Stellantis’ 2025 Factory Booster Day Showcases Technology

Stellantis is proving once again that it’s not just in the business of building cars—it’s in the business of building the future of how cars are made. The company’s 2025 Factory Booster Day, held at the Conner Center in Detroit, showcased more than 100 manufacturing innovations developed in partnership with 80 different suppliers and startups. The event underscored Stellantis’ ongoing transformation into a tech-driven manufacturer, with artificial intelligence (AI), robotics, and sustainable solutions leading the charge.

Reinventing The Factory Floor –

Now celebrating its 10th anniversary, Factory Booster Day has evolved into much more than a corporate demonstration. It’s a collaboration hub—where plant engineers, startup founders, and automation experts meet to tackle the challenges of modern vehicle production. The open-challenge format allows innovators to pitch real-world solutions for everything from improving line quality to cutting energy use and waste.

What makes the 2025 event stand out is the scale and maturity of the technologies on display. According to Stellantis, many showcased innovations are already in use across global facilities—delivering tangible results in uptime, quality control, and cost efficiency. Since 2021, these combined efforts have reduced transformation costs by 11%, lowered energy consumption by 23%, and cut quality issues by 40%.

“Factory Booster Day is not just an event, it’s a reflection of our manufacturing culture and global collaboration,” said 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.”

Award-Winning Ideas In Action –

The highlight of this year’s event was the 2025 Innovation Awards, honoring the most impactful projects submitted by Stellantis teams worldwide. The winners represented an impressive range of disciplines, from AI-driven predictive maintenance and paint-oven temperature monitoring to Body-in-White material optimization and the development of “quiet gears” that enhance the driving experience of future EVs.

One award-winning idea centered around a new ski-hemming welding process, which improves precision and reduces material fatigue during body assembly. Another focused on using virtual reality (VR) to retrain plant operators for retooled lines, minimizing downtime and improving worker readiness.

Practical Innovation For Real Plants – 

Unlike many tech expos where concepts stay theoretical, Factory Booster Day is all about real-world deployment. At Sterling Heights Assembly Plant (SHAP), Stellantis introduced a VR Forklift Training Simulator that immerses operators in realistic warehouse scenarios. This system helps employees build muscle memory in a safe virtual space—cutting training time while enhancing safety and performance.

At the Detroit Assembly Complex – Jefferson (DACJ), KEYENCE’s IV4 smart-camera system uses integrated AI to perform more than 50,000 inspections per day, ensuring every fastener is installed correctly. The all-in-one camera unit combines lighting, lenses, and deep-learning software that delivers instant feedback to line operators, triggering repair alerts and generating daily analytics for continuous improvement.

Another major step forward involves AI-powered predictive maintenance developed with KCF Technologies. This system analyzes real-time data from pumps, fan units, and oven exhausts to predict component failures before they happen—reducing downtime and saving thousands in maintenance costs.

Automation Meets Sustainability – 

Beyond efficiency, sustainability was a major focus in 2025. Startups showcased technologies that use digital twins, smart sensors, and machine vision to fine-tune energy use, material thickness, and fluid dynamics across production lines. Some even demonstrated ways to retrofit existing carts and dollies into autonomous mobile robots (AMRs), enabling seamless material movement across plants without major retooling.

A Glimpse At The Future – 

The 2025 Factory Booster Day ultimately paints a clear picture of Stellantis’ manufacturing future: one where AI, automation, and human creativity work side by side. The event has become a proving ground for technologies that will define how the next generation of Chrysler, Dodge, Jeep®, and Ram vehicles are built.

For Stellantis, innovation isn’t confined to the design studio or the proving grounds anymore—it’s happening right on the factory floor, one smart sensor, robot, and virtual reality headset at a time.