A — Set the stage (~10 min)
1. Hook & problem (2–3 min)
a. E.g. car value-chain emissions and logistics’ share (include lifetime fuel
use vs. transport fuel use)
2. What is green logistics? (3–4 min)
a. Definition: planning/executing transport, warehousing, packaging, and
returns to cut CO₂e, waste, and cost while maintaining service.
b. Key concepts: modal shift, load factor, intermodal, route optimization,
reverse logistics, nearshoring….
3. Why it matters in automotive (2–3 min)
a. High part count, global multi-tier supply, heavy components, Just-In-Time /
Just-In-Sequence (JIT/JIS) production sensitivity → many tonnekilometers and disruption risk
b. Risk mitigation
Script:
1. Hook & Problem (2–3 min)
Before you ever drive a car, it has already traveled more miles than you will probably put on it in
years.
From screws and semiconductors, to seats, engines, and batteries- car parts come from thousands
of suppliers across different continents.
Modern vehicles contain around 20,000-30,000 components, and many of these travel globally
through complex networks before reaching the assembly line.
This makes the automotive industry one of the most logistics-intense industries in the world.
And logistics isn't just trucks delivering cars to dealerships.
It includes shipping raw materials, moving parts between suppliers, factory-to-factory transport,
warehousing, packaging, and returns.
Why is this important?
Because logistics represents a major share of automotive Scope 3 emissions — estimates show
that 20–30% of a vehicle’s lifecycle emissions come from the supply chain and logistics alone.
(put here source)
And for electric vehicles, these logistics emissions are even higher because of the long-distance
movement of minerals and battery components.
So the problem we're looking at today is:
How can the automotive industry reduce CO₂ and environmental impact in its logistics
operations, without compromising delivery performance and production stability
2. What is Green Logistics? (3–4 min)
Green logistics can be defined as:
Planning and executing transport, warehousing, packaging, and return flows in a way that
reduces CO₂ emissions, waste, and cost - while maintaining service reliability.
So three things are happening at once:
- Reduce emissions
- Reduce waste
- Reduce logistics cost
This should all happen whilst maintaining service levels - meaning the parts still arrive on-time,
in-full, supporting lean Just-In-Time and Just-In-Sequence manufacturing.
“This is not just “being eco-friendly.”
It's about re-engineering the logistics system to be cleaner, more efficient, and more resilient.”
Problems that arise during green automotive logistics planning (examples from the real
world)
-Cars (~30 000 parts a car)
- Warehousing and Inventory problems (Ford)
- Supplier coordination and shortages (Toyota during the 2021 chip crisis)
- Complexity in transportation and packaging (Volkswagen group produces parts for
other car brands like Audi and Skoda all with minor differences and specificationsthe problem
is that they have similar looking components that require different packaging, labelling and
customs documentation which increases transport complexity and error risk)
- Assembly line delays (Tesla early Model 3 2018 production Problem Tesla initially
used too many small and unique components in it’s automation systems which caused too many
bottlenecks and slower output)
- Demand forecast (forecasting which combinations will be used is nearly impossible,
General Motors offered hundreds of seat fabric options across models)
- Logistics and its emissions impact (mainly scope 3)
- BMW has recognized logistics as a key lever for reducing its value chain co2 emissions
shifted more of its finished vehicle distribution to rail but unfortunately this has come with a
lot of problems due to diversions and lack of harmonised infrastructure across Europe
- Renault reports that tracking and reducing supply chain/logistics emissions is difficult
because standards and regulations continue to change- supply and demand cause networks to
morphe and fluctuate whilst geopolitical events inhibit certain transport modes or routes and
force companies to use higher emission alternatives
-Why is this important for logistics?
-congestions, delays and inefficient transport modes all increase fuel use & emissions per
units transported (parts or vehicles)
- the large complexity and multi tier supplier network make consolidating/loading
optimisation harder meaning more trips, lower load factors and higher emissions
-EV Batteries
- Tesla: Nevada–Fremont shuttle with 52 truckloads per night of batteries/parts → shows
energy-intensive, long-distance truck logistics.
Why this is energy-intensive


The route is hundreds of kilometres through the mountains ). Heavy trucks + long
distance = high fuel use and CO₂ .
Studies on road freight show that heavy-duty trucks used for long-distance transport
are responsible for most of road-freight CO₂ emissions.
- Volkswagen: Volkswagen ships huge volumes of battery cells and modules across
Europe; the flows are so big that moving them from long-distance trucking to rail cuts about
11,000 tonnes of CO₂ per year.
