Historically, factories might not have been something you bragged about. Dirty, old, dark buildings, far away from the essence of a company’s brand. But times change. The next generation of automotive manufacturing sites are intelligent, innovative, and green. As the first wave of Polestar 4s roll out of our state-of-the-art facilities (and with Polestar 3 production just around the corner), we’re opening the doors to some of our current and future sites around the world. So, come with us and see what goes into building a high-performance, exclusive electric vehicle.
Car manufacturing
can be an intricate process. But manufacturing high performance, next
generation cars is something altogether different. With vehicle-to-grid charging
capabilities, advanced driver assistance systems,
and an assortment of other cutting-edge car technology under the hood, our latest range of SUVs are some
of the most sophisticated vehicles in production today. This mix of
technological complexity – coupled with a premium build philosophy – creates a
unique manufacturing environment in which to build a car.
Robots and big data
“You're
looking at one of the most advanced automotive facilities on the planet,” says
Chunlin Zhao, Head of Hangzhou Bay facility. And it’s true. Since opening in
2021, the Hangzhou Bay facility has quickly established itself as one of the
region's most impressive car manufacturing plants, capable of producing 300,000
vehicles annually.
Currently
responsible for Polestar 4 production, the facility is no stranger to
pioneering technology, using a mixture of robots, big data, and artificial
intelligence to ensure vehicles retain a premium build and improve overall
efficiency of the manufacturing process. The site boasts over 3,000 inspection
points across the production line, meaning comprehensive checks are in place
throughout production. With safety forming the centrepiece of our design and
manufacturing objectives, nothing is left to chance. “We have a reputation for
implementing some of the latest technological advancements into our facilities.
If we see something that can improve our processes, we'll look for ways to
include this in our sites," explains Chunlin Zhao.
This isn’t
just lip service. The welding shop, known locally as the “dark factory” (which
isn't quite as scary as it sounds and points to its ability to operate without
human intervention), has over 800 fully automated flexible robots capable of
performing ultra-complex (but highly repetitive) tasks. The data room turns an
endless stream of information into actionable insights. Is the factory running
low on a particular item? Which robots require maintenance? These kinds of
questions are all handled in real-time by advanced analytic systems.
And then
there’s the production line, home to the advanced mega casting equipment that
makes large sections of a vehicle from molten aluminium. Although this
technology is not currently used in the Polestar line-up, it illustrates the
forward-thinking ambitions of the facility. “You can find technology here that
you won't find anywhere else in the world,” finishes Chunlin Zhao.
But while
robots and big data give the facility a distinctly futuristic feel, its
sustainability credentials ensure its roots are firmly planted in the ground.
Green
power
In an
industry currently shaking off its carbon-emitting past, efforts have been made
to cement Hangzhou Bay’s status as one of the cleanest automotive plants in the
region. From solar-panelled roofs to hydro-powered smelters, the facility ticks
all the boxes expected from a facility manufacturing Polestar's lowest carbon
footprint car at launch. “We are very serious about reducing carbon emissions across all our
sites. We make sure that environmental considerations are included in pretty
much every decision taken here. If you look at the progress we’ve made, we're
very confident that we can achieve carbon neutrality across all our facilities
in the medium term. That’s the goal," says Chunlin Zhao.
And it’s a
goal that’s taken seriously. The facility comes with its own solar powered
power plant capable of producing over 48 million kWh annually. With an on-site
power storage system also available, the PV plant can meet the electricity
needs for a single production shift.
Global
footprint
Asia isn’t
the only region responsible for Polestar’s manufacturing output. Our
‘asset-light’ model – which leverages partner companies’ existing manufacturing
infrastructure – has grown our global production footprint. This model of
manufacturing is relatively new in the automotive world. But its flexibility
provides considerable benefits.
"I
think a lot of people don't realise how costly it is to set up the
infrastructure required to build a car. For a young brand like Polestar to be
part of the Volvo and Geely Holding ecosystem comes with some pretty important
benefits. To be able to tap into the infrastructure and capabilities that are
usually only available to the world's biggest automotive companies is extremely
advantageous," explains Jonas Enström, Head of Operations at Polestar.
Interestingly,
this approach has opened access to not just new markets but new technological
advancements.
Over 12,000
kilometres from Hangzhou Bay lies Volvo’s Ridgeville facility. Located in
Charleston, South Carolina, the site is in the middle of a $600m expansion that
will see the development of the company’s first U.S. battery assembly plant.
It’s also one of the locations for Polestar 3
production that is set to commence in 2024 following an additional $118m
investment.
In a
similar move, manufacturing
of the Polestar 4 will also begin in South Korea at RKM’s Busan Plant in 2025. This unique joint venture between
Geely Holding and Renault underscores the impact of Polestar's asset-light
manufacturing model. “This type of deal means we can put more resources into
designing and developing the best EVs in the world because we know that we can
use the scale and expertise of our manufacturing partners around the world,”
says Jonas.
It is an
enviable position to be in; leaving us to focus on doing what we do best:
designing and developing the world's most beautiful EVs.
Fr:
Source: Polestar
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