The primary series-produced cars of the brand new BMW 7 Collection have rolled off the manufacturing traces of BMW Crew Plant Dingolfing. In reality, it used to be a double debut, with the brand new top-of-the-range BMW manufactured no longer simplest with extremely effective combustion engines but additionally because the absolutely electrical BMW i7. Milan Nedeljković, BMW AG Board Member for Manufacturing: “Our new BMW 7 Collection is the primary luxurious sedan on the earth to provide consumers a call between 3 forms of pressure. Whether or not absolutely electrical, combustion-powered or, quickly, plug-in hybrid, we now have the versatile manufacturing constructions and exceptional integration abilities we want to manufacture one of these numerous differ of drives successfully.”
Over €300 million invested in Dingolfing car plant
The BMW Crew invested over €300 million to in a position the Dingolfing car plant for manufacturing of the brand new BMW 7 Collection. Because it strives constantly to put in force the BMW imaginative and prescient of manufacturing of the longer term, its biggest Eu plant is more and more being remodeled right into a BMW iFACTORY training the ‘Lean. Inexperienced. Virtual.’ means. For the primary time, the BMW Crew is piloting automatic manoeuvres inside the manufacturing surroundings by means of just-made BMW 7 Collection cars – and optimising meeting and outbound logistics processes because of this.
BMW i7: The most recent milestone at the highway to e-mobility within the luxurious section
With manufacturing underneath means, as soon as gross sales organisations had been supplied with the display and demonstration cars they want, the brand new BMW 7 Collection can be to be had to consumers international within the autumn of this yr. The BMW i7, particularly, marks the next move within the BMW Crew’s electromobility marketing campaign for the luxurious section, which Dingolfing has come to symbolise. Board Member Milan Nedeljković: “Precisely a yr in the past, we had been right here to have fun the beginning of manufacturing of our BMW iX. the BMW i7 is the newest milestone on our adventure. Subsequent yr will see the release of the absolutely electrical variant of the BMW 5 Collection as we step up the tempo of electromobility and electrify our core fashion sequence.” Via the top of 2022, one in 4 BMWs leaving Dingolfing is already anticipated to include an electrical pressure, emerging to approx. 50 % of the plant’s overall output by means of the center of this decade, in step with present plans.
one hundred pc trade flexibility between several types of pressure
The brand new BMW 7 Collection is assembled at the similar line because the BMW 5 Collection, 8 Collection and the absolutely electrical BMW iX. “We’re one hundred pc versatile and in a position to change between pressure variants for the BMW 7 Collection,” defined Christoph Schröder, Plant Director. “This implies we will manufacture totally in step with call for for the more than a few drives and use our plant capability as absolutely as imaginable.”
BMW 7 Collection advantages from product and procedure modules of the BMW iX
The brand new BMW 7 Collection builds on more than a few generation modules of the BMW iX – no longer only for particular person options just like the onboard community structure, consumer interface and driving force help techniques but additionally on the subject of manufacturing and validation processes in meeting, for which the BMW iX used to be the trailblazer. Examples come with the redesigned mixture becoming station, sling loop meeting, take a look at rigs for driving force help techniques and the brand new end procedure, which is now much more effective all the way through, from first ignition to the car dispatch space. The BMW iX is lately certainly one of Dingolfing’s maximum a success cars.
Re-using techniques, plus the particular two-tone paint procedure
Transformed all the way through manufacturing shutdowns, the bodyshop used to be in a position to combine the brand new BMW 7 Collection into the constructions in the past used to fabricate the fashion’s predecessor. Via adapting and re-using techniques on this means, the BMW Crew has stored loads of hundreds of thousands of euros and a wealth of sources. The ground assemblies of the brand new BMW 7 Collection have distinct geometries and range partly, relying on the kind of pressure, but they are able to all be manufactured totally flexibly in any mixture on one and the similar major manufacturing line. As well as, automation – in door becoming, for example – and a discount in subject matter combos and the bonding processes required have made processes extra effective. Within the paintshop, a distinct procedure has been established for the unique two-tone paintwork of the brand new BMW 7 Collection, melding ways from sequence manufacturing with the guide portray abilities of the Dingolfing experts.
