Automotive industry adopts ‘dark factories’ through advanced robotics

The automotive industry is increasingly adopting ‘dark factories’—highly automated manufacturing plants that operate without visible light. These facilities utilize thousands of robots, autonomous vehicles, and 5G connectivity to perform assembly tasks, relying on sensors, radar, and infrared cameras rather than human vision.

In Chongqing, China, Changan operates a plant where a new vehicle is completed every 60 seconds in total darkness. Similarly, Xiaomi maintains a massive complex in Beijing featuring 700 robots and 91% automation in its bodywork area, producing an SU7 sedan every 76 seconds. In Ningbo, Zeekr, a Geely group brand, operates a welding workshop with over 800 robots.

While heavy processes like welding, painting, and pressing are highly automated, final assembly of delicate components still often requires human intervention. To address this, manufacturers are investing in humanoid robots. For instance, BMW has conducted testing with humanoid robots at its Spartanburg facility in the United States to assist in part movement.