BYD's Zhengzhou factory production is almost 100 percent robot-operated.

KatadataOTO – The BYD super factory in Zhengzhou, China is located close to or within the same area as the all-train circuit that KatadataOTO recently visited and reviewed. This certainly facilitates and increases efficiency in product development, technology, and the testing of new models.

The factory, built in the Zhengzhou Airport Economic Zone covering an area of 10.67 square kilometers, is also integrated with the research and development (R&D) division and technology validation.

Construction began in 2021, and the factory is capable of performing four main processes, from stamping or forming shapes from sheet metal, welding, painting, to assembly.

During the visit (15/1/2025), KatadataOTO along with a media delegation from Indonesia began the tour by witnessing the stamping process. There are five 7,900-ton press machines that can operate at high speed, capable of forming up to 15 steel and aluminum panels per minute.

Photo: KatadataOTO

KatadataOTO also received direct information that this factory has an automation rate of 98 percent. Upon entering the welding area, based on KatadataOTO's direct observation (as photography was not permitted in the closed area), very few workers were visible. This is because 98 percent of the welding process is carried out by industrial robots.

There are at least 1,800 industrial robots, including 14 robot teams working simultaneously. The process of joining components to form the body assembly takes only 35 seconds, including automated quality inspection.

“The composition of robot and human labor use differs at each stage of the process. The closer it gets to the final stage or requires quality control, the more human labor is needed,” explained the factory manager who guided the visit.

In addition, the BYD super factory also has facilities for manufacturing major vehicle components such as the blade battery, a power battery park, and a new material park. There are also installations for manufacturing electric motors for EVs and PHEVs, electronic components, drive systems, air conditioning, steering, lights, frames, seats, and so on.

Photo: Courtesy

“From batteries, components, assembly, to testing, everything is consolidated in one place. This certainly has the advantage of strict quality control, while still being able to be carried out efficiently,” explained Eagle Zhao, President Director of BYD Indonesia.

The BYD Zhengzhou Super Factory is one of eight BYD factories that support global capacity. Some of its products include the BYD Shark 6 and Denza B5 for the Australian export market. Throughout 2025, BYD claims to have sold 4.6 million vehicles worldwide, with New Energy Vehicle exports exceeding one million units.