Lear Corporation is building an automated manufacturing facility in Michigan, set to begin operations next year, which will serve as a blueprint for scaling automation across its global production footprint. The Orion facility will utilize automation technology to reduce conversion costs by 10% to 15% while manufacturing seating for three General Motors models: the Cadillac Escalade, Chevrolet Silverado, and GMC Sierra. This initiative is part of Lear’s strategy to modernize production through technology-driven efficiency. The facility will feature two automated storage and retrieval systems, one for raw materials such as foam and another for finished goods, developed through acquisitions of companies like WIP Industrial Automation, Thagora Technology, and InTouch Automation.
CEO Raymond Scott stated that these acquisitions enable Lear to develop proprietary technology for its manufacturing sites, creating a “competitive moat that will be difficult for others to replicate.” The company owns the intellectual property and controls the roadmap for scaling these technologies globally. Beyond storage, the facility operates through what Scott calls “integrated intralogistics,” a connected intelligence layer that ties together inventory, material management, storage, and real-time decision-making from component arrival to finished product departure.
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Key features include an overhead suspended material storage and delivery system, automated guided vehicles, automated trailer loading, a four-directional storage system, autonomous mobile robots, smart ovens, automated end-of-line testing, and AI vision inspection. Lear is also implementing proprietary automation tools for workforce management, such as cycle time deviation and dynamic line scheduling. Scott emphasized that these advancements allow employees to focus on problem-solving rather than routine tasks. The Orion facility represents the culmination of a 10-year journey built on strategic acquisitions and technology development, with the internal team from ASI Automation playing a key role in developing core storage solutions.
The launch of the Orion site comes more than two years after Lear unveiled its IDEA by Lear strategy, which prioritizes digital tools and automation for efficient manufacturing. Scott recalled initial investor skepticism but affirmed that the company is fundamentally changing its manufacturing model. The Orion facility will serve as a model for scaling automation to other sites, including support for programs like Ford’s Super Duty line. Lear’s focus remains on validating the system’s efficiency before pursuing broader adoption across its global facilities.