- BMW: Global sourcing of cells and new battery logistics hub; BMW itself says “shorter
transport distances” are key to reducing logistics CO₂ .
- Ford/Stellantis etc.: For companies like Ford and Stellantis, battery materials may be
mined in Chile or Australia, refined and turned into cells in China, and only then shipped to
Europe or the US for pack assembly – a very long and energy-intensive logistics chain.
All of these issues lead to JIT/JIS instability which cause a lot of issues throughout the
production and delivering procces.
3. Why It Matters in Automotive (2–3 min)
Green logistics is especially critical in automotive because:
- Cars use thousands of parts from hundreds of suppliers
- Supply chains are global and multi-tier
- EVs create new logistics needs (battery minerals, hazardous transport)
- Many parts are heavy and bulky → high emissions per shipment
- Production relies on JIT/JIS delivery → delays can stop the entire assembly line
- The industry succombs to CO₂ regulations, ESG pressure, and rising energy prices
- And logistics disruptions can cost millions of euros per day. For example when the
Suez canal blockade happened, up to 10 billion in daily trade losses were recorded
- So green logistics is not only about sustainability — it is also about:
- Cost control
- Risk reduction
- Resilience
- Maintaining competitive advantage
In other words:
A greener logistics system is also a stronger, safer, and more efficient logistics system.
Slides:
1. Hook & Problem
“Before a car reaches a dealership, its components may travel more than the car will in its
entire life. Logistics is a hidden CO₂ hotspot in automotive.”
Slide content
Cars = ~30,000 parts from global suppliers
Logistics = major contributor to automotive Scope 3 emissions
JIT/JIS deliveries → frequent transport
EV batteries = long-distance, energy-intensive logistics
Example stat: ~20–30% of lifecycle emissions come from supply chain (varies by OEM)
2. Slide title: What is Green Logistics?
Definition:
Planning & executing transport, warehousing, packaging, and return flows to reduce CO₂e,
waste, and cost while maintaining service performance.
Slide visual: 4 pillars
Reduce CO₂ emissions
Reduce waste
Reduce cost in long term
Maintain service (On-Time-In-Full, JIT/JIS stability)
3. Problems that arise during green automotive logistics planning (examples from the real
world)
Cars: Complexity Creates Logistical Problems
Key Idea: A single car has around 30,000 parts, making logistics extremely complex.
Real-World Problems:





Ford – Warehousing & Inventory: Too many unique parts cause overflow and tracking
errors in warehouses.
Toyota – Supplier Coordination: 2021 chip shortage exposed how global suppliers and
part variants make coordination fragile.
Volkswagen – Transport & Packaging: Similar parts for Audi, Skoda, and VW need
different labels and customs forms → mis-shipments and delays.
Tesla – Assembly Line Delays: Early Model 3 production suffered “production hell”
because too many unique parts slowed automation.
General Motors – Forecasting: Offering hundreds of seat fabrics made predicting demand
impossible → unused parts, waste, and high storage cost.
Takeaway:
More parts = more complexity, higher costs, slower production, and increased emissions.
Slide 2 – Logistics & Emissions Impact (Scope 3)
Key Idea: Logistics is a major source of Scope 3 CO₂ emissions in the automotive supply chain.
Real-World Problems:


BMW: Shifted finished-vehicle transport to rail to cut CO₂, but faces rail bottlenecks and
lack of harmonized infrastructure across Europe.
Renault: Finds it hard to track and reduce emissions because standards, routes, and
geopolitical conditions constantly change, forcing use of high-emission transport modes.
Why It Matters:


Congestion, delays, and inefficient modes increase fuel use and emissions per vehicle.
Multi-tier global networks make load optimization and consolidation harder, leading to
more trips and wasted capacity.
Takeaway:
Greening logistics is essential but difficult—emissions reduction often conflicts with reliability
and cost.
Slide 3 – EV Batteries: The New Logistics Challenge
Key Idea: Electric-vehicle batteries are heavy, hazardous, and travel long distances — making
logistics energy-intensive.
Real-World Examples:



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Tesla: Moves batteries daily between Nevada and California (≈52 truckloads/night) →
long-distance, high-energy trucking.
Volkswagen: Imports lithium-ion cells from Asia and ships them across Europe;
switching to rail saves 11,000 t CO₂e/year.
BMW: Still sources globally; building new hubs to shorten transport routes and cut
logistics CO₂.
