Lear to open automated Michigan factory as model for global network

Lear plans to open a new automated factory in Michigan next year, designed to serve as a model for its global manufacturing network, Manufacturing Dive and Supply Chain Dive reported.

The facility, known as the Orion site, will include multiple automation tools such as two separate automated storage and retrieval systems—one for raw materials like foam and another for finished goods. These systems were developed by an internal team formed after Lear's acquisition of ASI Automation.

Executives described the Orion factory as the culmination of a decade-long strategy involving acquisitions of companies like WIP Industrial Automation, Thagora Technology, and InTouch Automation. These acquisitions have enabled Lear to develop proprietary technology that provides a competitive advantage difficult for others to replicate.

Beyond storage systems, the plant incorporates an integrated intralogistics system that connects inventory, material management, storage, and real-time decision-making from component receipt to finished product shipment. Additional features include overhead suspended material delivery, automated guided vehicles, autonomous mobile robots, smart ovens, automated testing, and AI vision inspection.

Lear is also employing proprietary automation tools for workforce management, such as cycle time deviation and dynamic line scheduling, aiming to automate routine tasks and allow employees to focus on problem-solving. The company intends to scale this technology across its global operations to improve efficiency and innovation.