While vehicles integrate software and hardware to create new functionality, flexible manufacturing platforms are active behind the scenes to help meet customer requirements and changing market demands.
By Mark Shortt
For today’s automakers, the use of software to enhance the functionality of hardware is fertile ground for innovating new products.
A prominent example is a new electromechanical suspension developed by the mobility technology supplier Marelli. Although not yet commercialized, Marelli’s Fully Active Electromechanical Suspension was selected for a 2025 Automotive News PACEpilot Award for its “potential to revolutionize the future of mobility.”
The electromechanical system integrates software to actively manage the vertical dynamics of a vehicle’s suspension in a new way, creating what the company called “a cutting-edge alternative to traditional shock absorber solutions.” According to a release from Marelli, the system autonomously defines the optimal behavior of each vehicle’s suspension.
Its four electronically controlled actuators are reported to modulate each wheel’s suspension and damping parameters in real time to provide optimal handling. Vehicle dynamics software calculates “the most suitable target action for each actuator based on the information collected from sensors that are mounted on the suspension, as well as from other electronically controlled systems installed in the car.” The technology is adaptable to various vehicle architectures, and its reduced volume and weight give carmakers more flexibility in design, the company said.
Manufacturing execution systems offer key advantages
To the general public, it’s the products—components, systems, and finished automobiles—that are the most readily recognizable automotive innovations. Not as visible are the processes and platforms that manufacturers are using to bring these products to market.
Today, manufacturers are increasingly adopting manufacturing execution system (MES) software platforms that provide part traceability, supply chain transparency, and a basis for various ways to enhance production. And as industries ramp up efforts to maximize efficiency and data-driven decision making, the market for manufacturing execution systems is shaping up to grow substantially in the next five years. Overall, the global market for MES is forecast to increase from roughly $16 billion in 2025 to nearly $26 billion in 2030, according to a report from the management and consulting firm MarketsandMarkets™ . (See Manufacturing Execution Systems Market Projected to Reach $25.8 Billion in 2030.)
“Manufacturers within an Industry 4.0 environment use MES solutions with IoT components, artificial intelligence, and cloud computing to gain real-time data and automate processes while enabling predictive maintenance capabilities,” the company said in a release summarizing the findings of its report. “Businesses are increasingly opting for cloud-based MES platforms due to their scalability, remote accessibility, and cost-effectiveness. Advanced MES solutions with enhanced security capabilities are in high demand as manufacturers require protection against cybersecurity threats, data privacy issues, and industry regulation compliance.”
One of the sectors most likely to expand its use of MES over the next five years is automotive, due to the process enhancements that manufacturers stand to gain with these systems. By using MES, automotive manufacturers and their suppliers can sharpen their ability to trace parts in an ever more transparent supply chain. They can also implement real-time production monitoring, quality control, and enterprise connectivity, the company said in the release.
“Manufacturing execution systems are now essential for the automotive industry to manage operations efficiently, minimize production downtime, and enhance supply chain traceability,” the release stated. “As smart manufacturing evolves, the automotive sector’s reliance on MES will be pivotal in achieving higher productivity, maintaining stringent industry standards, and supporting future technological advancements.”
Flexible, adaptable manufacturing systems
Another benefit of manufacturing execution systems is that they can help spur automotive manufacturers to build more flexibility and precision into their production process—capabilities that are more crucial than ever amid increasing demand for electric and autonomous vehicles.
To meet customer requirements and adapt to changing market conditions, makers of electric and autonomous vehicles are recognizing the benefits of flexible, adaptable manufacturing systems that enable faster production and scale-up while allowing customization for various vehicle types. Kodiak Robotics, Inc., Roush Industries, Inc., and Honda are among the companies using flexible manufacturing systems to accommodate different vehicle configurations on the same production line. (See How Automakers Are Leveraging Software, Hardware, and Flexible Manufacturing to Create Space for All.)
Kodiak and Roush are working together to scale the customization of autonomous trucks that are equipped with Kodiak’s AI-powered autonomous platform, the Kodiak Driver. The platform “combines advanced AI and modular hardware in a system designed to integrate seamlessly across vehicle platforms—enabling scalable autonomy in real-world conditions,” according to Kodiak Robotics’ website.
The modularity and scalability of EV build platforms is also valued by the British classic electric sports cars manufacturer RBW EV Cars, which is currently constructing a state-of-the-art U.S. manufacturing facility in Danville, Virginia. Described as an “automotive hub,” the facility will house RBW’s assembly operations and Spirit EV, a patented, electric vehicle-integrated system that powers RBW EVs and enables “scalable electrification systems for automakers and specialty builders,” according to a company release.
Spirit EV, the developer of the system, is an EV design, build, and integration company that makes modular, scalable, and turnkey EV powertrain products for automakers. The company’s proprietary electric powertrain is reported to meet global compliance standards while simplifying the electrification process across vehicle body types.
“Breaking ground and preparing the city for its first major automotive player is exciting,” said RBW Director of U.S. Operations Peyton Sellers, in the release. “We are not only generating jobs, but we are also creating a new automotive hub for the industry to lean in on. The proprietary EV platform Spirit EV has developed allows an automaker to literally plug and play, saving them millions in R&D.”