Ford & Stellantis: Rely on global chains — mining in Australia/Chile, refining in China,
assembly in Europe/US → massive transport emissions.
Takeaway:
EVs may reduce tailpipe emissions, but battery logistics remain carbon-intensive until
production becomes more local and transport more efficient.
4. Why It Matters in Automotive
Slide content
High part count & global suppliers → massive transport volume
Heavy parts (batteries, engines) → high carbon intensity
JIT/JIS plants extremely sensitive to logistics delays
Sustainability & regulatory pressure (EU Green Deal, CBAM)
Supply-chain resilience = competitive advantage
Quellen:
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J Poschmann et al., “Decarbonization Potentials for Automotive Supply Chains”,
Sustainability (2023) — shows that a substantial share of life-cycle emissions
remains in upstream supply chain (manufacturing and logistics) in
automotive. MDPI
Y Wang et al., “Optimizing scope 3 emissions in the automotive supply
chain” (2024) — focuses on emissions quantification and supply-chain
optimization in automotive. SpringerLink
Capgemini Research Institute, “Automotive Supply Chain: Pursuing Long-Term
Resilience” (2023) — examines supply-chain risks, global footprints and the
logistics intensity of automotive. Capgemini
Dörnhöfer & Herold, “Logistics performance measurement system for the
automotive industry”, Logistics Research (2016) — develops a PMS
(performance measurement system) for automotive logistics, linking logistics
metrics to lean-manufacturing context. bvl.de
F Nunes et al., “Implementing Key Performance Indicators and Designing
Dashboard Solutions in an Automotive Components Company: A Case Study”,
Administrative Sciences (2024) — shows how KPIs are used in automotive
components/logistics. MDPI
KPMG/“Automotive Industry: Make fragile supply chains more robust” (2022)
— highlights how global auto supply chains (including logistics) are vulnerable
and why logistics matter for risk/resilience. KPMG
“Emissions calculation and reporting guideline for automotive supply chains” by
ECG/VDA (2023) — gives industry guidance on emissions reporting in
automotive logistics/transportation. ecgassociation.eu
S Saji, “Shifting Gear Towards Green Logistics” (2024) — discusses green
logistics concepts including modal shift, warehousing, packaging, etc. DIVA
Portal
Quellen powerpoint:
Automotive Logistics Media (2019), Ford Part 3: Supply Chain Upgrades, retrieved November
2025, from https://www.automotivelogistics.media/supply-chain/ford-part-3-supply-chainupgrades/206673
McKinsey & Company (2021), Semiconductor Shortage: How the Automotive Industry Can
Succeed, retrieved November 2025,
from https://www.mckinsey.com/industries/semiconductors/our-insights/semiconductorshortage-how-the-automotive-industry-can-succeed
Logistics Viewpoints (2009), Ford’s Service Parts Supply Chain, retrieved November 2025,
from https://logisticsviewpoints.com/2009/10/27/fords-service-parts-supply-chain/
Fastnacht, B. (2017), Application of Part Kitting Methodology in High-Volume Automotive
Production at Ford Valencia Plant, Technische Universität Wien, retrieved November 2025,
from https://repositum.tuwien.at/bitstream/20.500.12708/7406/2/Fastnacht%20Benjamin%20%202017%20-%20Application%20of%20part%20kitting%20methodology%20in%20high...pdf
Automotive Logistics Media (2023), Why Just-in-Time Will Remain the Way Forward for
Toyota, retrieved November 2025, from https://www.automotivelogistics.media/oems/why-justin-time-will-remain-the-way-forward-for-toyota/181678
Supply Chain Digital (2023), BMW Group Targeting Logistics to Meet 2030 Net-Zero Target,
retrieved November 2025, from https://supplychaindigital.com/sustainability/bmw-grouptargeting-logistics-to-meet-2030-net-zero-target
UECC (United European Car Carriers) (2021), Green Logistics: The Logical Route for BMW
Group, retrieved November 2025, from https://www.uecc.com/news/2021/july/green-logisticsthe-logical-route-for-bmw-group/
ESG Today (2022), BMW Launches Initiatives to Improve Sustainable Packaging and Reduce
Emissions in Supply Chain, retrieved November 2025, from https://www.esgtoday.com/bmwlaunches-initiatives-to-improve-sustainable-packaging-reduce-emissions-in-supply-chain/
Automotive Logistics Media (2024), BMW Group’s Thomas Wiech Talks Present-Day
Challenges and Digital Transformation in Vehicle Distribution, retrieved November 2025,
