JLR has begun trialling drones at its Electric Propulsion Manufacturing Centre (EPMC) in Wolverhampton, slashing machinery and site inspection times by as much as 95% as the company accelerates its vision for the factory of the future.
The pilot uses Flyability’s Elios 3 drone, which can reach high or confined spaces to carry out inspections that would previously have required elevated platforms, significantly reducing risk for maintenance teams. Operated via tablet, the drone streams a live 3D map of the facility to help identify issues earlier, prevent maintenance-related downtime and free employees to focus on business-critical work.
Nigel Blenkinsop, Executive Director of Industrial Operations at JLR, said the trial reflects a wider re-evaluation of how the company operates its manufacturing sites. “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.”
The Elios 3 relies on LiDAR sensors that fire out laser pulses and measure how long they take to return, building detailed 3D maps of the plant. A thermal camera also detects overheating components or insulation failures—supporting energy optimisation and helping JLR cut operational emissions.
For the engineers involved, the technology is opening new doors. “I never imagined I’d be learning to fly drones as part of my role,” said project engineer Shantnu Mehta. “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.”
Following the success at EPMC, the next phase will move to JLR’s Logistics Operations Centre in Solihull—an area the size of 13 football pitches—where the drone will be fitted with barcode scanners to automate inventory checks. Replacing manual stock takes is expected to improve accuracy, enhance safety and support better decisions on storage, stock levels and supply flow.
The initiative forms part of JLR’s £18bn investment programme over five years from FY24 and is being explored through the company’s Open Innovation programme. It also supports JLR’s Future Skills plan, which aims to train 29,000 employees in electrification and digital capabilities.
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