BMW i4 production Germany, Munich

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Setting up production of the fully electric BMW i4 in the confines of the almost 100-year-old plant, the conversion and installation of systems proved particularly challenging. “We succeeded in integrating the new vehicle into our existing systems without halting production. The team and our partners did an amazing job,” added Peter Weber, Director of BMW Group Plant Munich. Space constraints notwithstanding, existing systems were removed, and new ones installed and ramped up. “Our bodyshop is a shining example of intelligent, efficient integration. Most of the new production processes for the BMW i4 can be carried out on the existing bodyshop systems,” Weber explained.

Digitalisation is progressing

Increasing digitalisation plays an important part in BMW Group production. The whole of Plant Munich is currently being 3D-scanned in minute detail to obtain a full set of basic digital data of both the building and its systems. The scans are then processed and saved on the cloud so the data can be accessed from anywhere using an intuitive, browser-based tool. Several plants have already been fully 3D-scanned – Spartanburg and Regensburg among them – and Plant Dingolfing is undergoing the process at the moment. By the end of 2022, the structure of all the major car plants in the BMW Group production network will have been scanned, and digital data will be available for everyone.

The BMW Group already utilises virtual planning tools to plan buildings and systems today. Axle pre-assembly for the BMW i4, for example, was planned with the Omniverse Nucleus platform, by NVIDIA. This converges data from the design and planning tools of various producers to create photorealistic real-time simulations in a single collaborative environment. The data from the 3D scans is also fed into the Omniverse platform.

Other digital applications are used directly in production. Radio frequency identification (RFID), for example, allows parts to be identified and assigned contactlessly and automatically along the value chain, eliminating the need for manual scanning and ensuring the right one is fitted to the right car. RFID technology is already in use in seat production but has also made its way into various areas of vehicle assembly at Plant Munich. The smart labels required for it are attached to parts while they are still with suppliers or in BMW Group component production, ready for use in assembly. They are then picked up by line-side antennae that track every labelled component in every car. Digitalisation of this kind makes processes faster and more secure, and enhances efficiency and quality as a result.

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0:00 BMW i4 M50 Production Munich
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