Sixth-formers saw up-to-the-minute manufacturing technology on a visit to one of Britain’s most famous car factories.
The first QE trip of its kind to the historic Mini Plant Oxford provided a look behind the scenes at how advanced manufacturing processes, automation, and teamwork are combined on a single production line.
The Year 13 pupils also learned about the history of the iconic Mini, from the 1960s classic car through to today’s newer version, first produced in 2001.
QE’s Head of Technology Bilaal Khan said: “It was an outstanding experience for the students, allowing them to see the theories and concepts they have been studying brought to life in a real industrial setting. The trip not only deepened their understanding, but also inspired many of them to think more broadly about future careers in engineering, technology, and design.”
The plant on the Oxford ring road was the car body manufacturing business of the Pressed Steel Company, founded in 1926. It became part of the huge Morris Motors – later British Leyland and then Rover Group – site at Cowley, which incorporated three factories. Today only the Mini plant remains.
The original Mini became an icon of the 1960s, featuring in the 1969 film caper, The Italian Job. Its role was reprised by the modern Mini in a 2003 remake of the film.
BMW bought the Rover Group in 1994. The new Mini was first unveiled as a concept car in 1997. When BMW sold the other parts of the Rover Group in 2000, it retained the rights to the Mini.
After an initial tour during which they learned about the history of the iconic car, the pupils were shown around the factory.
Among the group was Danyal Talha, of Year 13, who said: “We witnessed a clear progression in the design styles of the cars, with evident links to design movements and ideas of the time.
“The factory tour then took us through one of the most advanced flexible manufacturing systems (FMS) in the world. FMS allows for various specifications of a product to be produced on a single line, and we witnessed this, with endless variations of Minis being made: from cabriolets to hard-tops, left and right-hand drives, with customised-to-order body colours and wheel alloys.”
They delved into details of the manufacturing process such as the ‘Prüfcubing process’, used to evaluate the fit, function and development of parts before a model launch. The boys saw a Prüfcubing body – a life-size model of a car body with a tolerance of +/- 0.2mm that was manufactured from solid aluminium, taking 2,000 hours to machine and worth some 1m Euros.
The group also saw automated guided vehicles (AGVs) in use. These are portable robots which, unlike autonomous robots, rely for their navigation on infrastructure in their environment, such as lines or wires on the floor, radio waves, or lasers.
“While we had already learned about AGVs in our theory lessons, getting to see them communicate with one another and work seamlessly to optimise the production line’s efficiency was fascinating,” said Danyal.
“Overall, the trip was a fabulous insight to real-world flexible manufacturing systems, and taught us about the evolving nature of production lines becoming fully automated.”
During the Art department trip, boys were encouraged to draw parallels between their classwork and the professional practices they saw at the studios in Watford.
“Through our QE Flourish co-curricular programme – and thanks to QE’s advantageous location – we can offer educational experiences like this to bring classroom subjects to life, broaden horizons and develop future-ready skills.”
There were rave reviews afterwards from the boys. It was, said Akhil Kotha, “a truly beneficial trip, pulling out the secrets of designing a movie, with all the complex roles and activities clearly explained, aided by the hospitable staff”.
Active since the 1970s in promoting classical liberal ideas, he decried what he saw as the recent decline in American democracy, but expressed his beliefs that, with the application of optimism it can be successfully renewed, and that all democracies must constantly look to renewal to avoid decline and collapse.
The invitation to QE came about after Senior Vice-Captain Vu-Lam Le-Nguyen met Dr Palmer at an event organised by the John Locke Institute. QE’s well-attended talk in The Robert Dudley Studio was organised by Vu-Lam and his fellow Year 12 student, Keshav Aggarwal.
A development economist by training, he explained how important it is to understand local culture and context to create appropriate policies. Local knowledge and processes might not make immediate sense to an outsider, but there are often good reasons for those processes, perhaps based on local geography. You cannot just impose western methods and expect them to work, he said.
The new independent school, which will open in August 2026, will be in Gurugram – a satellite city of Delhi in the northern Indian state of Haryana that is known as a financial and technology hub.
QE Barnet Headmaster Neil Enright said: “We are delighted to have this opportunity to offer a rounded and enriching QE education to children in India, spreading opportunity and supporting students to become the leaders of their generation. Our school in Barnet is built upon the high levels of aspiration, dedication and active engagement of our Elizabethan community, and these are values that we think will resonate strongly in Gurugram.
Caroline Pendleton-Nash, Chief Executive Officer of Queen Elizabeth’s Global Schools, said, “The opening of Queen Elizabeth’s School in Gurugram is another landmark moment for our organisation.