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How AI solutions can solve the challenges faced by automotive suppliers


AI solutions & use cases for automotive suppliers.

Challenges for automotive suppliers


Automotive suppliers have faced considerable challenges since 2020: Disrupted supply chains, rising energy and raw material costs, the transition to electromobility and major production fluctuations are putting enormous pressure on the industry. Automotive suppliers are a key part of the automotive value chain and their ability to operate flexibly and efficiently is crucial to the success of the entire industry. Unfortunately, the numerous crises and upheavals in recent years have dramatically increased the burden on suppliers.

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  1. Supply chain disruptions and material shortages: The automotive supply industry is highly globalized and even minor disruptions can have far-reaching effects on the entire supply chain. In particular, the dependence on specific components and raw materials has led to bottlenecks that are difficult to overcome. Missing materials have not only caused production stoppages, but have also driven up the cost of affected components.
  2. Rising energy and raw material costs: Energy prices and raw material costs have climbed to a new high, which poses a considerable challenge for suppliers who generally operate energy-intensive production processes. Medium-sized companies in particular, which are less able to pass on price increases to their customers, are under enormous financial pressure.
  3. Transformation pressure towards electromobility: The automotive industry is currently undergoing one of the biggest transformations in its history - the switch from combustion engines to electromobility. For suppliers, this means adapting and realigning their entire production processes and developing new skills. At the same time, new regulatory requirements and the growing demand for more climate-friendly solutions require extensive investment.
  4. Fluctuating production volumes: Automotive suppliers are also confronted with strong fluctuations in production volumes. The uncertainty in the industry, exacerbated by the shortage of important raw materials and volatile markets, makes it difficult to plan production efficiently. Many companies are struggling with the fact that they sometimes work below capacity to save costs and then have to compensate for production peaks without having sufficient resources available.
  5. Increasing competitive pressure and falling margins: the entire automotive industry is under considerable pressure to reduce costs. As a result, OEMs (Original Equipment Manufacturers) are increasingly trying to pass this cost reduction on to their suppliers. In conjunction with rising raw material and energy costs, this is leading to an erosion of margins, making it difficult for many companies to remain profitable.

How can AI overcome these challenges? Our approaches and solutions.

Artificial intelligence offers innovative tools to tackle these problems in a targeted manner and strengthen competitiveness. AI solutions make it possible to leverage efficiency potential, reduce costs and ensure flexibility in production processes. Some specific areas of AI application are described below, which are tailored to the special challenges of automotive suppliers. Nelpx is at your side at all times and offers a wide range of AI-Portfolio to provide you with the best possible support.


Supply chain optimization through AI-supported forecasts

A key problem in recent years has been the instability of supply chains. AI systems are able to mitigate this instability by identifying potential bottlenecks at an early stage and highlighting possible alternatives. With solutions from our partners, automotive suppliers can forecast demand more accurately, optimize logistics processes and secure requirements at an early stage. In addition, AI can also analyze economic trends and global events to identify risks to the supply chain before they become serious problems.

Use Case: An automotive supplier uses a  Ai Solution from one of our partners to analyze supply chain risks in real time. The AI detects a delay in a key raw material delivery and simulates alternative sourcing scenarios. This AI-based decision support enables the supplier to find an alternative source of supply so that production interruptions are avoided. In addition, the AI provides a visual representation of the bottlenecks and helps to proactively redesign the supply chain to prevent future risks.


Energy efficiency through AI-controlled production processes

The sharp rise in energy costs is putting automotive suppliers under enormous pressure. With the help of AI, production plants can be operated more energy-efficiently. Leading AI providers from our network offer solutions that analyze production processes in real time and make suggestions for adjustments to reduce energy consumption. AI can not only monitor energy consumption, but also analyze historical data to identify long-term savings potential and achieve sustainability goals.

Use case: A supplier uses an AI platform, available through our partnerships, to analyze energy consumption in its production facilities. The AI identifies inefficient energy use in areas such as heating and cooling and makes adjustments to optimize energy consumption. These measures lead to savings of up to 20 % and not only reduce energy costs, but also improve the company's environmental footprint. The AI also produces detailed reports that help decision-makers to better plan investments in energy-efficient technologies.


Quality control and error detection in real time

Due to rising material costs, production errors are becoming increasingly costly. AI-supported quality controls offer the opportunity to detect errors at an early stage and take direct countermeasures. The machine vision solutions provided by our partners use machine learning to identify production errors in real time and take immediate corrective action. In addition, AI can recognize patterns that indicate systematic production problems, leading to long-term improvements in quality.

Use case: In the production of components for electric motors, a supplier uses AI-supported cameras to check each component during the manufacturing process. An AI solution detects even the smallest deviations and provides immediate feedback before the part moves on to the next process step. This reduces waste, saves raw materials and shortens production time. In addition, the AI analyzes the most common sources of error and thus helps to continuously improve production processes.


Predictive maintenance to minimize downtimes

Unplanned machine downtimes cause high costs. AI-supported predictive maintenance can prevent such downtimes. The AI solutions provided by our partners continuously monitor machines and predict maintenance requirements before a problem occurs. This not only contributes to higher machine availability, but also reduces maintenance costs, as maintenance work is carried out in a targeted and non-reactive manner.

Use case: An automotive supplier that manufactures body parts uses a predictive maintenance solution from one of our partners. The AI continuously monitors parameters such as vibrations and temperature and identifies anomalies at an early stage. This allows the maintenance team to intervene in good time before a machine breakdown occurs. This reduces downtimes by up to 30 %. The AI also evaluates historical maintenance data in order to optimize maintenance intervals and avoid unnecessary maintenance work.


Accelerating the transformation to electromobility

The transition to electromobility requires suppliers to fundamentally adapt their production processes and product lines. AI-based tools, available through our partnerships, help to efficiently retool production lines and analyze the requirements of new products. AI can simulate different scenarios so that suppliers can make informed decisions on how to optimally convert their production to minimize costs and changeover times.

Use case: A supplier that previously manufactured components for combustion engines uses an AI-supported production analysis to optimize the production of battery modules. The AI simulates different production configurations, identifies the most efficient options and thus helps to minimize changeover costs and shorten the changeover time. During the changeover, the AI provides continuous feedback so that the transition runs more smoothly.


Optimization of material procurement and warehousing

Raw material prices are often volatile and difficult to predict. AI can help to optimally plan material requirements and efficiently manage inventories in order to minimize storage costs. Our partners offer AI-supported material management solutions that forecast requirements and optimize orders. In addition, AI can monitor stock levels in real time and help avoid bottlenecks.

Use case: A supplier faced with highly fluctuating aluminum prices uses a material management solution from one of our partners to optimally plan material requirements. The AI analyses historical data, current market trends and changes in demand to optimize order quantities and timing. This allows the supplier to take advantage of more favorable purchasing times and reduce inventory costs by 15%. At the same time, the AI ensures that excess stock is avoided and reliable material availability is guaranteed.

Get in touch with us


The automotive industry is in a phase of profound change, and suppliers in particular have been severely affected by the challenges of recent years. The use of AI offers the opportunity to overcome these issues, increase efficiency and reduce costs. Field-proven AI solutions available through our partnerships help automotive suppliers to become more competitive and successfully master the transition to electromobility. AI not only helps to improve existing processes, but also opens up new opportunities for value creation and innovation.

Are you interested in delving deeper into a specific use case or planning a demo to experience the benefits of AI solutions? We at Nelpx are happy to support you in finding customized solutions for your specific requirements. Let's shape the future of the automotive industry together!

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