Stellantis recently hosted its 10th edition of its annual Factory Booster Day at the automaker’s Conner Center in Detroit.
The event brought together 80 suppliers and startups that showcased more than 100 innovations, many of which leverage artificial intelligence (AI), vision systems, and autonomous technologies to improve quality, efficiency, and sustainability across Stellantis’ global operations.
A highlight of the day was the 2025 Innovation Awards, which recognize outstanding contributions from Stellantis employees across all regions.
The awarded projects include advancements in predictive maintenance, the use of virtual reality for retooling production lines, innovative monitoring of paint ovens, optimization of material thickness in Body-in-White, the development of a new ski hemming process for welding, and the design of quiet gears to enhance the customer experience in battery-electric vehicles.
“Factory Booster Day is not just an event, it’s a reflection of our manufacturing culture and global collaboration,” says Tim Fallon, senior vice president, global head of Stellantis Production Way. “By empowering our teams and partnering with startups and suppliers, we co-create smart solutions that drive quality, agility, and sustainability across Stellantis. Together, we are building the future of manufacturing.”
Through an open challenge process, plant leaders invited suppliers and startups to pitch ideas for improving manufacturing processes, making Factory Booster Day a global showcase for practical, forward-thinking solutions delivered through both physical and virtual demonstrations.
Many of the innovations over the years have been deployed across Stellantis plants worldwide, delivering measurable improvements in quality, lead time, and cost efficiency and significantly reducing production costs while enhancing product and process quality.
Below are some examples of innovations from past Factory Booster Day events implemented at Stellantis facilities:
Predictive Maintenance in Paint Shops
A highlight from the 2024 Factory Booster Day is the deployment of an AI-powered predictive maintenance system in North American paint shops, developed in collaboration with KCF Technologies. By leveraging real-time sensor data from critical assets, including pumps, fan units and oven exhaust systems, the system identifies emerging issues and prioritizes maintenance needs, empowering teams to act proactively to minimize disruptions. The technology has delivered measurable improvements in uptime, reliability and preventing costly breakdowns.
Artificial Intelligence Part Verification
KEYENCE showcased its IV4 smart-camera system with integrated AI that is now in operation at the Detroit Assembly Complex – Jefferson, performing 100 inspections per vehicle or more than 50,000 inspections per day. The solution ensures every fastener is installed, delivering real-time feedback to operators through in-station displays and automated repair alerts. The IV4’s all-in-one design, featuring built-in lighting, lenses, and AI-powered functions such as triggering, object tracking, and inspection drives adaptability, accuracy and long-term stability on the line. In partnership, Stellantis developed an AI Agent Tracker to provide daily performance analytics post-deployment. This data-driven feedback loop enables precise camera tuning, supports continuous improvement and lays the foundation for broader rollout across trim, chassis and engine line applications.
VR Forklift Training Simulator
Currently being installed at the Sterling Stamping Plant, the Forklift Simulator was selected for Factory Booster Day 2025 as a standout example of Stellantis’ drive to integrate advanced technology into manufacturing. The virtual reality training solution immerses operators in realistic scenarios, allowing them to develop essential skills and muscle memory in a safe, controlled environment. The deployment supports Stellantis’ commitment to a safe work environment, empowering teams to proactively address risks and uphold the highest safety standards across operations.
Stellantis brands include Abarth, Alfa Romeo, Chrysler, Citroën, Dodge, DS Automobiles, FIAT, Jeep, Lancia, Maserati, Opel, Peugeot, Ram, Vauxhall, Free2move, and Leasys.
For more information, visit www.stellantis.com.
