation Dodge Durango. With 1,500 jobs to be restored, the move signals a strategic reset amid challenges and a reshuffling of priorities.

Ilkhan Ozsevim

Automotive suppliers and producers confront existential crisis: mass layoffs and plummeting electric vehicle investments threaten European manufacturing

Major automotive suppliers including Bosch and Continental announce massive workforce reductions as electric vehicle market challenges intensify European manufacturing sector’s most significant restructuring in decades.

Ilkhan Ozsevim

Nissan plans to cease AD van production in November as merger discussions with Honda progress towards 2026 integration

In a strategic move preceding its anticipated merger with Honda, Nissan announces the cessation of its AD compact van production by November. This decision reflects efforts to streamline operations and address surplus capacity as the OEMs plan to integrate by 2026.

Ilkhan Ozsevim

Rivian strengthens EV ambitions with $6.6B federal loan to develop advanced manufacturing facility in Georgia

Rivian’s $6.6 billion loan from the US Department of Energy bolsters its ambitious plans for a key Georgia manufacturing hub. The 9 million sq. ft facility will increase production of next-gen EVs, foster innovation and boost regional production.

Ilkhan Ozsevim

Polestar plans European production of imminent Polestar 7, moving away from China in nearshoring drive, solving for supply chain complexities

Polestar aims to hit profitability by 2025 with Polestar 7 to be built in Europe, exiting China in regionalisation move enhancing supply chain resilience. The carmaker’s strategy includes streamlined product lines eyeing growth targets for premium EV market.

Ilkhan Ozsevim