Tag: quality

SEAT automates bolt checks with 3D sensors at Martorell

SEAT has introduced an automated inspection system at Martorell using 3D sensors and RFID tracking from LMI Technologies, STT Systems and Stemmer Imaging to detect missing bolts, improve traceability and reduce costly production delays.

BMW Regensburg deploys GenAI to reinvent quality checks

BMW’s Regensburg plant is using generative AI to automate bespoke quality inspections, enhancing speed and consistency across its complex, mixed-model production.

Ilkhan Ozsevim

Benteler launches advanced manufacturing project in Morocco, integrating 4.0 tech

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.

Automotive expert Tunç Kip: Human-machine interfaces essential in boosting flexibility, quality, and performance in global manufacturing

From the factory floor to upstream design, digital human-machine interfaces are enabling smarter, leaner, and more flexible vehicle production - but humans need to be at the centre of gravity for it to work.

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.

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.

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.

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.

Henkel’s next-generation gap filler solutions for automotive electronics

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Henkel.Thermal gap fillers are under greater stresses from electronic components as trends like autonomous driving take shape.

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.

ArcelorMittal’s Multi Part Integration enhances vehicle manufacturing with reduced costs, better flexibility, and improved safety, offering a scalable solution for the automotive industry.

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with ArcelorMittal.Philippe Aubron, Head of Global Automotive at ArcelorMittal explains how the automotive producer’s Multi Part Integration (MPI) solves multiple manufacturing challenges and assists automakers to cut costs and exceed critical targets.

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.

Henkel’s digital battery simulation team accelerates EV battery design and development, cutting costly iterations and physical testing for faster market readiness

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Henkel.Material supplier Henkel has created a new simulation team that is helping customers to be much faster and more efficient during battery design and development.

How ALM and PLM integration enhances collaboration, accelerates development and ensures compliance in automotive manufacturing

PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with PTC.As the automotive industry transitions to software-defined vehicles, integrating Application Lifecycle Management (ALM) and Product Lifecycle Management (PLM) systems becomes crucial. This integration enhances cross-domain collaboration, accelerates product development, and ensures compliance with safety standards. Experts from PTC and Veoneer share insights on leveraging ALM-PLM integration to maintain competitiveness in this dynamic landscape.

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.

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.

Honda upgrades production with advanced processes for 2026 Passport models

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

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.

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.

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.

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.

Thomas Dose discusses leadership, diversity, and challenges at BMW’s Chennai Plant

How do you go from being a consultant to being a plant manager? Thomas Dose, managing director of the BMW plant in Chennai, India, talks in an interview about his path, the challenges and opportunities in India and the importance of diversity and sustainability.

GM Ventures invests $10m in Forge Nano to improve EV battery performance and reduce costs

General Motors drops the Ulitum brand and shifts from single chemistry approach. The OEM has also entered into a strategic partnership agreement with Forge Nano to collaborate on atomic layer deposition applications for GM’s electric vehicle batteries.

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.

EV battery testing – new software supports testing rapidly changing battery technologies

New battery technology is being developed, and testing companies are focused on the same old parameters. But change could be on the horizon with new software.

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.

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.

Designing manufacturing systems for flexibility and scalability

Comau discusses assembling e-drives, developing battery manufacturing solutions, and collaborations with universities for next-generation cells.

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.

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.

Quality data drives F1 peak performance

Formula one cars represent the pinnacle of automotive engineering and behind the scenes, high quality components and manufacturing data are key to on-track success. Oracle Red Bull Racing offered AMS a glimpse of its championship winning engineering operations.

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.

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.

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.

Breaking down silos: the necessity for co-creative collaboration

The Design4Production event in Munich proved that collaboration between is key to success across automotive production, engineering and design. The topic was present across every single session in one form or another. Here are the highlights of the theme…

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.

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.

Quality control: 3D vision inspection systems

LMI Technologies offers insights into current trends in automotive quality control requirements and the technology solutions available.

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.

Perfecting paint transfer by focusing on improving efficiency in vehicle exterior paint application

The paintshop is an area of the production process where throughput, quality and sustainability need to be carefully balanced. Paint application specialist, Sames, looks at key areas where efficiencies can be made.

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

“We have a clear strategy towards electromobility”: Gerd Walker, Audi

Gerd Walker controls production and logistics on the Audi board. In this interview, he explains how Audi flexibly and digitally designs the production network and what role the target image of the 360factory plays.

Artificial intelligence – New developments in surface inspection

AI and automation are becoming key technologies for surface inspection in the paintshop, but human workers are still providing the finishing touches.

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.

Compas wins category for site transformation at FYA: Interview with Santiago Jurado, chief quality officer

Watch how Compas, winner at the Factory of the Year Awards, reshaped quality production management to overcome extreme complexity in automotive production. Chief Quality Officer Santiago Jurado shares insights with AMS Chief Content Officer Christopher Ludwig.

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

“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

Toyota Alabama accelerates production unveiling the i-FORCE engine line to power the enhanced Tacoma, focused on versatile powertrains and demand-led job stability

Toyota Alabama launches i-FORCE 2.4L turbo engine line, fortifying commitment to responsive powertrains amid market shifts. The OEM ramps up towards its wider electrification goals

Powertrain – Reducing waste in machining fluids

Sustainability projects at plant and team levels are vital to reducing the operational carbon footprint in manufacturing operations. These range from simple energy management protocols to more involved process improvement related projects. JLR offers a very interesting case study on the latter at its Electric Propulsion Manufacturing Centre.

Porsche plant in Leipzig wins Factory of the Year

The Porsche factory in Leipzig, germany has won the ‘Factory of the Year’ award, presented by consulting firm Kearney and Automobil Produktion, a sister publication of AMS.

