analysts have predicted that a ‘dark factory’, where new cars are made entirely by robots without human involvement, will open as soon to 2030 and revolutionise vehicle manufacturing.
In what way could it be the biggest shake-up since Ford’s move to use the moving assembly line for making the Model T in 1913 – cutting production times and costs while dropping showroom prices will have serious implications beyond the factory floor.
According to Automotive News, the move could reshape vehicle design principles, workforce training and the economics of car manufacturing through faster model changeovers.
This is based on a McKinsey study that US$150 billion (A$223 billion) in annual ‘economic potential’, which could be produced by adding robotics and artificial intelligence (AI) to manufacturing.
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A robot’s ability to change tasks and perform processes humans cannot, while a robot is also not fatigued – or as experienced at Ford in the 1910s, boredom from repetitive jobs.
Similarly, these factors also reduce the risk of errors relative to human production-line workers; they increase manufacturing efficiency and quality of finished vehicle.
The use of robotics in vehicle production and development is far from new.
Ford Australia even used robot test drivers in the development of its Ranger Super Duty ute which went on sale late last year.
But there’s also an increasing interest in humanoid robots being used as a vehicle production tool, which is likely to culminate with the first ‘dark factory’.
Several major automotive players, including Warburg Research, said analysts at tech firm Gartner told Automotive News that “are already creating disruptive manufacturing processes and revealing more about a focus on humanoid robots” (e.g.
The Gartner vice president of research Pedro Pacheco said at least a dozen leading automakers are testing advanced robotics in their factories, and that ‘an entire robotised ‘dark factory’ will open by “the end of this decade” according to Garthner.
However, at the very least now they don’t have a significant effect on vehicle assembly. Nevertheless, it’s likely they will be doing better in this decade as so many automakers focus on their major work.” Mr Pacheco said the company was ‘amazingly focused’ at his home last year.
Gartner analyst Marco Sandrone told Automotive News that the only parts of the vehicle manufacturing process are not fully automated ‘Wire harnesses and interior components have been installed, but they don’t really make it all so much.
Companies within the automotive supply chain with publicised plans to use humanoid robots include Tesla and BYD.
BMW has already been collaborating with robotics company Figure AI. The company touted in November that an 11-month deployment of its Figure 02 robot saw it run 10-hour shifts five days a week loading 90,000 parts and contributing to the production of over 30,000 X3s.
Hyundai is planning to use its Boston Dynamics robots at its Georgia, US, plant from 2028.
Earlier this month, it demonstrated its ‘Atlas’ humanoid robot at the Consumer Electronics Show (CES) in Las Vegas, which says it plans to integrate Atlas across its global network.
The pair were pursuing a ‘robotics value chain’ to help build cars faster and keep safe, Hyundai Motor Group (HMG) bought an 80 per cent stake in Boston Dynamics in 2021.
Korean automaker said the robots provide ‘opportunities for rapid growth and could have positive effects on society through work safety and better productivity’.
The Hyundai’s ‘smart factory’ for electric vehicles in Singapore, opened in 2023 “with integration between humans, robotics and AI technology” is already using robots.
The factory is testing humanoid robots, with a 2025 announcement that it will have its ‘Apollo’ robot (made by Apptronik) interact with humans.
“Around 2030 we will see at least some humanoid robots in production,” said the automaker’s production boss, Jörg Burzer.
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