Significant Milestone in Production
Munich. The BMW Group Plant Munich is set to reach a pivotal point in its transformation as it commences series production of the BMW i3, the second model in the Neue Klasse line, this August. This initiative signifies the beginning of the Neue Klasse rollout across BMW’s global production network.
Strategic Framework for Production
Milan Nedeljković, Member of the Board of Management at BMW AG, emphasises that rigorous preparations have been undertaken. “With the BMW iFACTORY, we have established a consistent strategic framework for our production,” he states. The company has invested heavily in advanced technologies, digitalisation, and artificial intelligence to facilitate upcoming launches across all its plants.
Modernisation and Efficiency Gains
The Munich plant has undergone extensive modernisation in recent years, enhancing its efficiency, flexibility, and digital capabilities to meet the demands of electric mobility. By 2027, the facility will exclusively produce all-electric vehicles, further improving efficiency. Proactive planning and collaboration with development teams and suppliers have played a crucial role in this transformation. Peter Weber, Head of BMW Group Plant Munich, notes that overall production costs will decrease by an additional 10 per cent with the introduction of the BMW i3, lowering them below current vehicle generation levels.
Investment in Electric Production
A substantial investment of around 650 million euros is being allocated to transform the Munich plant into a fully electric production site. This shift aims to optimise production processes through targeted automation and digitalisation while leveraging the new vehicle architecture of the Neue Klasse to enhance efficiency.
Historic Site Reinvented
The Munich plant has continuously evolved over its century-long history, now producing up to 1,000 vehicles daily amidst a significant redevelopment phase. New structures for body shop operations and vehicle assembly have been established across approximately one-third of the plant’s footprint, alongside substantial upgrades to existing technologies.
Innovations in Production Processes
The BMW iFACTORY prioritises efficiency, sustainability, and digitalisation. This vision is being implemented across all technologies at the Munich plant. “We have re-evaluated the entire value stream from supplier to finished vehicle,” Weber adds. Every process has been optimised to ensure heightened efficiency and flexibility.
Advanced Body Shop Operations
A new body shop specifically for the Neue Klasse employs 800 industrial robots for joining processes. The automation rate stands at around 98 per cent, significantly simplifying operations while maintaining high quality standards through automated surface inspections.
Enhanced Paint Shop Techniques
The paint shop utilises AI-assisted systems to monitor quality processes. Digital inspections identify even minor deviations in surface quality, allowing immediate corrective actions during production. The energy-efficient eRTO process purifies exhaust air while maximising heat and energy recovery.
Assembly Line Advancements
Formerly a hub for engine manufacturing, the assembly area now supports end-to-end digital processes. Up to 20,000 features of the BMW i3 are digitally transmitted during assembly. Enhanced ergonomic workstations and targeted training help ease employee workload while adapting to new digital requirements.
Streamlined Logistics Operations
The logistics department at the Munich plant moves approximately 2.5 million parts daily, with plans for around 70 per cent of these components to be delivered directly to assembly stations in the future. This approach reduces internal transport distances and accelerates supply lines through an innovative multi-storey building structure designed for urban settings.
In-House Seat Manufacturing
The unique in-house seat manufacturing facility plays a crucial role in quality assurance within the production network. Seats for all models produced in Munich are made on-site and delivered directly “just in sequence”. This facility sets high standards for quality assurance across BMW Group while contributing to innovation in materials and manufacturing processes.
Bavarian Value Creation: Batteries and E-Drives
The new assembly plant for high-voltage batteries located in Irlbach-Straßkirchen will support local production by supplying Gen6 batteries to the Munich facility. This aligns with BMW’s “local for local” strategy. The Irlbach site employs cutting-edge technologies alongside strict quality controls in battery production.
Meanwhile, the Gen6 e-motor for the BMW i3 is produced at BMW Group Plant Steyr in Austria. With over 40 years of drivetrain manufacturing experience, this location will provide essential components for the integrated e-drive system.
© BMW Group
