A ‘dark factory’, where latest cars are produced entirely by robots without human involvement, is ready to open as soon as 2030 and revolutionise vehicle manufacturing, in response to analysts.
In what often is the biggest shake-up since Ford’s adoption of the moving assembly line to fabricate the Model T in 1913 – cutting production times and costs while lowering showroom prices – the ‘dark factory’ may have serious implications beyond the factory floor.
Based on Automotive News, the move could reshape vehicle design principles, workforce training and the economics of automotive manufacturing through faster model changeovers.
It cites a study by McKinsey suggesting US$150 billion (A$223 billion) in annual ‘economic potential’ might be generated by integrating robotics and artificial intelligence (AI) into manufacturing.
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Benefits on the factory floor include a robot’s ability to vary tasks and perform processes humans cannot, while also not suffering fatigue – or, as experienced at Ford within the 1910s, boredom from repetitive jobs.
These aspects also reduce the likelihood of errors compared with human production-line staff, improving manufacturing efficiency in addition to the standard of the finished vehicle.
Using robotics in vehicle production and development is way from latest.
Ford Australia even used robot test drivers in the event of its Ranger Super Duty ute which went on sale late last 12 months.
Nevertheless, there’s an increasing deal with humanoid robots in vehicle production, something that’s expected to culminate in the primary ‘dark factory’.
Analysts at tech firm Gartner, in addition to Warburg Research, told Automotive News several major automotive players “are already establishing disruptive manufacturing processes and reveal more of a deal with humanoid robots”.
Not less than a dozen leading automakers are testing advanced robotics of their factories, and in response to Gartner vice chairman of research Pedro Pacheco, a totally robotised ‘dark factory’ is more likely to open by “the tip of this decade”.
“Recognisably, for the time being they don’t have a serious impact on vehicle assembly. Nonetheless, it’s likely their capabilities will progress throughout this decade, given the foremost focus dedicated by so many automakers,” Mr Pacheco said.
Gartner analyst Marco Sandrone told Automotive News the one parts of the vehicle manufacturing process not fully automated are the installation of wiring harnesses and interior components.
Corporations throughout the automotive supply chain with publicised plans to make use of humanoid robots include Tesla and BYD.
BMW has already been collaborating with robotics company Figure AI. The corporate touted in November that an 11-month deployment of its Figure 02 robot saw it run 10-hour shifts five days per week loading 90,000 parts and contributing to the production of over 30,000 X3s.
Hyundai is planning to make use of its Boston Dynamics robots at its Georgia, US, plant from 2028.
It showed its ‘Atlas’ humanoid robot on the Consumer Electronics Show (CES) in Las Vegas earlier this month, saying it “plans to integrate Atlas across its global network”.
Hyundai Motor Group (HMG) bought an 80 per cent stake in Boston Dynamics in 2021, saying the 2 corporations were working on a ‘robotics value chain’ to assist construct cars faster while maintaining safety.
The Korean automaker said robots offer “opportunities for rapid growth and the potential to positively impact society by making work safer and more productive”.
Robots are already in use at Hyundai’s ‘smart factory’ for electric vehicles in Singapore, which opened in 2023 “with integration between humans, robotics and AI technology”.
Mercedes-Benz is testing humanoid robots in its factories, with a 2025 announcement outlining plans to have its ‘Apollo’ robots, made by Apptronik, interact with humans.
“Around 2030 we are going to see not less than some humanoid robots in production,” said the automaker’s production boss, Jörg Burzer.
This Article First Appeared At www.carexpert.com.au
