Winning Bizness Desk
Mumbai.Expensive humanoid robots lag humans despite billions invested in factory automation
Despite billions being spent on humanoid robots, humans continue to outperform machines in speed, flexibility and productivity across factory floors. At BMW’s South Carolina plant and Hyundai’s Georgia facility, AI-powered robots are being used for routine jobs such as pulling trolleys and moving parts. But executives and researchers admit that the technology is still struggling to match human efficiency.
Robots prove slower at routine factory jobs
BMW logistics vice-president Ulrich Wieland has acknowledged that robots are slower than human workers. MIT’s Ben Armstrong has described humanoids as an extremely expensive answer to relatively simple problems, saying a task that could cost around $100 (Rs 9,500) is being addressed with technology costing up to $1 million (Rs 9.5 crore).
Companies are nevertheless betting heavily on humanoids because they can increase automation without redesigning entire factories. Unlike human workers, robots do not require lunch breaks, union representation or health insurance. However, professors Susan Helper and Lawrence Els argue that blindly introducing expensive robots could actually slow operations and leave workers with only low-paid, repetitive jobs.
Hyundai and BMW expand their robot workforce
At Hyundai’s Alabama plant, automated vehicles, robotic dogs and flat robots transport Ioniq 5 and Ioniq 9 cars to testing stations. Assembly manager Jerry Roach says the machines can navigate the factory without crashing into pillars. Hyundai has also acquired robotics company Boston Dynamics as it expands its presence in the sector.
The growing use of robots is visible across major carmakers:
- BMW is using robots developed by Figure AI.
- Mercedes is deploying robots from Apptronik.
- Hyundai is expanding robotic systems across its plants.
- Tesla is developing its Optimus humanoid for factory use.
Musk admits human dexterity remains hard to copy
Tesla chief Elon Musk has also confronted the limitations of humanoid robots. After using an Optimus robot at Tesla’s Los Angeles restaurant, Musk acknowledged that reproducing the dexterity and sensitivity of human hands remains one of the hardest challenges. That limitation is directly affecting the speed and productivity of robots. Yet companies continue expanding their use. Musk even halted production of Model S and Model X cars in California to focus on Optimus production. In China, a strong component supply chain is helping make robots cheaper, prompting the US Federal Communications Commission to impose import restrictions. Workers fear robots could replace human jobs
Hyundai chief administrative officer Brent Stubbs argues that robots will create better jobs in maintenance and robot care. But United Auto Workers president Shawn Fain has called the technology a serious threat to human employment. Workers in South Korea have also gone on strike in protest against Hyundai’s increasing automation. The debate is increasingly focused on whether robots should replace workers or assist them. The concern is that companies may prioritise expensive machines without proving that they can actually improve productivity. Ford brings engineers back after AI struggles
Ford has taken a different approach after facing problems linked to AI errors and slow work. The company brought back 350 experienced and retired engineers to improve quality. Ford subsequently ranked first in a J.D. Power study. General Motors’ Sterling Anderson has also questioned the value of expensive legged robots, arguing that cheaper wheeled “cobots” can be more effective. These machines assist workers rather than replacing them, offering a simpler route to automation. Key lessons emerging from the debate:
For now, the factory of the future may not be fully robotic. In many cases, the most effective solution could still be a human working alongside a simpler machine.
