Tag Archives: Production

News

BMW Dadong Hits 3.5 Million: The Black Warrior Rises

China loves a milestone, and BMW’s Shenyang Dadong plant just clocked a big one: 3.5 million cars built since 2003. That’s two decades of Bavarian metal rolling off Chinese assembly lines, capped by a landmark car that sounds more Marvel than Munich: a BMW 5 Series Shadow Edition, nicknamed the “Black Warrior.”

And fittingly so. If there’s one car that embodies BMW’s Chinese success story, it’s the 5 Series long-wheelbase, a chauffeur special that’s become the go-to ride for executives who prefer to stretch out in the back. More than 2 million 5ers have been built here alone, making it the undisputed heavyweight champ of China’s premium sedan ring.

But Dadong isn’t just about pampering backseat bosses. The factory has morphed into one of BMW’s most advanced facilities worldwide. In 2022 it got a digital makeover worthy of Silicon Valley—AI cameras at 30+ stations keep watch for the tiniest assembly hiccup, while paint quality is checked by 100,000 images per car, hunting down shadow imperfections with almost obsessive precision. If you thought BMW was fussy about panel gaps in Germany, Dadong is on another level.

It’s also the only plant on Earth building the iX3 EV for export markets, and it cranks out the long-wheelbase X3 and X5 for SUV-hungry Chinese buyers. All on flexible lines that can switch between petrol, plug-in, and full electric builds without skipping a beat. That’s iFACTORY strategy in action—lean, green, and digital.

Still, the gloss hides some cracks. BMW’s China sales were down 15 percent in 2024, exports sank by more than a third, and local EV upstarts are circling like sharks. Even the mighty 5 Series is under siege in a market where apps and range anxiety matter more than leather and legroom. Enter Birgit Böhm-Wannenwetsch, BMW Brilliance’s new CEO as of August, tasked with steering the ship through these choppy waters.

For now, though, BMW has every reason to toast Dadong’s achievement. 3.5 million cars is no small feat, and with its sister plant Tiexi, Shenyang is about to chalk up 5 million units combined later this year. Not bad for a hub that started out as BMW’s first China foothold.

And if the last car off the line was a Black Warrior, perhaps that’s exactly what BMW needs in China right now: a fighter.

Source: BMW

News

Subaru Indiana Plant Builds 6 Millionth Vehicle, Marks End of Legacy Sedan

Subaru of Indiana Automotive (SIA) has reached a major manufacturing milestone, rolling out its six millionth vehicle—a 2025 Subaru Legacy Limited in Cosmic Blue Pearl—at its Lafayette, Indiana facility. The moment marks both a celebration of longevity and a poignant farewell, as the milestone vehicle also represents the final generation of the Subaru Legacy sedan, which will end production this fall.

“This milestone is a powerful reminder of how far we’ve come over the past 38 years,” said Scott Brand, president and COO of SIA. “I’m incredibly proud of our associates and the consistent dedication they bring to exceeding our customers’ expectations for safe, high-quality vehicles.”

The Lafayette plant, Subaru’s only manufacturing site outside of Japan, has become a cornerstone of the brand’s North American strategy. Currently producing the Ascent, Crosstrek, Legacy, and Outback, the facility is responsible for assembling approximately half of all Subarus sold across North America.

Yet the six-millionth vehicle comes with a hint of nostalgia. The Legacy, first launched for the U.S. market on September 11, 1989, was the very first Subaru built at SIA. Designed to compete in the mid-size sedan segment, the Legacy brought advanced technology and sharp styling to the table. Its wagon variant would later evolve into one of Subaru’s most successful and recognizable nameplates—the Outback.

Over its seven generations, the Subaru Legacy has garnered over 1.3 million U.S. sales. However, like many sedans, its market share has dwindled amid consumer preference for SUVs and crossovers. Subaru has acknowledged this shift by preparing for the next phase of its U.S. manufacturing roadmap.

Production of the popular Subaru Forester will begin at the Indiana plant this fall, with the Forester Hybrid following in spring 2026. This move not only expands the plant’s capacity but also aligns with Subaru’s broader push toward electrification and sustainability.

