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
BMW’s shop floor digital transformation: Driving standardisation, AI, and human-centric innovation BMW layers lean manufacturing principles with the application of digital technologies to develop standardised, human-centric production processes. 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
Circular economy targets inspire new design, sourcing and supply‑chain strategies for 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
Hybrid vehicles return to North America’s production lines as automakers rethink strategy Automakers that once aimed to skip hybrids and go straight to electric vehicles are now reintegrating hybrids into their North American line-ups. Building “half-and-half” cars is proving technically tricky but strategically worthwhile. 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
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. Ilkhan Ozsevim
Tariffs changing the automotive landscape in North America Donald Trump’s tariffs have triggered some shorter-term shifts in US production operations and longer-term evaluation on investments and strategies as supply chains are restructured. Ian Henry
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
How Mercedes-Benz, BMW and Dräxlmaier are using digitalisation, automation and AI to transform production, logistics and sustainability across their global manufacturing networks European automotive manufacturers are building digitally integrated production systems across their global operations to increase resilience, reduce emissions and prepare for new vehicle architectures and future technologies Götz Fuchslocher
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. Ilkhan Ozsevim
Building better digital twins: Optimising visibility across production operations PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Cintoo.As automotive manufacturers digitise operations and look to modernise legacy facilities, the ability to convert laser scan data into actionable, cloud-based digital twins is becoming essential. AMS
Software-defined vehicles are transforming value creation, customer models, and strategies across the automotive industry, from BMW to Stellantis and NXP It’s now time to take a more holistic view of software-defined vehicles (SDVs). After all, they involve completely new business models. Who is pursuing which strategy? By Andrea Hoffmann-Topp
UK competition regulator fines 10 carmakers and trade bodies over collusion in green advertising and recycling disclosures The UK’s competition watchdog has fined major carmakers and two trade bodies over £77m for colluding on green advertising. A whistle-blower tip from Mercedes-Benz exposed years of consortium activity that limited consumer choice. 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
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
BMW plants prepare for a new era with Neue Klasse production As BMW gears up production towards its Neue Klasse electric vehicles, the factories are to remain flexible. Gotz Fuchslocher looks at the strategies the manufacturer is pursuing as it prepares to launch production of the new models. Götz Fuchslocher
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
BMW’s Neue Klasse redefines electric mobility with advanced Software-Defined Architecture and high-performance energy management BMW’s Neue Klasse redefines electric mobility with a software-centric vehicle platform, high-voltage 800V battery technology and four advanced computing modules. A new era of efficiency, flexibility, dynamic performance and seamless energy management is emerging? By Andrea Hoffmann-Topp
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
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
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
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
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
The automotive industry weighs the challenges of geopolitics and market factors in 2025 Trade wars, geopolitical tensions, mergers, increasing competition are all considerations that need to be addressed and navigated by vehicle makers and suppliers. Ian Henry highlights some of the key factors to look out for in 2025. Ian Henry
BMW Group strengthens circular economy through SK tes battery recycling, advancing sustainability in Europe and beyond The BMW Group has launched a partnership with SK tes to recycle high-voltage batteries across Europe. This closed-loop process reclaims critical materials such as cobalt, nickel, and lithium, boosting sustainability and reducing supply chain risks. 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
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
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. Ronja Schmiedchen
China: Fierce domestic competition sees international brands suffer lower sales and a contraction of output As China’s domestic brands consolidate and grow both at home and internationally, the international brands, which have benefited from growth in the Chinese market over the years, now face serious headwinds. Ian Henry
BMW’s new aeroacoustics and Electric Drive Centre features world’s largest and quietest wind tunnel enhancing acoustic research for Electric Vehicles BMW has inaugurated its Aeroacoustics and Electric Drive Centre at the Research and Innovation Centre in Munich. The facility features the world’s largest and quietest vertical acoustic wind tunnel, enabling precise measurement of aerodynamic noise in electric vehicles. Ilkhan Ozsevim
The digital production hub at BMW’s San Luis Potosi blends electrification, AI, and sustainability to lead the way in next-generation automotive manufacturing BMW’s San Luis Potosi facility is a testbed for next-generation automotive production. From digital twins and AI to high-voltage battery assembly, it pioneers lean, green, and smart manufacturing to meet global demands for electrification and sustainability. Ilkhan Ozsevim
BMW’s iFactory Network expands automated driving technology across production with Dingolfing now acting as testing ground BMW’s dingolfing plant pioneers automated in-plant driving, achieving CE certification and setting a benchmark for efficiency in automotive production. Expansion across its global network is underway. 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 debrecen ramps up for Neue Klasse production as test vehicles signal progress in electric innovation BMW group’s debrecen plant in hungary has commenced near-series production of the Neue Klasse x model. The facility’s advanced processes are rigorously tested as it prepares for full-scale electric vehicle manufacturing by late 2025. 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
How Trump’s presidency could reshape automotive production, trade relations, and the green transition for manufacturers across the US, Europe, and Mexico With Trump as President, automotive manufacturers are bracing for major policy shifts affecting production, tariffs, and the electric vehicle landscape. With opposing stances on trade and green policies, candidates Kamala Harris and Donald Trump could alter the course of the automotive sector across the US, Europe, and Mexico. Ilkhan Ozsevim
BMW Leipzig starts production of the second generation 2 Series Gran Coupé The new 2 Series Gran Coupé joins the 1 Series, 2 Series Active Tourer and MINI Countryman in production at Leipzig, with the four models with three different drive options made on a single production line. Nick Holt
