Jaguar Land Rover (JLR) is piloting drone-based inspections at its Electric Propulsion Manufacturing Centre (EPMC) in Wolverhampton, reporting inspection time reductions of up to 95% as it explores new approaches to factory safety, maintenance and workforce skills.
The trial uses the Elios 3 drone from Flyability to inspect machinery and infrastructure in high or confined areas without the need for elevated platforms.
Operated via a tablet, the system streams a live 3D map of the environment, allowing maintenance teams to identify and diagnose issues while remaining on the factory floor.
According to JLR, this is intended to reduce the risk associated with working at height, minimise unplanned downtime and release staff for other tasks.
“As we transform our facilities, we’re rethinking every part of our factories, including how we maintain and operate them,” said Nigel Blenkinsop, executive director of industrial operations at JLR.
He added that trials with advanced drone technology are helping the business “improve employee safety, reduce maintenance downtime and operate more efficiently,” while also supporting the upskilling of employees “in the latest digital technologies” so they can participate in “our factories of the future”.
The Elios 3 platform uses lidar sensors to emit laser pulses and measure their return time, generating detailed 3D maps of the surrounding environment. JLR is also using the drone’s thermal camera to detect overheating components or insulation issues.
The company says this early identification of anomalies can support energy efficiency and help reduce operational emissions by addressing inefficiencies before they lead to failures.
As part of the pilot, JLR employees are being trained to operate the drones in-house.
Following the initial deployment at EPMC, JLR plans to extend the trial to its Logistics Operations Centre (LOC) in Solihull, a warehouse space of around 91,800m², described as equivalent to 13 football pitches.
In this second phase, the drone will be equipped with barcode scanners to automate inventory checks, replacing manual stocktaking and supporting faster, more accurate updates to stock records.
JLR expects this to improve safety by reducing the need for staff to access high racking, while also reducing errors and informing decisions on space utilisation, stock levels and supply flows.
The initiative sits within JLR’s £3.8bn annual investment in industrial transformation, new products and technology.
It is being explored through the company’s Open Innovation programme, which connects JLR with start-ups, scale-ups and other external partners to test and deploy next-generation technologies and sustainability solutions.
The drone trial also supports JLR’s Future Skills programme, which aims to train 29,000 employees in electrification and digital capabilities as part of the company’s wider Reimagine strategy.
That strategy includes a target to become carbon net zero across supply chain, products and operations by 2039, and to accelerate electrification across its vehicle portfolio.
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