“Our associates have every reason to take great pride in this achievement,” Brand added. “They’ve weathered a number of industry challenges in recent years with resilience, never losing sight of their commitment to excellence.”

Looking ahead, SIA expects to reach another production milestone—its eight millionth vehicle—by November. As the automotive landscape evolves, Subaru’s U.S. plant remains a symbol of adaptability and forward-thinking manufacturing.

While the end of the Legacy may mark the conclusion of one chapter, it also underscores a strategic pivot toward electrified mobility and localized production. In the ever-shifting terrain of the automotive world, Subaru’s Indiana plant stands firm—part legacy, part future.

Source: Subaru

News

Volvo to Begin U.S. Production of XC60 at South Carolina Plant in 2026

Volvo Cars has officially confirmed that it will begin producing its best-selling XC60 mid-size SUV at its U.S. plant in Ridgeville, just outside Charleston, South Carolina. The move, set to begin in late 2026, comes as the Swedish automaker looks to strengthen its position in the U.S. market while strategically sidestepping tariffs imposed by former U.S. President Donald Trump.

The decision marks a significant milestone for Volvo’s American operations, especially as the XC60 continues to dominate the brand’s sales charts. In the first half of 2025 alone, the XC60 accounted for over 33 percent of Volvo’s U.S. sales, with a 22.9 percent year-over-year increase in June and a total of 21,907 units sold that month.

A Strategic Shift for a Critical Model

“Adding the XC60 to our Charleston production line will further strengthen its position and attractiveness in the competitive U.S. market, while supporting and creating American manufacturing jobs,” said Håkan Samuelsson, CEO of Volvo Cars. “It is also in line with our ambition to build where we sell and reinforces our long-term commitment to the U.S. market.”

The Ridgeville plant, which began operations in 2018, currently assembles the fully electric EX90 flagship SUV and the Polestar 3. However, both models have struggled to gain traction in the U.S. market. By adding the XC60—a proven sales leader—Volvo hopes to invigorate production lines and better align with U.S. consumer preferences.

Luis Rezende, President of Volvo Cars Americas, echoed the sentiment: “The XC60 is the right car for this market. It offers the best of Volvo in a versatile size with the powertrain options to suit our U.S. customers. We’re proud we’ll soon be able to offer American families the XC60 they love, assembled here by American autoworkers.”

A Pillar in Volvo’s Global Portfolio

The XC60 isn’t just Volvo’s top performer in the U.S.—it’s a global powerhouse. With over 2.7 million units sold globally, it recently surpassed the iconic Volvo 240 as the brand’s all-time best-selling model. U.S. customers have long gravitated toward the XC60 for its blend of safety, luxury, and Scandinavian design.

The model will be produced in both mild hybrid and plug-in hybrid variants in Charleston. That’s a particularly strategic move, given that 25 percent of XC60s sold in the U.S. this year are plug-in hybrids—making it the fourth best-selling luxury plug-in hybrid in the country. For Volvo, it’s not just about meeting current demand, but also about accelerating its push toward electrification.

Investment in the Future

Volvo has invested $1.3 billion into the Ridgeville facility over the past decade, preparing it for high-volume, flexible production. The plant now includes a state-of-the-art battery pack assembly line and upgraded body and paint shops. These enhancements ensure the factory can handle a wide variety of platforms and powertrains.

Governor Henry McMaster and state officials have played a key role in supporting Volvo’s expansion, with South Carolina’s pro-manufacturing policies and workforce development initiatives cited as major factors in the decision.

Looking Ahead

With the addition of the XC60, Volvo is reinforcing its commitment to building vehicles closer to where they are sold—both to reduce costs and to stay agile in a turbulent global trade environment. While the fully electric EX90 will continue to target forward-looking buyers, the XC60 will serve as the brand’s volume leader and bridge to an electric future.

In a year when Volvo celebrates 70 years in the U.S. and surpasses 5 million vehicles sold stateside, the XC60’s American production marks a new chapter in the company’s legacy—and a bet that South Carolina can deliver for one of Europe’s most storied automakers.

Source: Volvo