JLR deploys drones to slash inspection times by 95%

The tedium of factory inspections, once measured in hours and manpower, is being compressed into minutes at Jaguar Land Rover. At the carmaker's Electric Propulsion Manufacturing Centre in Wolverhampton, a trial involving Flyability's Elios 3 drone has demonstrated what happens when aerospace technology meets automotive manufacturing. A four-hour inspection process now takes just 10 minutes.

But a closer look reveals that the transformation extends beyond mere timekeeping. Where maintenance teams have previously navigated elevated platforms and confined spaces to examine machinery, or reach components, they now pilot drones from the factory floor via tablet. JLR shared that the aircraft employs Light Detection and Ranging sensors, transmitting laser pulses that calculate distances upon return, constructing three-dimensional maps of equipment and infrastructure. A thermal camera supplements this capability, identifying overheating components and insulation failures that signal inefficiencies in energy consumption.

Nigel Blenkinsop, Executive Director of Industrial Operations, frames the initiative within JLR's broader manufacturing evolution. "As we transform our facilities, we're rethinking every part of our factories, including how we maintain and operate them," he said.

"Trials like this one with advanced drone technology are helping us improve employee safety, reduce maintenance downtime and operate more efficiently. Just as importantly, they're helping upskill our people in the latest digital technologies, ensuring our teams are part of our factories of the future."

From reactive checks to predictive intervention

The efficiency gains mask a more significant shift in vehicle production philosophy. Traditional inspection protocols are inherently reactive, identifying problems after they manifest, and as any serious automotive producer knows, preemption is production’s new - and mission critical approach. The drone system's thermal imaging and spatial mapping enable predictive maintenance, detecting anomalies before they escalate into production disruptions. This represents a fundamental reorientation of how manufacturers are beginning to approach equipment reliability.

The technology also liberates skilled personnel from routine inspection duties. Engineers previously occupied with climbing structures to document equipment conditions can redirect their expertise towards higher-value tasks. This is the ideal of technological advancement in automotive manufacturing - and indeed, across all industries where technological disruption is imminent. But here, the ‘free-up’ is clear. The drone delivers consistent, high-resolution visual data, eliminating variability in manual inspections whilst simultaneously reducing physical risk.

Shantnu Mehta, Project Engineer at JLR, articulates the personal dimension of this technological adoption. "I never imagined I'd be learning to fly drones as part of my role," he said. "It's been exciting to learn how to use this technology and the skills I've developed will stay with me throughout my career. Being part of such an innovative project and contributing to how we're transforming our factories for the future is something I'm genuinely proud of."

Training engineers for digital manufacturing

The human element of JLR's drone deployment warrants particular attention. Engineers receive structured training in drone piloting, safety protocols, and data capture techniques. And interestingly, the programme is designed for scalability, ensuring teams across multiple facilities can confidently operate and maintain the technology. This approach closely aligns with JLR's Future Skills programme, an initiative targeting 29,000 employees for training in electrification and digital technologies.

The upskilling imperative grows more pressing as autonomous systems proliferate across manufacturing environments. "Upskilling is essential," Mehta explained when asked about workforce development. "As we integrate more advanced technologies, we're committed to ensuring our people evolve with them, building a future-ready workforce that's empowered to lead innovation."

As with most new technologies, the first rollout was not without its hurdles. Folding drone data into existing management systems took more thought than expected, and there were also regulatory questions to resolve around using autonomous aircraft inside manufacturing sites. Just as important was winning over the organisation itself, building confidence in autonomous inspections through evidence, rather than promises. JLR shares that early results have been positive enough to justify taking the next step and scaling up.

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Scaling from production lines to logistics

The Wolverhampton pilot's success has prompted JLR to extend trials to its Logistics Operations Centre in Solihull, a warehouse spanning approximately 91,800 sq. m. Here, drones equipped with barcode scanners will automate inventory checks, replacing manual stocktaking processes that are both time-intensive and prone to human error. And the scale of the facility makes it an ideal proving ground for autonomous inventory management.

Whilst equipment inspection demonstrates the technology's technical capabilities, inventory management tests its operational value in a different context. Faster, more accurate stock updates enable better decisions regarding space utilisation, inventory levels, and supply flow. The system promises to reduce errors whilst improving safety by minimising the need for personnel to access high storage locations.

"The Wolverhampton pilot has shown clear benefits in speed, safety, and data quality," Mehta noted. "These results give us the confidence to expand and explore broader applications across Industrial Operations."

Technology maturity meets manufacturing readiness

The question of timing merits examination. Drone technology for inventory management has existed for several years, yet JLR is only now implementing it at scale. Mehta's explanation points to technological maturation rather than organisational hesitation. "The technology has matured," he said. "Advances in autonomy, safety, and data analytics now allow drones to deliver real, measurable value."

This observation highlights a broader principle in manufacturing technology adoption. Early iterations of potentially transformative tools often lack the reliability, precision, or integration capabilities required for industrial deployment. The convergence of improved sensor technology, enhanced processing power, and sophisticated software has elevated drones from experimental curiosities to practical manufacturing instruments.

Looking forward, Mehta anticipates drones becoming integral to JLR's operational architecture. "Drones will help us shift from reactive to predictive maintenance, reduce manual workloads, and enhance safety," he said. "They're a key enabler of smarter, more agile supply chain operations." This, of course, applies to vehicle production processes too.

How JLR’s ‘Reimagine’ strategy anchors innovation initiatives

The drone programme sits within JLR's Reimagine strategy, the company's blueprint for transformation announced in 2021. The strategy emphasises modern luxury delivered through sustainability, digital innovation, and operational agility. It is supported by £18bn ($24bn) in investment over five years from the 2024 financial year.

The Open Innovation programme, through which the drone trials are being explored, represents JLR's systematic approach to evaluating emerging technologies. Rather than wholesale adoption of unproven systems, the carmaker pilots technologies in controlled environments, measuring performance against specific operational metrics before scaling implementation.

"Reimagine is about delivering modern luxury through sustainability, digital innovation, and agility," Mehta explained. "It's our roadmap for transforming JLR into a more resilient, future-focused business."

The programme's pipeline reaches beyond drones. Mehta indicated that JLR is exploring artificial intelligence-driven logistics systems, digital twins for virtual factory simulation, and sustainable materials development. "Expect more collaborations and pilots that push boundaries and accelerate our transformation journey," he said.

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Manufacturing's autonomous future

JLR's drone deployment illustrates a manufacturing sector increasingly willing to borrow technologies from other domains. Aerospace, defence, and logistics have employed unmanned systems for years. Their migration into factory environments reflects both technological advancement and shifting cost-benefit calculations. As sensors become cheaper and software more sophisticated, applications that once seemed fanciful become economically viable.

But the broader implications of the programme have implications far beyond mere efficiency metrics. Autonomous systems alter the skill requirements for manufacturing workforces, demanding proficiency in operating and maintaining digital technologies rather than purely mechanical expertise. This transition poses challenges for organisations and employees alike, requiring sustained investment in training programmes and cultural adaptation.

Yet the alternative carries greater risk. Manufacturing competitiveness increasingly depends on operational agility and the ability to extract value from data. Automakers that resist technological evolution risk ceding ground to more nimble competitors. JLR's approach suggests a middle path between hasty adoption and paralysing caution, using controlled pilots to build capability whilst managing risk.

The Wolverhampton pilot represents one iteration in this ongoing evolution. As results accumulate and confidence grows, expect similar deployments across JLR's manufacturing network and, eventually, the broader automotive sector. The factory of the future, it seems, will be populated not only by robots below on production lines but by drones navigating the spaces above them.