HMGMA, Future Factory with Robots and AI Applied Is Just Ahead

World's First Technologies Such as Panel Hole and Crack Detection System Applied
Key Affiliates' Capabilities Concentrated... High-Efficiency, Human-Centered Work Environment

'Cutting-edge Manufacturing Innovation Platform' and 'Human-friendly Manufacturing Site.' This is how Hyundai Motor Group's third production base in the United States, 'Hyundai Motor Group Metaplant America' (HMGMA), is defined.

The Ioniq 5 being produced at the Hyundai Motor Group Meta Plant America (HMGMA) body shop located in Ellabel, Georgia, USA. Photo by Hyundai Motor Group

HMGMA realized high-efficiency and high-quality production based on the cutting-edge manufacturing innovation platform developed and demonstrated at the Singapore Global Innovation Center (HMGICS). Manufacturing innovation technologies were applied to each element of the automobile production process, including press, body, painting, and assembly. Representative examples include the panel hole and crack detection system, autonomous door gap and step correction installation, and automatic door removal and attachment. Hundreds of advanced robotic devices ensure high productivity and consistent quality.

The world's first applied technology, the panel hole and crack detection system, operates in the press factory. It supports AI-based quality control by learning data captured through dozens of cameras using deep learning. The manufactured panels move to the next process through a 100% automated logistics system. The Automated Storage and Retrieval System (ASRS) classifies panels by vehicle model, loads dozens onto pallets, and Autonomous Guided Vehicles (AGVs) transport these pallets to the next process just in time. AGVs operate based on simultaneous localization and mapping (SLAM) technology.

The body factory achieved full automation by applying the world's first autonomous door gap and step correction installation system during the process. In exterior quality inspection, Boston Dynamics' quadruped robot 'Spot' performs specification inspections and provides real-time feedback of measured quality information to assembly robots. The painting process is also automated from coating to quality inspection. In the assembly factory, a system that automatically removes vehicle doors and precisely installs them after painting was implemented for the first time in the world. Fourteen robots cooperate in control to install doors with zero margin of error.

Various automobile parts to be combined with the body are transported by over 200 Autonomous Mobile Robots (AMRs). Based on SLAM technology, AMRs generate routes from the logistics warehouse to the desired locations in each process to deliver parts. Completed vehicles ride on parking robots and undergo automated unmanned quality inspections. Previously, workers had to drive vehicles manually to move them, but the creation of a human-centered work environment reduces physical burdens and prevents injuries for workers.

Panels produced at the HMGMA press factory are loaded onto pallets and transported by autonomous guided vehicles (AGVs). Provided by Hyundai Motor Group

HMGMA also integrates the technological capabilities of major affiliates. Hyundai Mobis operates the largest battery system and module factory among global production bases on the site. Additionally, a separate base producing PE systems, a core component of electric vehicles, is established nearby.

Hyundai Glovis manages overall parts supply through the HMGMA logistics center. The logistics center uses autonomous flying drones equipped with vision cameras to monitor parts status in real time, and AGVs load parts for one complete vehicle and connect them to the vehicle manufacturing conveyor.

Hyundai Steel processes automotive steel sheets, including ultra-high-strength steel, and supplies them to the press factory, while Hyundai Transys produces seats with an annual production capacity of 420,000 units. Hyundai Wia supports logistics automation based on its robotic technology capabilities. Hyundai Rotem supplies servo press equipment that forms vehicle steel sheets into body panels.