BMW Group Plant Regensburg honoured for excellence in large-scale assembly, recognised for flexibility, digital innovation, and leadership in prestigious Factory of the Year competition The coveted “Factory of the Year” award has gone to Regensburg in the category of large-series assembly. The plant was lauded for its remarkable flexibility, workforce dynamism, and cutting-edge digital innovation, further solidifying its place as a leader in automotive production. Ilkhan Ozsevim
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
With the hope of exponential problem-solving on the horizon, are quantum computers the future of the automotive industry? Quantum computers promise to give industry and science a boost when it comes to solving complex tasks in the future. But how exactly do quantum computers work and which model currently has the highest computing power? Götz Fuchslocher
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
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
BMW’s ‘motionless’ and ‘silent’ wind energy system installed at Oxford plant in collaboration with Aeromine BMW’s commitment to sustainability shines through again as the OEM installs the UK’s first “motionless” wind energy system, offering a unique and efficient solution to traditional wind power challenges. The technology, developed by Aeromine Technologies, has the potential to revolutionize renewable energy production. Ilkhan Ozsevim
BMW and Toyota’s mixed powertrain approach sees collaboration to produce Fuel Cell Electric Vehicle options for passenger cars Utilising a fuel cell powertrain, developed in collaboration with Toyota, BMW plans to launch its first-ever series production fuel cell electric vehicle (FCEV) in 2028. Nick Holt
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
Despite industry fears, global EV sales reach record highs in 2024 and remain on an upward trajectory How will slowing growth in EVs impact auto industry investment strategies? As the industry navigates challenges from rising costs and charging infrastructure gaps, to consumer range anxiety and rising competition, Daniel Harrison explodes some EV myths. Daniel Harrison
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
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
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
Weak demand dims electric future Consumer resistance and trade disputes mean the future may not be so electric after all as vehicle makers express caution on zero emission vehicle targets. Ian Henry
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
UK auto production prospects improving Economic headwinds, supply chain challenges and future trading uncertainty have put the UK’s automotive manufacturing sector under considerable pressure, but there are signs of a positive change ahead. Ian Henry
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
Impacts of global geopolitics on European production Geopolitical influences on the automotive manufacturing sector are intensifying and becoming ever more powerful. European trends cannot be looked at in isolation; their impact on the ground in Europe have their roots in wider global factors… Ian Henry
The changing shape of Europe’s automotive production operations European vehicle manufacturing is having to adapt to weakening EV demand and increasing competition. This means revising production volumes and rethinking the ICE-EV balance in the short term. Ian Henry
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
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. Michael Nash
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
“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
BMW gears up for round-the-clock production with three-shift operation in Leipzig to accommodate electric Mini Countryman expansion By integrating the new Mini Countryman into production through their electric offensive, BMW wants to significantly increase capacities at the Leipzig plant again. The Saxony location is currently preparing for a new night shift. AMS
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
Automotive production resilience and strategic progress for the UK automotive industry with latest SMMT figures showing record growth SMMT’s latest figures show UK production breaking records for total investments from both public and private sources with £23.7 Billion in commitments. Confidence grows for production innovations and a sustainable future. Ilkhan Ozsevim
Is sodium-ion the future of battery tech? - Stellantis Ventures all-in on France-based battery tech startup, Tiamat The battle of battery tech continues. Stellantis is investing in Tiamat’s sodium-ion tech, eyeing cost-effective, sustainable energy, while, BMW pursues Solid Power’s solid-state batteries for efficiency gains. Which chemical composition will lead? Will any? Ilkhan Ozsevim
Design and manufacturing integration key to BMW’s Neue Klasse To realise large cost and emission savings on its EV architecture, BMW is redesigning vehicles and manufacturing in parallel, and rolling out rapid digital solutions. Christopher Ludwig
BMW Munich plant to go full electric with Neue Klasse and revamped, digital production system BMW’s home plant will produce only EVs by 2027, with much of the century-old factory rebuilt to meet new levels of efficiency and digitalisation, without missing a beat of ongoing production. Christopher Ludwig
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 Ilkhan Ozsevim
BYD to establish passenger car production in Europe BYD has chosen Szeged, Hungary as the location for its first passenger car production facility in Europe Nick Holt
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 AMS
A natural fit: how and why the automotive production industry is turning to bio-materials for sustainable solutions in pursuit of zero emissions and enhanced performance Bio-based materials like flax, hemp, kenaf, and jute are reshaping automotive production for sustainability. These natural fibres offer durable, lightweight alternatives for several vehicle components, from dashboards to electric vehicle batteries. Martin Kahl
Next steps towards solid-state Solid-state batteries are seen as the next big technology step for electric vehicles, potentially reducing battery pack weight and offering improved energy density and range. AMS reports on progress at Solid Power. Mike Farish
New world order: How the US is boosting EV production with new technologies and investment The US is leading the way in the transition to EVs, with significant government support to increase domestic battery production and new technologies. Ian Henry explores how the US is becoming competition to China, and what it means for the rest of the world. Ian Henry
BMW: ‘Flexibility is in our genes’ BMW, Mini and Rolls Royce are driving a tight electrification course. Nevertheless, the group remains open to drive diversity. In an interview, production director Milan Nedeljković talks about flexibility and the concept of the iFactory. Götz Fuchslocher
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. Megan Kelly
BMW begins production at German cell manufacturing competence centre BMW has started production of cylindrical battery cells at its €170m Cell Manufacturing Competence Centre (CMCC) near Munich in Parsdorf, Germany. Megan Kelly