The co-evolution of EVs, architectures and production processes

Electric vehicles and batteries are influencing automotive manufacturing decisions, driving changes in vehicle architectures, production processes and material choices. Gestamp and ArcelorMittal discuss their strategies

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.

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

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

The automotive value-add of additive manufacturing and simulation technologies: an agile and resilient powerhouse in engine development

Markforged’s additive manufacturing solves Punch Torino’s automotive challenges with robust camshaft tools. Simulation technology streamlines design, reducing iterations with a future focus on sustainable internal combustion engines and alternative fuels.

How battery and electric motors and EVs are reshaping the European automotive supply chain

The automotive industry is in a major shift with EVs reshaping the supply chain. Challenges and opportunities include replacing traditional components tied to combustion engines, new players in the battery market, disruptors facing tariffs, and the looming influence of China in Europe; all adding new layers of complexity.

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.

JLR accelerates digital transformation with Tata Communications connecting 128 of its global sites through cloud-based digital production network

The two companies are collaborating to build JLR’s robust digital network to foster supply chain resilience. The collaboration integrates AI for real-time data analysis, enhancing production efficiency and security.

Stellantis’ Factory Booster Day 2023 fosters OEM/supplier collaboration to solve automotive production challenges

The eighth instalment of Factory Booster Day produced ninety-nine solutions demonstrated by sixty-four partners to tackle thirty-five Stellantis plant challenges setting an example to other OEMs

Advanced materials application for EV battery production

Coatings, adhesive and sealant application equipment, plays a crucial role in enabling the efficient implementation of advanced materials in the EV battery manufacturing process. SAMES discusses how its technologies and experience can be instrumental in ensuring the quality and safety of EV batteries.

How BMW will maintain quality in its 3,000-step battery cell production process

At its recently opened German Cell Manufacturing Competence Centre (CMCC) in Parsdorf, BMW is aiming to achieve ‘expertise in every cell’ of its generation six batteries for its Neue Klasse EV models. But to do this, the carmaker needs to ensure the 3,000-step production process is consistently quality checked along the way.

Hyundai partners with Saudi sovereign wealth fund (PIF) to establish highly automated vehicle production plant in the region

Hyundai Motor Company has entered into a joint venture agreement with the Public Investment Fund (PIF) of Saudi Arabia to establish “a highly automated vehicle manufacturing plant,” in the kingdom. Hyundai to lead as as strategic technology partner.

Back in the USA

Returning to Detroit for the first time in over 10 years the AMS Automotive Evolution North America event delivered expert panels and a fully engaged audience who combined to share their valuable insights and experience, through panel discussions, Q&A and networking. Here are some of the highlights from the sessions.

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

Watch: Automated weld seam inspection of EV-battery trays with VIRO WSI

An EV battery tray typically has many welds. But even one defect weld risks stability, tightness, and safety

Skoda Kvasiny to become electromobility powerhouse

Head of Skoda Kvasiny plant, Miloš Halbich, talks to Mike Nash about recent socioeconomic challenges, fluctuating markets and how the facility is a “crucial pillar” in the company’s global production network

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.

New motor technology to transform electric vehicle production

Opher Doron of EVR Motors describes how a novel electric motor design could have a dramatic impact on vehicle production and the electric vehicle market

Volta Trucks partners with ZF Commercial Vehicle Solutions for core systems for its all-electric urban delivery truck

Scandinavian electric vehicle OEM, Volta Trucks, partners with ZF Commercial Vehicle Solutions (CVS) to leverage their expertise and tech, accelerating the advancement of the Volta Zero—a fully electric 16-tonne truck designed for urban deliveries

Supporting ADAS – AMS Expert Interview with Henkel

Forming innovations – press shops get smarter

Digital tools are playing a major part in innovating every area of production. The press shop is no exception, with data gathering and AI increasing the visibility and efficiency of the forming process

Neckarsulm – Audi’s plant prepares for more electric vehicles

Audi’s Neckarsulm plant manager Fred Schulze discusses sustainability and digitalisation, and shares some insights into the transformation of the factory and its importance within the Audi production network

Case Study: Daimler Relies Upon HiveMQ During Automotive Manufacturing

Learn how and why Daimler uses HiveMQ to manage information flow between vehicle diagnostics system test devices on the factory floor and server-side enterprise IT systems

Heat-treatment – AMS Expert Interview with Nitrex

Focus on flexibility – optimising battery pack production

The AMS Evolution Livestream expert panel representing Ford, AMTE Power and Henkel, discussed the fast-changing production requirements as cell manufacturers and OEMs ramp up Gigafactories and battery pack assembly.

Powering up: AMTE ramps up cell production volume

AMTE CEO Alan Hollis discusses ramping up cell production, establishing a new Gigafactory and developing a flexible, sustainable manufacturing approach

Shaping the future – Developing electric vehicle architectures

In our AMS Evolution Livestream experts from ArcelorMittal and Gestamp tackle EV production challenges and explain how digital tools, new technologies, processes and materials innovations could help solve some key issues

Form and function: Developing production processes and structures for electric vehicle architectures

As much as we read about battery cell development and production, in parallel the new electric vehicle architectures are also continuing to evolve as vehicle makers strive to find the optimum balance between platform flexibility to meet changing market demands for new models, while also being viable for high-volume production. To get some insights in to this ongoing process AMS spoke with Paul Belanger, Gestamp’s R&D Director for North America

Solving electric vehicle production challenges with smart manufacturing and logistics

Siemens discusses how the latest digital tools are enabling the transition to e-mobility and explains why these are now essential to OEMs and tier suppliers if they are to create transparent, sustainable supply chains

Kia starts building facility for electric purpose-built vehicle (PBV) production

The new plant will be dedicated to production of Kia’s electric PBVs, with planned annual capacity of 150,000 units