Inhouse manufacturing of e-drive elements
The e-drive elements of the BMW i7 – in particular the high-voltage battery and extremely built-in electrical pressure – also are made in Dingolfing. Like the ones of the BMW iX, BMW i4 and BMW iX3, they’re manufactured close by, within the BMW Crew Competence Centre for e-Power Manufacturing.
Lately the Competence Centre introduced two new manufacturing traces, enabling the ability to provide enough e-drives for greater than 500,000 electrical vehicles a yr. The group of workers has additionally greater, from approx. 600 in early 2020 to over 2,300 as of late.
“The transformation to a BMW iFACTORY is easily underneath means”
“With their step forward applied sciences, cars just like the BMW 7 Collection are catalysts for trade – together with in our vegetation,” emphasized Milan Nedeljković, declaring that they contain inventions no longer simplest within the product but additionally in manufacturing. “Dingolfing’s transformation right into a BMW iFACTORY is easily underneath means,” added Christoph Schröder. “We’ve loads of workers operating to make our plant extra effective, versatile and sustainable, with efficient inventions and digitalisation answers as the important thing drivers of growth.”
The Lean. Inexperienced. Virtual. means of the BMW iFACTORY is already a fact within the manufacturing halls of Plant Dingolfing.
Lean. Flexibility and the in style rollout of sensible logistics answers
The facet of Lean is being realised at Plant Dingolfing to a big stage by means of the versatile format of manufacturing constructions. “Our constructions give us the trade flexibility we want to transfer between other fashions and pressure sorts, the quantity flexibility to react briefly to radically fluctuating call for, and the order flexibility to house the last-minute adjustments consumers can request as much as only a few days sooner than their automotive is produced. Right here in Dingolfing, flexibility is just part of our DNA,” mentioned Christoph Schröder.
Every other instance of the way digitalisation helps the potency targets of Plant Dingolfing is the great rollout of sensible logistics answers. Dingolfing is the corporate pioneer on this regard, working no longer simplest automatic forklifts but additionally self reliant tug trains, automatic out of doors logistics answers and sensible delivery robots (STRs) that elevate portions to the line-side. Made by means of the BMW Crew subsidiary Idealworks, STRs are anticipated to greater than double in quantity to over 200 by means of the top of 2022 as sequence manufacturing of the BMW 7 Collection ramps up. “Due to versatile, automatic answers like this, we now have develop into extraordinarily effective at managing the complexity and myriad phase numbers we paintings with right here on the plant,” mentioned Schröder.
Inexperienced. Making an investment in sustainable manufacturing
The Inexperienced facet of the BMW iFACTORY and sustainable manufacturing in Plant Dingolfing is realised by means of a variety of measures. Those come with sourcing one hundred pc inexperienced calories, re-using a number of hundred current manufacturing robots within the bodyshop, and decreasing the intake of sources within the paintshop. Right here, investments of over €50 million are lately being made in new cathodic dip traces and a dry separation machine, which is able to save important quantities of water and effort. As well as, the waste warmth from the drying furnaces will now not be used purely as procedure warmth but additionally to generate electrical energy.
Different sides of sustainable manufacturing come with energy-efficient techniques, packaging making plans, visitors logistics, recycling and water control. On-site transportation, for instance, is performed by means of electrical truck. Additionally, Dingolfing lately has a recycling quota of greater than 90 % and a good upper re-use quota of greater than 99 %. In 2021, this despatched overall residual waste tumbling to simply 580 grams consistent with automotive produced. And on the subject of water, Dingolfing lately covers 40 % of its wishes by means of drawing by itself supply, thereby serving to to maintain the area’s ingesting water provides as smartly.
Virtual. Computerized high quality keep watch over by means of cameras with AI
Clever virtual answers are utilized in all spaces of manufacturing at BMW Crew Plant Dingolfing, however particularly in car meeting – be it for digital coaching, sensible scanners, automatic AI-based high quality keep watch over or automatic riding by means of freshly manufactured cars.
In relation to AI, the BMW Crew has confirmed its pioneering credentials with its AIQX (Synthetic Intelligence High quality Subsequent) challenge, which makes use of sensors and AI to automate high quality processes. Sensible digital camera techniques and sensors embedded within the manufacturing traces report information for backend analysis in real-time utilizing algorithms and AI. Comments is then despatched without delay to workers at the line, by the use of their sensible gadgets. AIQX can be utilized to decide variants, examine completeness and stumble on any anomalies that can have passed off all the way through becoming. It’s lately working in 40 programs in manufacturing of the brand new BMW 7 Collection.
