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The automotive sector is in the midst of a major transformation. A joint study by ABB and Automotive Manufacturing Solutions (AMS)—the ABB / AMS Automotive Manufacturing Outlook Survey—maps how producers and suppliers view the near-term landscape. The report captures a clear shift in priorities as the industry moves from theoretical disruption to practical delivery, especially around electric vehicles, manufacturing flexibility and digital resilience.
The survey findings indicate that companies are not only optimistic about opportunities but also realistic about hurdles. Rising energy costs, labor rate pressures and supply chain fragility are forcing strategic re-evaluations. Many respondents highlighted the need to adopt automation and connectivity while redesigning plant footprints to handle mixed production runs for internal combustion engine, hybrid and electric vehicle platforms.
Core trends identified by the survey
Three themes consistently appear across the survey responses: the maturation of EV production, the ascent of cybersecurity as a manufacturing priority, and the push toward flexible, connected facilities. Respondents stressed that transitioning to mass EV output is no longer just a product strategy but a manufacturing imperative. At the same time, digitalization exposes plants and supply chains to new threats, elevating cybersecurity to the top of operational risk registers.
EV production: moving from experimentation to scale
According to the survey, the industry is shifting from pilot programs to volume EV manufacturing. That requires investments in new tooling, re-skilled labor and revised supply networks. Manufacturers are planning for mixed manufacturing lines capable of handling ICE, hybrid and EV variants concurrently. The study makes clear that mixed manufacturing—the capability to produce different propulsion types on shared lines—is essential for managing demand variability and extending factory utility as fleets evolve.
Cybersecurity as a manufacturing priority
Digital transformation has placed connectivity at the heart of operations, but it has also introduced vulnerabilities. The survey ranks cybersecurity ahead of many traditional manufacturing concerns, with firms prioritizing protections for production networks, supply chain data and remote diagnostics. Respondents emphasized that cybersecurity investments must be integrated with automation rollouts to ensure operational continuity and protect intellectual property.
How manufacturers can respond strategically
To capture the upside described in the survey, companies should pursue three complementary strategies: adopt smart factory concepts, accelerate automation across the supply chain, and invest in workforce transformation. A smart factory approach fuses sensors, analytics and robotics to enable real-time decision-making and greater flexibility. Survey participants see fully flexible, connected plants as central to handling mixed production and improving throughput while managing costs.
Smart factories and automation
Implementing smart factory principles helps reduce dependency on manual processes and strengthens responsiveness to market shifts. The survey highlights the need for adaptable automation that supports multiple vehicle architectures without long changeover times. Beyond shop-floor robotics, manufacturers are exploring digital twins, predictive maintenance and AI-driven scheduling to boost efficiency and lower risk.
Supply chain and workforce strategies
The survey also signals that supply chains must embrace more automation and diversification to withstand shocks. Companies are reassessing the traditional just in time model, balancing lean inventory goals with strategies that build resilience, such as regional sourcing and buffer stocks. Workforce challenges remain a top concern: successful transformation depends on reskilling programs, hybrid roles combining digital and mechanical expertise, and partnerships with suppliers to transfer best practices.
In sum, the ABB / AMS survey paints a picture of an industry that is adapting pragmatically. Manufacturers that prioritize secure, flexible operations and invest in people and technology will be best positioned to turn the transition to electric vehicles and digital production into sustainable advantage.