A world-class engine family designed and built from scratch to bring manufacturing back to the UK

Jaguar Land Rover is the UK’s largest automotive manufacturer, with a history going back almost 70 years. The company has been named as a finalist for the 2016 MacRobert Award in recognition of the world-class innovation behind the most significant decision the company has ever made: to design and manufacture its own engines for the first time in a generation.

In 2011, it was announced that Jaguar Land Rover would invest £1.5 billion a year for the next five years on new product development. The design, development and creation of a new family of Ingenium engine supports the company’s ambition to be completely self sufficient by 2020 in the design and manufacture of engines. Starting with little more than a blank sheet of paper and an empty field, the Jaguar Land Rover team has developed an entire suite of world-leading engines, Ingenium, that meet the growing demand for lower fuel consumption and cost of ownership, without compromising performance and driver experience, thus delivering commercial robustness for the company now and into the future. The first diesel engine launched in early 2015, and the petrol engine is due to launch in September 2016.

The Ingenium engines are the result of almost 200 innovative ideas, combined to deliver significant emissions and weight reductions alongside improved performance. Despite adding features and increasing power output, Ingenium engines weigh up to 80 kg less than today's equivalent engines, and with the 4-cylinder Ingenium engine, the Jaguar XE has become the first ever sub-100g/km CO2 2.0L diesel premium saloon car (at 99g/km).

In order to build the Ingenium engines, Jaguar Land Rover had to build an entire facility from scratch, which presented an opportunity to create a world-class manufacturing environment. Just outside Wolverhampton, work started on the £500 million, 98,000m2 state-of-the-art Engine Manufacturing Centre (EMC) in 2012. Work is currently underway to extend the facility through an 85,000m2 expansion at a cost in excess of £450 million. The EMC also has impressive green credentials with one of the largest solar panel roofs in the UK, with over 21,000 photovoltaic rooftop panels, capable of generating up to 30% of the site’s electricity needs.

Filling a brand new factory with skilled staff presented its own challenge and Jaguar Land Rover took a novelapproach to creating job opportunities and up-skilling its workforce. Every EMC employee undertakes an intensive two-week immersive training programme called the Powertrain Way, which has successfully introduced bus drivers, bricklayers and beauticians to new careers in engineering. Wolverhampton has the second highest unemployment rate in the UK, and the EMC is already providing a large number of opportunities in the region. The facility officially opened in October 2014 and already has nearly 1,000 employees, supporting a further 5,500 in the supply chain. Over 40 people have enrolled on an apprenticeship programme at the EMC, and last year Jaguar Land Rover opened an Education Business Partnership Centre working with local schools to encourage children to pursue STEM subjects.

MacRobert Award judge, Professor Gordon Masterton OBE FREng FRSE, said: “What Jaguar Land Rover has achieved in such a short space of time is remarkable. Starting from scratch, the company has developed a world-leading facility of which Britain should be extremely proud. The ambition behind the decision to develop and manufacture their own engines for the first time can not be underestimated, but it took world-class engineering talent to make that dream a reality.”

Team members

  • Ron Lee, Director, Powertrain
  • Paul Whitwood, Chief Engineer, Engines Engineering
  • Graham Page, Chief Engineer, Engines Engineering
  • Alan Jones, Chief Engineer, Calibration Engineering
  • Trevor Leeks, Operations Director, Engine Manufacturing Centre (UK)