BMW outlines iFACTORY manufacturing technique; transformation to e-mobility; Plant Debrecen first CO2-free plant

BMW outlines iFACTORY manufacturing technique; transformation to e-mobility; Plant Debrecen first CO2-free plant


BMW’s iFACTORY manufacturing technique defines the long run orientation of crops and manufacturing applied sciences on the BMW Group and meets the challenges of the transformation to e-mobility.

Automotive manufacturing of the long run requires a brand new, holistic mind-set. With our BMW iFACTORY, we’re main the way in which and setting new requirements in flexibility, effectivity, sustainability and digitalization.

—Milan Nedeljković, Member of the Board of Administration of BMW AG, liable for Manufacturing

The strategic imaginative and prescient of the worldwide manufacturing community is the BMW iFACTORY. LEAN. GREEN. DIGITAL., with an integrative, world method.

The BMW iFACTORY shouldn’t be a one-off showpiece however an method we are going to implement in any respect our crops sooner or later —from our 100-year-old house plant in Munich to our forthcoming plant in Debrecen, Hungary.

—Milan Nedeljković

BMW Group Manufacturing Community: 31 manufacturing websites in 15 nations.

The BMW iFACTORY focuses the BMW Group’s manufacturing experience on three key matter areas:

  • LEAN, which stands for effectivity, precision and excessive flexibility;

  • GREEN, for sustainability, resource-efficiency and circularity; and

  • DIGITAL, for the energetic use of digitalisation in knowledge science, synthetic intelligence (AI) and virtualization.

The holistic method of the BMW iFACTORY is underpinned by the pliability, launch experience and integration functionality within the firm’s manufacturing system.

LEAN: Primarily based on extremely versatile, environment friendly manufacturing. The BMW Group’s manufacturing community is on the cusp of a elementary transformation: the Neue Klasse, due for manufacturing launch in 2025, is predicated on a very new car structure.

With its clear deal with the all-electric drive, it units the situations for future car generations to be manufactured effectively and in step with the corporate’s profitability and high quality objectives. The BMW iFACTORY is now set to strengthen the confirmed success elements of the worldwide manufacturing community.

LEAN is about extremely versatile, environment friendly manufacturing by streamlined processes in aggressive buildings. A single BMW manufacturing line can produce completely different drive sorts and car fashions. Additionally they set the usual by way of speedy responsiveness and adaptableness, absorbing provide bottlenecks and shortages comparatively spontaneously and reacting shortly to fluctuations in demand. For patrons, this flexibility means they’ll change sure components of their car configuration as much as six days earlier than the manufacturing date.

The purpose of the BMW iFACTORY is to make use of much more significant real-time knowledge from all through the manufacturing course of to manage world manufacturing extra intently and transparently obtain the quickest attainable response occasions. This can improve not solely quantity and market planning but in addition provide chain and stock administration and help focused work on high quality as nicely.

GREEN: Sustainability alongside the complete worth chain. With BMW iFACTORY, the deal with sustainable manufacturing is stronger than ever.

Environmental, financial and social duty are inseparable, and we attempt to realize all three not solely within the product itself however alongside the complete worth chain. By 2030 we purpose to scale back CO2 emissions from manufacturing by 80 % in comparison with 2019,

— Milan Nedeljković

With its new plant in Debrecen, Hungary—the place manufacturing of the all-electric Neue Klasse will launch in 2025—the BMW Group is coming into a brand new period in sustainable automotive manufacturing.

Our plans are for Plant Debrecen to be the primary automotive plant on the planet to dispense fully with fossil power sources in its manufacturing processes. Debrecen shall be our first CO2-free car plant and places us clearly on the vanguard of developments on this regard.

—Milan Nedeljković

A big share of the plant’s electrical energy shall be generated immediately on website. The rest shall be lined by 100% renewables, the overwhelming majority of which can come from regional sources.

One other aspect of sustainable manufacturing is constant circularity. Wherever attainable, manufacturing supplies and assets shall be reused. Metallic offcuts and filings from milling, for instance, shall be recycled and reused, whereas waste warmth from cooling shall be fed right into a circuit to warmth indoor areas and water.

Saving assets considerably advantages the corporate economically. Examples embody the resource-saving wet-in-wet portray course of (IPP) and the usage of direct present in automobile physique development for the primary time.

The power that powers the BMW Group’s crops around the globe is sourced purely from renewables. As Plant Leipzig develops into a middle of excellence for hydrogen, the corporate’s amenities worldwide have gotten more and more unbiased of third-party power suppliers or different exterior influences. That is enabled by a mixture of self-generated and saved power with versatile load profiles all through manufacturing. Right here, the most recent digital strategies and complete methods guarantee most transparency and help the constant discount of power consumption in addition to the needs-based use of renewables on the idea of correct forecasts.

An additional key concern within the discipline of local weather safety is biodiversity. The number of wildlife at BMW Group websites worldwide is being promoted by focused, region-specific measures, from beehives and falcons to meadow orchards.

In the meantime, to help GREEN logistics each inside and out of doors the crops, the BMW iFACTORY adopts an open-minded method to applied sciences, specializing in environmentally sustainable ideas. Throughout the subsequent few years, for instance, elevated use of rail transport and electrical vehicles will imply zero native emissions from transport logistics at Plant Munich.

DIGITAL: From improvements to efficient use instances. Manufacturing on the BMW Group makes use of the most recent applied sciences to hyperlink all of the related product, course of, high quality and value knowledge between growth, planning and manufacturing processes. The principle focus right here is on functions from the fields of virtualization, knowledge science and synthetic intelligence.

Virtualization performs an necessary position throughout the BMW iFACTORY technique mannequin. In a primary step, each element of all of the BMW Group’s manufacturing websites is being recorded in a 3D scan. On this manner, planning work will be carried out nearly at any time and from wherever. Within the subsequent logical step, a digital illustration—or digital twin—is created of every manufacturing unit in its entirety. This could then be utilized by planning specialists in real-time collaborations throughout completely different places and time zones.

This method permits digital merchandise to be built-in into the manufacturing unit early on, for instance, and considerably reduces planning work additional down the road. It additionally permits investments to be optimized and enhances course of effectivity and the steadiness of product launches.

Knowledge science offers the foundations for fact-, figure- and (real-time) data-based decision-making. Constant, clear knowledge permits the foundation causes to be recognized shortly and proactively in order that processes will be optimized. BMW Group manufacturing already makes use of greater than 200 AI-based functions. The expertise permits varied logistics and manufacturing processes to be automated for higher high quality assurance. As well as, standardized platforms and self-services imply options will be scaled quickly for utility throughout all applied sciences and places.

The important thing elements behind the transformation of BMW Group manufacturing are the developments within the automotive market and specs round local weather change. The BMW Group is already doubling its manufacturing of electrical autos in 2022, having delivered greater than 35,000 totally electrical automobiles to clients within the first quarter alone. On the similar time, the most recent technical improvements are supporting the corporate because it contributes considerably to local weather safety and sustainability.

The BMW iFACTORY delivers not solely on the growing buyer demand for electrical autos but in addition on our need, as a member of society, to help local weather safety and sustainability. We’re utilizing digitalization to make this occur – whereas remaining completely aggressive.

—Milan Nedeljković


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September 2022