from https://www.ecgassociation.eu/wp-content/uploads/2024/06/BMW-Groups-ThomasWiech-talks-present-day-challenges-and-digital-transformation-in-vehicle-distribution.pdf
Automotive Logistics Media (2024), Inside BMW’s Smart Logistics Strategy at Debrecen and
Munich Plants, retrieved November 2025, from https://www.automotivelogistics.media/leanlogistics/inside-bmws-smart-logistics-strategy-at-debrecen-and-munich-plants/1619429
ResearchGate (2023), BMW Supply Chain Management System, retrieved November 2025,
from https://www.researchgate.net/publication/389749925_BMWSupply_Chain_Management_System
Renault Group (2023), Artificial Intelligence in Logistics: Driving Our Industrial Performance,
retrieved November 2025,
from https://www.renaultgroup.com/en/magazine/technology/artificial-intelligence-in-logisticsdriving-our-industrial-performance/
Automotive Logistics Media (2023), How the Automotive Industry Is Tracking and Reducing
Logistics and Supply Chain Emissions, retrieved November 2025,
from https://www.automotivelogistics.media/sustainability/how-the-automotive-industry-istracking-and-reducing-logistics-and-supply-chain-emissions/189629
IDEAS/RePEc (2025), Automobile Dacia Logistics Case Study: Supply Chain Challenges and
Delivery Lead Times, retrieved November 2025,
from https://ideas.repec.org/a/vrs/poicbe/v19y2025i1p1201-1215n1015.html
RMI (Rocky Mountain Institute) (2024), The EV Battery Supply Chain Explained, retrieved
November 2025, from https://rmi.org
DB Cargo / Volkswagen AG (2023), Rail Transport of Battery Cells Cuts 11,000 t of CO₂ per
Year, retrieved November 2025, from https://www.dbcargo.com/rail-de-en/industrysolutions/automotive/vw-battery-transport
BMW Group (2024), Neue Klasse Battery Cell and Logistics Hub Development, retrieved
November 2025, from https://bmwgroup.com
Mag Toyota UK (2020), Just-in-Time: How Toyota’s Lean Production Works, retrieved
November 2025, from https://mag.toyota.co.uk/just-in-time/
Gerpisa (2001), Transplant Suppliers and Honda’s Just-in-Time Production Network, retrieved
November 2025, from https://gerpisa.org/ancien-gerpisa/actes/7/7-5.pdf
POMS Conference Proceedings (2007), Case Study of a Japanese Vehicle Manufacturer’s UK
Plant: JIT Deliveries Every Two Hours, retrieved November 2025,
from https://pomsmeetings.org/confpapers/008/008-0679.pdf
Handout text:
The automotive industry is one of the most logistics-intensive sectors in the world. Before a car
even reaches the dealership, it has already traveled thousands of miles through a vast global
network. Modern vehicles contain 20,000–30,000 parts sourced from thousands of suppliers
across multiple continents. These components move through complex flows of shipping,
warehousing, packaging, factory-to-factory transport and returns [1].
Because of this enormous movement, logistics represents a major share of automotive
emissions. Around 20–30% of a vehicle’s total lifecycle CO₂ comes from supply-chain and
logistics activities. This share is even higher for electric vehicles due to the transport of heavy
batteries and raw materials [2].
Green logistics is the strategic effort to make these systems more sustainable. It
involves planning and executing transport, warehousing and packaging in ways that reduce CO₂
emissions, waste and cost, while maintaining delivery speed and reliability [3]. It is not just about
being eco-friendly; it is about redesigning logistics systems to be more efficient, resilient and
aligned with environmental goals [1].
In the automotive sector, green logistics is essential for balancing sustainability with operational
performance. By optimizing transport routes, consolidating shipments and integrating cleaner
modes of transport, automakers can lower emissions, reduce costs and strengthen supply-chain
resilience [2][3]
[1] Automotive Logistics Media. (2023). How the automotive industry is tracking and reducing
logistics and supply chain emissions. Retrieved November 2025,
from https://www.automotivelogistics.media/sustainability/how-the-automotive-industry-istracking-and-reducing-logistics-and-supply-chain-emissions/189629
[2] Rocky Mountain Institute (RMI). (2024). The EV battery supply chain explained. Retrieved
November 2025, from https://rmi.org
[3] Supply Chain Digital. (2023). BMW Group targeting logistics to meet 2030 net-zero
target. Retrieved November 2025, from https://supplychaindigital.com/sustainability/bmw-grouptargeting-logistics-to-meet-2030-net-zero-target