Top 10: Biggest Manufacturing Factories

Factories are integral to manufacturing operations as the site of product production, refinement and distribution. They can positively impact local economies, bring new labour opportunities and, fundamentally, determine the future trajectory of businesses. 

As demand for specific products increases, the space, equipment and labour needed to facilitate their production grows as well. This is why the world’s biggest manufacturers tend to have factories to match.

With this in mind, Manufacturing Digital has ranked the top ten biggest manufacturing factories in the world, each of which is shaping the industry and global supply chains.

10. Mitsubishi Motors Okazaki Plant, Japan

• Revenue: US$19bn

• Employees: 36,551

• CEO: Takao Kato

• Company founded: 1870

Covering 1.8 million square feet, Mitsubishi Motors’ plant in Okazaki, Japan, produces models like the Eclipse Cross and Outlander.

This facility is a key domestic production site for the company, integral to its supply chain in Japan. Mitsubishi pursues innovation and advancement at this factory.

These plants are critical hubs for their respective companies, each contributing significantly to their global manufacturing capabilities and product offerings.

9. Toyota Motor Manufacturing, Kentucky, USA​​​​​​​

• Revenue: US$237.9bn
• Employees: 380,793
• CEO: Kōji Satō
• Company founded: 1937

The largest of Toyota’s manufacturing plants outside of Japan, this 7.5 million square foot automotive factory in Georgetown has been operational since 1988. 

Manufacturing premium Toyota vehicles such as the Avalon, Camry and Lexus ES, this facility plays a critical role in Toyota’s North American production network. 

The factory is known for abiding by Toyota’s philosophy of lean manufacturing and kaizen- continuous improvement.

8. Nissan Motor Company Plant, Smyrna, US

• Revenue: US$78.416bn

• Employees: 131,719

• CEO: Makoto Uchida

• Company Founded: 1933

One of Nissan’s key manufacturing plants in North America, its Smyrna, Tennessee plant produces iconic vehicles like the Altima, Maxima and Rogue. 

Producing more than 640,000 vehicles annually, this 6 million square foot facility began operations way back in 1983. 

Dedicated to serving the North American market, this factory focuses on reliable, innovative automotive production.

7. Kia Motors Hwaseong Plant, South Korea

• Revenue: $US 75.81 bn
• Employees: 35,737
• CEO: Ho Sung Song
• Founded: 1944

Operational since 2009, Kia’s automotive manufacturing factory in Hwaseong, South Korea produces models like the Seltos, Sportage and K5. 

A major manufacturing facility for Kia that plays a significant role in its global production network, the factory produces a wide range of vehicles with smart technology and design features. 

Hwaseong also hosts the Namyang Design Center, Kia’s primary design facility.

Kia has 14 manufacturing facilities in total across South Korea, China, India, Mexico, Slovakia, the United States, Vietnam and Japan.

6. Foxconn Longhua Plant, Shenzhen, China

• Revenue: US$198.9bn
• Employees: 88,000
• CEO: Young Liu
• Founded: 1974

Foxconn’s Longhua factory, located in Shenzhen, China, has been operational since the early 2000s. Best known for assembling Apple iPhones, this electronics manufacturing plant is integral to the electronics global supply chain. 

A massive facility with a colossal role to play in electronics manufacturing, Foxconn’s factory focuses on high-volume production and assembly.

5. Tesla Shanghai Gigafactory, China

• Revenue: US$24.9 bn
• Employees: 140,473
• CEO: Elon Musk
• Founded: 2003

Based in Shanghai, Tesla has a Gigafactory dedicated to electric vehicle and battery production. 

One of the manufacturer's major international factories, the Gigafactory is spread over 9.3 million square feet and produces the Model 3 and Model Y vehicles for the Chinese market.

Electric vehicles are popular in China and demand is surging. The Shanghai Gigafactory began operations in late 2020, and today aims to scale up its production and enhance innovation.

4. Boeing Everett Factory, Washington, USA

• Revenue: US$77.8bn

• Employees: 145,000

• CEO: David Calhoun

• Founded: William E. Boeing

Officially the largest building in the world by volume, the Boeing Everett Factory in Washington was originally built in 1967 for construction of the company’s iconic 747 aeroplane. 

Today, it produces a diverse range of Boeing commercial aircraft, including the 747, 767, 777 and 787 Dreamliner. 

With the capacity to produce multiple aircraft types simultaneously, this facility helps advance aerospace technologies, like efficient manufacturing processes and composite materials.

3. Tesla Gigafactory, Nevada, USA

• Revenue: US$24.9 bn
• Employees: 140,473
• CEO: Elon Musk
• Founded: 2003

This Tesla Gigafactory, located in Sparks, Nevada, is a leading electric vehicle and battery manufacturing plant. Sixteen city blocks long with a length of 4,300ft, this colossal factory is one of the largest buildings by footprint in the world. 

Opened in 2014 to drive the production of Tesla’s energy storage products, lithium-ion batteries and EV innovation, the Gigafactory leads on both large-scale production and advanced manufacturing techniques. 

Tesla aims to produce batteries for up to 500,000 electric vehicles per year at the Gigafactory.

2. Hyundai Motor Company Ulsan Factory, South Korea

• Revenue: US$125.6bn
• Employees: 250,000
• CEO: Chang Jae-hoon
• Founded: 1967

Located in Ulsan, South Korea, this Hyundai Motor Company factory produces more than 1.5 million vehicles annually, making it the largest in the world by production volume.

Incorporating advanced smart factory technology into the mass production of Hyundai’s cars and trucks, the Ulsan factory produces models like the Elantra, Tucson and Sonata. 

Covering 54 million square feet, the Ulson factory consists of five production plants, a fire station, a hospital and a harbour, equipped to handle supply chain logistics and address emergencies immediately.

1. Volkswagen Wolfsburg Plant, Germany

• Revenue: US$349.8bn

• Employees: 675,000

• CEO: Oliver Blume

• Founded: 1937

Volkswagen’s Wolfsburg Plant in Germany is one of the largest and most innovative manufacturing facilities in the world. 

A key hub for the automotive manufacturer, the Wolfsburg plant was established back in 1938 and primarily produces popular Volkswagen models like the Passat, Tiguan and Golf. 

Capable of producing hundreds of thousands of vehicles annually, in 2023 this figure reached 490,000.

Spanning 70 million square feet and housing approximately 70,000 employees, this plant helps meet the high global demand for Volkswagen vehicles and drives smart factory innovation and sustainable EV production.

These factories are true manufacturing landmarks and have a profound impact on surrounding communities, while driving innovation in their respective industries. 

As the global manufacturing industry weathers the challenges of an ongoing skills and labour gap in addition to the hardships of digital transformation, the factory floor will continue to be a site of transformation.  At these major factories in particular, expect to see profound changes moving forward. 

 To read the full story in the magazine click HERE 

****** 

Make sure you check out the latest edition of Manufacturing Digital and also sign up to our global conference series - Procurement & Supply Chain 2024 & Sustainability LIVE 2024

******

Manufacturing Digital is a BizClik brand.