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| Credit: Aston Martin |
Aston Martin Lagonda's facility, which manufactures the DBX and DBX707 luxury vehicles, relies on traditional techniques instead of robots and automation. Despite the dominance of automation in production lines, Aston Martin continues to use time-tested methods. The DBX, a luxury sports SUV, can accelerate from 0 to 100 kilometers per hour in approximately 4.5 seconds and has a top speed of 291 km/h, weighing around 2,245 kilograms. Its more powerful cousin, the DBX707, can achieve the same weight and has a faster acceleration time of 3.3 seconds and a top speed of 310 km/h. Other competitors in the luxury SUV market include the Bentley Bentayga, Lamborghini Urus, and Ferrari Purosangue, which are also handcrafted to varying degrees.
Stuart Lord, the Head of Manufacturing Operations at Aston Martin Lagonda, emphasized the human element in the production process during a rare visit to the manufacturing and testing site. The facility in Wales prominently showcases the human touch, from the car's interface with its owners to the reliance on human labor over machines. As one enters the building, two large displays list the names of every person involved in car production, including Lord himself. Aston Martin takes pride in its handcrafted attention to detail, choosing not to succumb to the pressure of automation on their massive factory floor. Even the final paint checks are performed solely by human inspection.
According to Lord, everything in the Aston Martin DBX is truly handmade, down to the smallest details, differentiating it from mass-produced vehicles. Each car is built for a specific owner, and the waiting period for a new Aston Martin is typically around 6 months, but it can extend to a year. With a price starting at approximately £191,000, the Aston Martin DBX707 is one of the most expensive cars available.
The production line at Aston Martin follows a lean production approach, encircling the massive space formerly used as an airfield and hangar. The assembly process involves sub-assemblies positioned at the center, enabling a shorter distance for components to move along the perimeter. Aston Martin DBX vehicles utilize high-strength adhesive instead of traditional nuts and bolts, which not only offers a higher weight-to-strength ratio but is also cost-effective. The manufacturing process maintains tight tolerances of about half a millimeter on a 4.2-meter-long car.
Paint inspections are conducted under different lighting conditions, replicating warm, cold, and sunlight environments. Any defects detected during inspection are promptly addressed, and if more complex issues arise, the affected car is isolated to prevent disruptions to the production line. The final stage includes extensive technology checks, such as camera, radar, wind noise, water splash, and engine rpm tests. A team of professional test drivers performs the final road test to assess braking performance, acceleration, handbrake strength, traction control systems, and any potential rattles or misfitted panels.
The presence of robots at the Aston Martin Lagonda facility is minimal, primarily used for water splash and wind noise testing. Technicians rely on a system that connects with the car's onboard computer to conduct thorough checks, ensuring everything is correct before the car is packed for delivery. Aston Martin offers customers a unique "build-log" for each vehicle, documenting the production stages, including any detected faults and how they were addressed.
Compared to other car manufacturers that heavily utilize robots in body assembly (up to 90% automation), Aston Martin Lagonda's production facility maintains a slower pace. The DBX production line produced 3,219 SUV units last year, with the number varying based on customer orders. Lord attributes the absence of build-stock situations to owner Lawrence Stroll's background in fashion and the importance of a demand-driven
