Mini-lover Marc West gets a peep behind the scenes at Cowley’s high-tech Plant Oxford – before driving off in one

On March 28, 1928, a century of car production began in Oxford.

It is a journey through industrial development, engineering innovation and social change – that continues to this day.

Designed by Sir Alec Issigonis, the Mini has become an icon of 20th century design – and the distinctive people’s car is still built in the very same factory as when it was conceived in 1959.

Plant Oxford is the birthplace and current beating heart of Mini production.

Manufactured to individual customer specifications, over three million vehicles (to date) have left the plant’s assembly lines to meet new owners in more than 100 countries around the world.

But, I’ve always wondered what exactly goes on inside the big black façade of that factory – having a Lowry-esque vision in my mind’s eye.

As I step into the £750m facility, I’m half expecting to see a legion of old chaps in greasy overalls clunking away with heavy spanners and mopping sweat from their brows. But, I couldn’t have been more wrong.

There’s not a spot of oil to be seen anywhere in the NASA-like Body Shop, where order and efficiency have prevailed since BMW Group introduced minimalism in manufacturing in 1994. Henry Ford eat your heart out!

Today, thousands of robotic arms do most of the work – picking and placing components 24/7 in an endless cycle which enables one car to be completed nearly every minute. This robot/human alliance is a synchronised ballet soundtracked by a mechanical symphony – a vision of the future, today.

And, amongst this cacophony of sound, is a place of calm. A Japanese-style Genba is a meeting place where new ideas can be brainstormed and production constantly analysed.

Nothing is seen as a problem, merely a challenge – and it’s this modern mentality that’s kept our city to the forefront of excellence.

At this stage, it’s hard to visualise my new wheels (I wish), but as we progress into the Paint Shop I can better imagine myself effortlessly cruising down to the French Riviera in one of these dream machines.

By now, every vehicle is considered a sold car and each is allocated a unique barcode to identify its owner’s exacting details – with over a million customisation combinations.

Before being allowed to work on the line, apprentices spend 16 weeks on the job in a buddy system learning how to… “make a cup of tea”.

I’m told this is the best way to demonstrate the importance of always following process – such as threading the complex wiring loom, fitting the doors and aligning the windscreen.

Quality can’t be added at this stage, it needs to be built in from the very start. By Station 200, it’s almost complete – ready to roll off the test track and onto motorways, interstates and autobahns across the globe. This is where the Mini adventure really begins!

As the next corner approaches, a smile of anticipation creeps across my face. The new John Cooper Works model is the ultimate expression of the brand and I get to test drive one.

It retains all the integrity of that original little car from Cowley.

GO ALONG
Visiting Plant Oxford offers a unique opportunity to see first-hand how a world-beater was born on our doorstep. Tours take place between 9am and 6pm Monday to Friday.
Book your tickets now via visitmini.com.