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2020 -- Magna’s roadmap to e-mobility includes technologies showcased in the all-new e4 technology demonstrator car
debuting today during the company’s winter test-driving activities in northern Sweden
The e4 showcases Magna’s eDrive systems in a pure EV format at a time when automakers are making and executing plans for decreasing CO2 emissions and meeting legislation requirements around the world
The demo vehicle provides a new benchmark in efficiency and driving dynamics
providing up to 120km more range than current production models
The e4 technology demonstrator includes highly integrated PSM-type eDrive systems on the front and rear axle
The unit on the front is equipped with a mechanical differential
while the unit on the rear has a twin-clutch torque vectoring system
The e4 is the latest example of Magna’s modular and scalable powertrain solutions as the mobility technology company helps automakers prepare for a future that emphasizes electrification
Magna expects that global growth in e-mobility will include mild and micro hybrids
high-voltage hybrids and electric vehicles
“We are positioned to capitalize on the changing landscape with a strong product portfolio that covers various powertrain types,” said Tom Rucker
“From reducing CO2 and supporting sustainability goals to delivering dynamic
we can lead automakers through the powertrain transition with our modular and scalable powertrain configurations.”
Callista Private Equity GmbH (Callista) has announced the acquisition of Carl Zeiss Automated Inspection GmbH from ZEISS Group by Callista Asset Management 27 GmbH
The company has been part of the Zeiss Group since since December 2012
the company and its workforce of around 75 highly qualified employees specialize in the development and installation of automated inline measurement systems in the production lines of automotive OEMs
The solutions enable customers to replace time-consuming and error-prone manual processes with more efficient and reliable quality controls
the sensor technology used supports the digitalization of the production process and enables the creation of digital twins of each vehicle produced
Project business and product business differ significantly
ZEISS is consistently focusing on the latter
the structures are to be more closely aligned with the needs of the company and its customers
Parts of the sensors installed by the company will continue to be sourced from ZEISS
the company will operate under the name ‘Newston Automated Solutions GmbH’
“The aim is to utilize and further expand Newston’s excellent market position
The company’s well-filled order book provides a strong starting point for this” says Christopher Irion
further fields of application are to be developed in the future
For more information: www.callista-pe.de
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GLS Germany has introduced its first battery-electric lorry into regular long-haul operations
The Volvo ‘FH Electric’ truck will become a permanent part of the GLS fleet in June 2024
This introduction follows GLS’s two-stage pilot programme
focusing on the potential of battery-electric technology for longer distances
The addition of this electric vehicle complements GLS’s existing fleet
which already includes trucks powered by alternative fuels such as (bio)LNG
more than 1,100 zero- and low-emission delivery vehicles are in daily use in more than 250 cities in Germany
the battery-electric truck has covered more than 20,000 kilometres and transported approximately 150,000 parcels
“We are driven by our desire to innovate and are constantly testing new technologies where they make sense
The addition of the electric truck to our fleet is a testament to our progress towards sustainable long-distance transport,” said Jakob Nielsen
The truck has a battery capacity of 540 kWh and can be fully charged in two hours using a standard fast charger
It has a tested range of up to 350 kilometres under full load
The vehicle is currently being used between the GLS sites in Kürnach
Charging is integrated into the daily logistics operations at the Neuenstein site
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The automotive industry and its suppliers are part of a highly competitive market. To succeed in this market, increasingly efficient processes and reliable quality are essential. Magna Powertrain aims to achieve both through a high degree of digitalization.
Spanning over 140,000 square meters
Magna Powertrain's Neuenstein facility manufactures transmissions for various automotive corporations
They utilize a digitalized shop floor to minimize unplanned downtime through predictive maintenance
(Image: Olaf Gallas/Magna Powertrain) Magna is one of the world's largest automotive suppliers
The company employs 179,000 people in 28 countries
it maintains 343 production sites and 105 product development
The company's history began over 65 years ago
and today Magna claims to be a 42-billion-dollar business
It has grown over the past 20 years both organizationally and through significant acquisitions
one of the many fields of activity of the automotive supplier
These powertrains for combustion engines as well as partial and fully electric vehicles are manufactured
at the Neuenstein site in Baden-Württemberg
Customers range from Audi to Ferrari and Xiaopeng
In addition to the automotive industry's current major challenge of moving away from fossil fuels
is also faced with the necessity of digital transformation
This transformation importantly includes the integration of processes
something the transmission specialist is well-acquainted with
they approached it with Swabian pragmatism
This decision was based on real challenges
one of which was the high scrap rate of so-called build-to-print components
Automotive suppliers understand these as parts manufactured based on precise specifications and drawings provided by a customer
This approach ensures that the manufactured components fit precisely into complex systems such as automobile engines or car bodies
The reason for the scrap was identified as the well-known but undesirable triad in automobile production abbreviated as NVH
These refer to the noises and vibrations during the drive that are perceived negatively
the focus was also on reducing production costs and enhancing quality
creating more efficient processes to remain competitive
The local managers recognized that the desired automatic quality control of components requires dynamic processes and therefore a move away from static specifications
the first step involved establishing the connectivity between machines and IT systems necessary for all further stages of digitalization
Alongside the technical challenges inherent in such retrofitting
General Manager Operations at Magna Powertrain
Foremost among these is the need to "bring people along," as Eichele puts it
This means developing the readiness to engage with new technologies and approaches—from management to specialists on the shop floor
the reality is that downtimes are not a viable option in this business
solutions had to be sought and implemented in parallel with ongoing operations
One of the specific technical solutions involved the implementation of a fully integrated Manufacturing Execution System (MES)
The objective behind this was clear: to conduct all shop floor processes MES-based in the future
Such a system not only enables real-time monitoring and control of manufacturing—thereby increasing transparency and efficiency—but also allows the supplier to quickly identify and eliminate bottlenecks and inefficiencies
the MES improves product quality by technically supporting the traceability of materials and processes
This is particularly important for the automotive industry
exceptionally high quality standards and traceability are required
production scheduling at Magna has also been MES-based
The system captures real-time data from machines
and personnel to create detailed production plans
It takes into account the availability and capacity of resources
ensuring that they are used as efficiently as possible
It constantly monitors production progress
By analyzing the data collected and reporting the results
such a system enables continuous improvements and increases production efficiency
"A closed loop is created from production planning to production execution and back to planning
forming a control circuit," summarizes Markus Eichele
This simplifies shop floor processes while simultaneously reducing system interfaces
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Thus, the MES forms an important part of the technical foundation for two key approaches at Magna Powertrain, termed "Smart Quality" and "Smart Maintenance."
And the results—a noticeable reduction in scrap, tool cost reduction, and higher machine availability—speak for themselves. However, beyond KPIs and directly measurable outcomes, this move seems to have paid off for the company as well, as the feedback from the shop floor is "consistently positive," according to the site manager.
Senior Manager Production at Magna in Neuenstein
explains the importance of large screens: The dashboards provide real-time insights into factory operations
supplying valuable information to the people on the shop floor.(Image:Olaf Gallas/Magna Powertrain)It may also be due to the fact that in Neuenstein
it feels like the employees working on the machines are genuinely being included in the digital transformation
several large and visually striking monitors are noticeable
continuously providing all sorts of information
The data is automatedly processed in the background
and the derived information is made available on the shop floor
these digital dashboards replace 16,244 pages of paper per year
equivalent to an annual CO2 saving of 85.9 kilograms
and provide onsite employees with real-time insights into the production processes and energy consumption
The goals are to reduce paper use and increase transparency across all levels in the facility
This transparency consistently proves to be a success factor for employee acceptance of new technologies
a fact that seems to hold true here as well
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