JLR tests drones that cut factory inspections from 4 hours to 10 minutes

JLR is testing drone technology at its Electric Propulsion Manufacturing Centre (EPMC) in Wolverhampton, where it reports machinery and site inspections can be completed up to 95% faster.According to the company, the pilot is part of its plan to improve operational efficiency and employee safety as it develops its “factories of the future.”
The trial uses the Elios 3 drone from Flyability, designed for indoor inspections. The drone can reach high and enclosed areas, allowing maintenance staff to work from the factory floor instead of using elevated platforms.

Controlled via a tablet, it produces a live 3D map that helps teams identify faults and prevent maintenance-related downtime. According to JLR, tasks that previously took four hours can now be completed in around ten minutes, giving employees more time for other critical work.

The Elios 3 uses LiDAR sensors that send laser pulses and measure their return time to build 3D maps of the environment. It also includes a thermal camera to detect overheating parts or insulation issues. JLR says this helps identify energy inefficiencies earlier and supports efforts to reduce operational emissions.

Nigel Blenkinsop, Executive Director of Industrial Operations, 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.”

Project engineer Shantnu Mehta said, “I never imagined I’d be learning to fly drones as part of my role. It’s been exciting to learn how to use this technology and the skills I’ve developed will stay with me throughout my career.”

Following the Wolverhampton trial, JLR will expand drone use to its Logistics Operations Centre in Solihull. There, drones equipped with barcode scanners will automate inventory checks, replacing manual processes and enabling quicker and more accurate stock updates.

JLR expects this to further improve safety, reduce errors and support better decisions on warehouse space, stock levels and supply flow.

The initiative is part of JLR’s £3.8bn annual investment in industrial transformation, new products and technology, explored through the company’s Open Innovation programme. It also supports JLR’s Future Skills programme, which aims to train 29,000 employees in electrification and digital skills.

JLR is continuing to recover from a cyberattack that disrupted production and business operations worldwide for more than a month, but says it is moving ahead with projects that improve efficiency and turnaround time.