In the century-old history of the automobile, there are few moments that have truly shaken up the industry. The latest dates back to Henry Ford’s introduction of the assembly line, an innovation that transformed automobile production for more than a century. Today, Tesla, under the leadership of its visionary CEO Elon Musk, is preparing to rewrite the rules of the game with a revolutionary patent that could make the traditional assembly line obsolete.
The Austin company, known for its disruptive approach, is not content with rethinking the way we travel. It aims to revolutionize the very way cars are manufactured. This new modular production system, announced since 2020, promises to enter service in the near future, potentially marking the start of a new era in automobile manufacturing.
Tesla plans to produce the Robotaxi with its “boxless system”.
The concept, revealed during the last investor day, radically moves away from the sequential production model that we know. Instead of a single line where each item is added successively, Tesla envisions a system of parallel assembly lines. Each line would be dedicated to assembling specific modules – from large castings to front and rear subframes – which would then converge for final vehicle assembly.
This innovative approach, which Tesla calls a “boxless process,” promises significant benefits. According to the company, this new format would not only speed up production, but also reduce costs by 50%. A tempting promise which, if it comes to fruition, could give Tesla a considerable competitive advantage in the market.
The Robotaxi, an autonomous vehicle in development at Tesla, will be the first to benefit from this new manufacturing process. It will serve as a full-scale laboratory to test and refine this revolutionary method before its deployment on a larger scale.
However, like any major innovation, this system raises questions. Engineers will face technical challenges, particularly regarding multiple electrical connections and hydraulic circuits. In addition, the transition to this new production model will require significant reconditioning of existing factories, an investment whose profitability remains to be proven.
It is interesting to note that Tesla is not new to innovation in production. “Gigacasting”, a technique for casting large metal parts developed by the company, is already on the way to becoming an industry standard. This method has demonstrated its ability to reduce costs without compromising vehicle safety or durability, and many manufacturers have already adopted it or plan to do so.
As the automotive industry faces unprecedented challenges – energy transition, component shortages, changing consumer expectations – innovation in production processes could well be the key to remaining competitive. If Tesla’s bet proves successful, we could witness a profound transformation of the industry, comparable to that initiated by Henry Ford more than a century ago.
Next October 10, the date announced for the official presentation of the Robotaxi, will perhaps mark the beginning of this new era. Beyond the vehicle itself, Tesla’s entire production philosophy will be highlighted. One thing is certain: whether it is vehicle design or manufacturing, Tesla continues to push the boundaries of automotive innovation.