Forvia Interiors is accelerating the digital transformation of its packaging and logistics processes as part of a broader effort to build a more transparent, automated and predictable global supply chain.
Forvia products, including door panels, dashboards and center consoles, rely on highly synchronized just-in-time flows that are increasingly volatile as OEM schedules fluctuate. Speaking at Automotive Logistics and Supply Chain Digital Strategies Europe 2025, Zvonimir Zaja, head of global supply chain and logistics at Forvia Interiors, said the interiors division was deploying data-driven automation across its factories, from injection molding to truck loading, to reduce inventory, improve load utilization and build resilience.
Automation reshapes packaging at Spain’s flagship factory
Zaja highlighted the company’s digital “flagship” factory in Tarazona, northern Spain, which produces door and instrument panels for a major OEM. There, Forvia digitized the entire injection molding process on 30 machines, recording temperatures and other parameters and transmitting the data directly to supervisors via dashboards.
One of the most important steps in packaging logistics within the company is the introduction of an automated “self-packing” process. “This is a door panel that is now used in the machine where we do what is called automotive wrapping,” Zaja said. “We produce and put these parts directly on the shelves.” Parts go directly from injection to packaging sites ready to ship without manual handling, reducing labor requirements and the risk of packaging errors or damage.
This packaging activity is integrated into an end-to-end automated material flow controlled by AGVs. “This is a part of end-to-end automation. We have used and implemented this AGV from injection molding in our so-called second level workshop stock. It automatically feeds the assembly line or even goes further,” Zaja said. The AGV system connects injection, packaging and assembly lines via a multi-level internal layout designed for high-mix, high-volume component flows.
Constitution of loads and handling without forklift
Forvia also manages logistics without forklifts and automated load creation to optimize outgoing flows. At Carazona, the team has tested unmanned forklifts for internal deliveries and is currently validating tools for automated truck loading and virtual load creation. “We measure the data and use it to understand certain parameters and models. This is a part of our delivery where we have tested the manless forklift. This is the truck loader loading building, we have a truck that we can load physically and in the system to really understand what the utilization rate of the truck is to optimize costs,” he added.
The enhanced load creation system uses MRP inputs and transportation management data to generate optimized load patterns that make greater use of trailer space, helping to reduce transportation costs and CO₂ emissions. This capability is being expanded globally as Forvia seeks to standardize packaging formats and integrate physical and digital cargo verification.
Integrating Resilience into Packaging and Logistics
Forvia’s long-term goal is to integrate risk awareness and predictive capabilities directly into its packaging, warehousing and transportation decisions. The company is developing new data-driven roles, including digital twin analysts and data engineers, to create and maintain the required models and ontologies. Change management remains essential, with teams testing in parallel to build confidence in AI-driven recommendations.
Packaging is at the center of this transformation. Automated packaging, forklift-less handling and smarter load-building serve not only to improve efficiency, but also to increase the resiliency of a supply chain where short-term changes can impact operations. With a strong business case from early pilots, Forvia is now evaluating the next phase of network-wide deployment.