
At Hyundai Motor Group’s ultramodern new auto plant, robots perform a stunning array of tasks. They move materials, attach doors and do almost all of the welding. Dog-like robots, their snouts laden with cameras, prance across the floor to inspect partially built Ioniq electric vehicles.
The factory, which opened near Savannah, Ga., late last year, deploys 750 robots, not counting the hundreds of autonomous guided vehicles that glide across the floor. About 1,450 people work alongside them. That roughly 2-to-1 ratio of humans to robots compares with the U.S. auto-industry average of 7-to-1, writes The Wall Street Journal (Aug. 25, 2025).
The human workforce is sparse in much of Hyundai’s plant. Metal arms move slabs of steel through presses that stamp them into components of the frame. An array of robots weld those parts together without a person in sight.
Human beings are still in the driver’s seat for some jobs. But it isn’t until the frames emerge from the paint shop that people take over. Hundreds are stationed along two assembly lines where seats, dashboards and other components are added. They spot burrs that must be smoothed and bits of trim that need replacing. They snap fabric door panels into place with grommets, push electrical connectors together until they click and duck into places robots can’t reach to bolt down seats and attach shock absorbers.
The factory was designed so that robots do tasks that are dangerous, repetitive or physically demanding. People are left to troubleshoot, monitor quality and bring craftsmanship to the manufacturing process. “We’re not trying to minimize human involvement—we’re trying to maximize human potential,” said the CEO.
“But the minute humans become more expensive, more recalcitrant, the more automation you’re going to get,” said an industry expert. The auto industry today is heavily robotized, particularly in Hyundai’s home country of South Korea. The country has one of the world’s lowest birthrates, helping to drive its adoption of the machines.
A complete robot takeover is decades away. Robots still struggle to handle fabric and other limp materials, and performing the most complex jobs will take technological breakthroughs that aren’t yet on the radar.
Classroom discussion questions:
- Will robots ever take over 100% in auto manufacturing?
- What are the OM implications of the 2 to 1 ratio?













