Halewood, Merseyside – September 2024: In a bold move signaling its commitment to an electrified future, JLR has invested £500 million to transform its historic Halewood factory. Once the birthplace of the Ford Anglia in 1963, Halewood is now being reimagined as a state-of-the-art facility poised to lead JLR’s electric vehicle (EV) production. This transformation aligns with the company’s ambitious Reimagine strategy, which aims to position JLR as a modern luxury carmaker with an electric-first approach by 2030.
So far, £250 million has already been poured into the site’s revamp, which has seen more than one million hours of construction work over the past year. The facility, extended by an additional 32,364 sqm, will manufacture medium-sized electric luxury SUVs based on JLR’s new Electric Modular Architecture (EMA) platform. This transformation is not just about new infrastructure—it’s about creating the ‘factory of the future.’
Cutting-Edge Technology and Automation
At the heart of Halewood’s modernization is a sophisticated blend of automation, digital management, and advanced manufacturing technology. The site now boasts 750 autonomous robots, ADAS calibration rigs for ensuring perfect alignment, and a suite of cloud-based digital systems that oversee production efficiency and quality. New EV build lines are central to the overhaul, reflecting JLR’s aim to produce a diverse range of vehicles at this singular facility—whether they are internal combustion engine (ICE), plug-in hybrid (PHEV), or battery electric vehicles (BEV).
The dual-track production capability represents a significant milestone for JLR. While the plant will initially produce a mix of ICE, PHEV, and BEV models, Halewood is set to become JLR’s first all-electric facility as the Reimagine strategy advances.
A Commitment to Sustainability and Carbon Net Zero
JLR’s transformation of Halewood is underpinned by a broader commitment to sustainability. As part of its goal to achieve carbon net zero by 2039, JLR has implemented energy-saving measures, renewables, and fuel-switching solutions across the factory. These efforts are set to remove 40,000 tonnes of CO2e from Halewood’s industrial footprint, a significant contribution to the company’s carbon-neutral objectives.
To further this mission, the site will install 18,000 photovoltaic panels, generating 8,600 GWh of energy—around 10% of Halewood’s total energy consumption. This approach reflects JLR’s holistic view of sustainability, where cutting-edge EV production goes hand-in-hand with reducing its environmental impact.
Preparing People for an Electric Future
Central to the factory’s transformation is the reskilling of its workforce. JLR is investing £20 million annually through its Future Skills Programme to ensure its employees are well-equipped for the electrification era. In Halewood, over 1,600 workers have already completed High Voltage Training (HVT), preparing them for the high-stakes task of handling battery assembly processes. This number is set to grow, with a further one hundred employees expected to receive HVT by year’s end.
A new training and development centre has been established within the facility, where workers will gain hands-on experience with EV systems and technologies, refining their skills at each stage of vehicle production.
Creating the Vehicles of Tomorrow
As JLR accelerates toward a future dominated by electric mobility, Halewood is not just a production site—it’s a key player in the company’s evolution. The new body shop can now produce up to 500 vehicle bodies per day, and the final production line has been extended to accommodate the larger proportions of the upcoming EMA-based electric SUVs. Meanwhile, automated mobile robots (AMRs) have been deployed to support employees with the fitment of high-voltage batteries, further enhancing the efficiency and safety of production processes.
Crucially, the facility is also equipped to support JLR’s ambitions in autonomous driving. New Advanced Driver Assistance System (ADAS) calibration rigs have been installed, ensuring that each vehicle produced at Halewood is fine-tuned for the autonomous era.
Looking Ahead
With its first test builds of EMA body shells completed, Halewood is poised to begin full-scale production of electric vehicles in the near future. This £500 million transformation is not just an investment in infrastructure but an investment in JLR’s vision of becoming a leader in electric luxury mobility.
Barbara Bergmeier, JLR’s Executive Director of Industrial Operations, summed up the significance of the transformation: “Halewood has been the heart and soul of JLR in the Northwest of England for well over two decades. Now, as our first all-electric production facility, it is a testament to the brilliant efforts of our teams and suppliers who have worked together to equip the plant with the technology needed to deliver our world-class luxury electric vehicles.”
With this extensive overhaul, Halewood is set to not only meet the demands of today but also power JLR’s electric ambitions for decades to come.