The release of the newest car has additionally boosted the choice of use circumstances of IPS-i. This digitalisation challenge makes use of an IT platform to converge information from a variety of location techniques and generate a virtual dual in real-time of the meeting corridor. From using sensible scanners and screwdrivers to RFID-based verification of the allocation of portions to cars, the IPS-i platform supplies the root for finding and interconnecting each merchandise – each car, element and power – concerned within the manufacturing procedure. With the brand new BMW 7 Collection, RFID-based element tracing on my own has been prolonged to 45 other phase households.
BMW 7 Collection pilots automatic riding inside plant
Manufacturing of the brand new 7 Collection additionally makes use of a virtual innovation with primary doable for meeting and outbound logistics in BMW Crew vegetation and distribution centres: automatic riding in-plant (‘automatisiertes Fahren im Werk’, AFW). As a part of the digitalisation technique, the AFW challenge can be piloted in Dingolfing from July and sees newly produced BMW 7 Collection pressure mechanically alongside a 170-metre path from the primary ignition and preliminary trying out space in meeting to the end space within the plant. The similar means can be used to get cars from the top of the end line to the dispatch space.
The AFW challenge used to be advanced by means of the BMW Crew and the 2 startups Seoul Robotics and Embotech, who give you the tool and generation. Venture supervisor Sascha Andree defined: “Computerized riding inside the plant is basically other from self reliant riding for purchasers. It makes use of a fully other machine. So as an alternative of depending at the car’s sensors, it makes use of an infrastructure out of doors the automobile to allow surroundings popularity and plan the car’s actions.” The path during the logistics spaces of the plant is fitted with sensors that use Seoul Robotics tool to generate information for car localisation and surroundings popularity. Additional externally founded drive-planning tool, by means of Embotech, then steers, brakes, hurries up and parks the driverless cars by means of sending them the related instructions.
AFW is anticipated to be piloted till 2023 and can first of all be rolled out on different fashions at Plant Dingolfing as smartly.
Dingolfing – House of the BMW 7 Collection since 1977
Plant Dingolfing, in Decrease Bavaria, has been the house of the flagship BMW 7 Collection since 1977 and is now production the 7th era. It’s the BMW Crew’s lead plant for massive BMWs and has in depth experience in manufacturing launches in addition to many years of enjoy within the manufacture of top rate cars for the luxurious magnificence. Up to now, Plant Dingolfing has manufactured a grand overall of greater than 11 million BMW vehicles, and an extra manufacturing milestone is at the agenda this yr: the 2 millionth BMW 7 Collection.
BMW Crew Plant Dingolfing – Key info.
Plant Dingolfing is likely one of the BMW Crew’s greater than 30 manufacturing websites world wide and its biggest in Europe. Each day round 1,600 BMW 4 Collection, 5 Collection, 6 Collection, 7 Collection, 8 Collection and all-new, absolutely electrical BMW iX cars roll off the manufacturing traces in automotive plant 02.40. In 2021, annual output totalled some 245,000 devices.
The website lately employs approx. 17,000 folks. Additionally it is coaching about 850 apprentices for 15 professions, making it the most important coaching organisation within the BMW Crew.
Dingolfing manufactures no longer simplest vehicles but additionally car elements, akin to pressed portions and chassis and pressure techniques. Situated in element plant 02.20 is the BMW Crew’s Centre of Competence for E-Power Manufacturing, which gives BMW car vegetation world wide with electrical motors and high-voltage batteries for plug-in hybrids in addition to absolutely electrical fashions. It’s underneath consistent construction and lately employs over 2,300 folks.
As well as, Dingolfing creates the bodies-in-white of the entire Rolls-Royce fashions. Additionally it is house to what’s referred to as the Dynamics Centre, a big garage and trans-shipment level and the centrepiece of central aftersales logistics on the BMW Crew, supplying BMW and MINI buying and selling organisations with unique BMW and MINI portions and equipment.
Supply: BMW Crew