At Hyundai Motor Group’s new MetaPlant America (HMGMA) in Ellaville, Georgia, robots outnumber humans. The plant, which began construction in October 2022, uses robotic technology not only in car production but across various tasks traditionally handled by humans, including parts transportation, vehicle handling, and quality inspections.
Upon entering the plant, a line of over 10 robots, standing at waist height, can be seen moving parts across the factory floor. Unlike traditional automotive plants where tasks like presswork and car body construction are automated, the sorting and transportation of components are now handled by autonomous mobile robots (AMRs). These robots communicate with a central control system, tracking production progress and optimizing movements in real-time.
HMGMA, completed after just two and a half years of construction, departs from the conventional car factory model. With approximately 880 human workers and over 950 robots deployed, it combines human labor with advanced automation. The plant features more than 200 autonomous transport robots, 48 parking robots, and 700 robots involved in welding and painting. “This plant embodies Hyundai’s vision for the future and its manufacturing capabilities,” said a company official.
Robots and AI technologies have significantly enhanced both automation and quality control across the production process. In the final stage of car body assembly, Boston Dynamics' four-legged robot “Spot” inspects the vehicle’s exterior by capturing images and comparing them with reference points to identify defects.
In the assembly plant, Hyundai has introduced the world’s first system for automatically removing and installing vehicle doors. Previously performed by humans due to concerns about gaps and alignment, this task is now handled by robots equipped with AI-powered camera systems. Similarly, dozens of cameras have been integrated into the press process to detect imperfections in finished panels.
The painting process also incorporates an innovative system, capturing and analyzing around 50,000 images per vehicle to ensure quality. These technological advancements are part of Hyundai’s ongoing efforts to experiment with future mobility solutions at HMGMA.
The plant is designed to support “low-volume, high-variety production,” a key feature for future vehicles. Unlike the mass production era, the focus has shifted to autonomous driving, connected cars, and in-car technologies. As a result, some areas of the assembly plant have no conveyor belts. Instead, autonomous transport robots carry car bodies, enabling a more flexible production flow that adapts to different models and options.
Hyundai envisions a plant that no longer depends on fixed processes but evolves toward more adaptable manufacturing methods. “By overcoming the limitations of conveyor belts, we expect our production system to evolve, bypassing unnecessary steps and streamlining processes,” said a company official. Additionally, the company plans to pilot the “All-New Atlas” humanoid robot, developed by its robotics affiliate Boston Dynamics, in the near future.
