The Hyundai Metaplant America is the kind of manufacturing facility that other OEM manufacturing execs probably dream about. . .

By Gary S. Vasilash

I have seen the future of automotive manufacturing and it is in Savannah, Georgia. More specifically, it is in Ellabell, GA, but it is proximate (20 miles) to the more well-known locale.

The Hyundai Motor Group Metaplant America (HMGMA), which had its grand opening in late March, has been building Hyundai EVs since early October 2024. The first product is the IONIQ 5. It has since added the IONIQ 9.

The complex consists of 11 buildings with 7.5-million square feet under roof.

Hyundai has invested $12.6 billion in HMGMA as well as two battery joint ventures, one with LG Energy Solution and one with SK On.

The initial announced capacity was 300,000 vehicles per year.

Even before the launch is fully ramped the company announced it is going to increase capacity to 500,000 units.

HMGMA will not only be producing EVs for Hyundai, but products for sibling brands Genesis and Kia. And in addition to EVs, the plant will manufacture hybrid vehicles.

Shiny & Bright

To be sure there is something to be said for a new plant the way there is for a new car. Everything is bright and clean.

But HMGMA is exceptionally bright and clean—there are even skylights in the vaulted roof of the General Assembly building.

The epoxied floors shine with nary a smudge.

Advanced Manufacturing Tech

Hyundai operates the Hyundai Motor Group Innovation Center Singapore, where the company is developing smart manufacturing systems as well as producing vehicles with the hardware and software developed there (it has an annual capacity of 30,000 EVs).

The Singapore site is the testbed for the tech that is deployed in HMGMA.

While there is a significant number of robots working in the Weld shop—475—what is more impressive is the number of automated guided vehicles (AGVs) of various types, sizes and configurations that are autonomously running throughout the plant. These units are doing tasks ranging from parts delivery to actually lifting the finished vehicles at the end of the line and positioning them for subsequent inspection and tests.

The people working on the line—called “Meta Pros”—are not only walking on wood surfaces to make it easier on the legs during a shift, but tasks that might otherwise have them climb into a vehicle-in-process—such as installing a center console—are automated so as to relieve them of what might be ergonomically awkward conditions.

Investing Even More

Hyundai has announced that between 2025 and 2028 it will be investing $21 billion in the U.S. Part of that funding—as in $9 billion—will be to increase the total production capacity it has to 1.2 million vehicles. (It also has a plant in Montgomery, Alabama, Hyundai Motor Manufacturing Alabama, which builds the Santa Fe, Tucson, Santa Cruz, and Genesis GV70.)

When HMGMA is fully staffed there will be approximately 8,500 people working there.

The average salary for a Meta Pro is $58,105, not including benefits. Other workers in Bryan County, where the plant is sited, have an average wage of $47,000.

A good job in a modern facility for a good salary. That’s what bringing manufacturing to the U.S. is really about.