BMW_Produktionsbroschuere_EN.pdf

The FascinaTion oF ProducTion

Global ProducTion neTwork

Flexible · eFFicienT · innovaTive

Global ProducTion

Production follows the market

Pursuing a strategy of local production, the BMW Group capitalises

on opportunities to penetrate and develop markets with long-term

growth potential. This enhances local acceptance in the market and

makes the BMW Group a local player. The BMW Group pursues this

strategy particularly in markets where high import duties obstruct

the import of fully assembled automobiles and thus prevent more

extensive market penetration. In addition to operating local automobile

plants, so-called “completely knocked down” (CKD) plants can

also be used in such cases to offer products in emerging markets at

competitive prices. In the CKD process, cars are assembled locally

from imported sets of parts and components and supplemented by

parts produced locally, thus fulilling the local content requirement

imposed by governments.

Four brands, four model series

Apart from BMW, MINI, and Rolls-Royce cars, the BMW Group

production network also builds BMW motorcycles of the BMW and

Husqvarna brands.

“Made by The bMw GrouP”

BMW automobiles are built at 13 plants all over the world. The

backbone of BMW’s production network is formed by six plants in

Dingoling, Leipzig, Munich, Regensburg, Rosslyn, and Spartanburg,

as well as a joint venture in Shenyang. Wherever appropriate, the

BMW Group integrates external partners into serial production.

But the BMW Group continues to retain the relevant expertise as well

as maintaining overall control and decision-making authority when it

comes to design, engine construction, purchasing, testing, service

and warranty matters.

The BMW Group aspires to be right at the top of all market segments in which our four brands are

represented. Highly emotional, individually tailored products with exceptional design and supreme

customer beneits are a clear expression of our consistent premium strategy.

Our fascinating products are created by a very versatile and highly eficient production network

with sophisticated work processes and state-of-the-art plants and facilities. Beyond the conines

of individual plants and borders, we constantly and consistently improve our resources and expertise.

And thanks to lexible management we are quickly able to adjust our production to the requirements

of the respective market.

The BMW Group also makes use of natural hedging: a high level

of purchase volume in key sales regions with differing currencies

serves to balance out the low of merchandise as well as make up

for currency luctuations and the associated trading risks.

The BMW Group operates the CKD plants in Chennai and Rayong,

while in Jakarta, Cairo, Kaliningrad and Kuala Lumpur BMW

cooperates closely with external partners.

Throughout this global production network, the BMW Group applies the same high standards to

processes, quality, safety, and sustainability. This guarantees that all products “Made by the BMW

Group” fulil the signiicant demands made of premium products.

The network is founded upon the sound expertise and enormous commitment of our associates.

They are the key to the success of the BMW Group.

Frank-Peter arndt

Member of the Board of BMW AG, Production

Production of the MINI is located in Great Britain, where the “MINI

Production Triangle” comprises the Oxford, Hams Hall, and Swindon

plants. Swindon produces pressings and body components for MINI

cars, which are delivered just-in-time to the body assembly plant in

Oxford. Hams Hall builds 4-cylinder petrol engines, which arrive at

the assembly line in Oxford just-in-sequence, i.e. exactly on time and

tailored to each car on the assembly line. The MINI automobiles for

the world market are manufactured at the Oxford plant. The MINI

Countryman is built by an external partner in Graz. Rolls-Royce Motor

Cars Ltd. has had its production facilities in Goodwood in t he south of

England since 2003. Working largely by hand, experi en ced specialists

create the exclusive Phantom models at this very special pla n t

dedicated entirely to Rolls-Royce: the classic Sedan (2003), the

Drophead Coupé (2007), the Coupé (2008) and the new model

Ghost (2009).

Berlin motorcycles

Dingolfing 5 Series, 6 Series, 7 Series

Eisen ach componen ts

Landshut components

Leipzig 1 Series, X1

Munich 3 Series

Regensburg 1 Series, 3 Series, Z4

Wackersdorf components

Rolls-Royce

BMW 1 Series

BMW 3 Series

Hams Hall engines

Oxford MINI

Swindon components

Goodwood Rolls-Royce

Kaliningrad

Steyr engines

BMW Z4

BMW 5 Series

BMW 5 Series Gran Turismo

Cassinetta Husqvarna

Shenyang

All BMW motorcycles and most motorcycle engines are built at BMW’s

motorcycle plant in Berlin, where production of the highest standard is

combined with truly outstanding tradition: production of motorcycles

involves a large share of craftsmanship and manual work. The decal

lines on various motorcycle components, for example, are still a p plied

by hand as in the early years of BMW motorcycle production.

Graz MINI Co untryman

Spartanburg X3, X5, X6

Cairo

Chennai

Rayong

BMW 6 Series

BMW 7 Series

BMW X1

The Husqvarna brand has also belonged to the BMW Group since 2008.

The Cassinetta plant near Varese in northern Italy employs a workforce

of over 260. This production site produces all 22 models in the areas

Enduro, Supermotard, Dual Purpose, Cross Country and Motocross.

Kulim

Jakarta

Engines and components

The heart of every vehicle is its engine – which is precisely why the

BMW Group has always focused consistently on the development

and production of power units. The BMW Group’s three engine

production plants in Hams Hall, Munich, and Steyr supply engines

to the Group’s worldwide production network. This is supplemented

by the production of components at four German production sites:

Berlin, Eisenach, Landshut, and Wackersdorf.

Rosslyn 3 Series

BMW X3

BMW X5

BMW X6

The same standards of quality, safety and the prudent use of

resources apply worldwide to all BMW Group plants and products.

Production plants Assembly plants Joint ventures Outsourced production

MINI

BMW motorcycles

Husqvarna motorcycles

The huMan success FacTor

inTelliGenT Processes

Close collaboration between the BMW Group’s Research and Innovation

Centre in Munich and the worldwide research and development ofices

ensures ongoing improvement and enhancement of BMW products.

Right from the start in a very early phase of the Product Development

Process (PEP), the two divisions – Development and Production –

cooperate very closely, assuming joint responsibility for the appropriate

completion of each vehicle project as well as the quality and reliability

of the automobiles supplied.

Fast and lexible

Despite the constant increase in model diversity, the BMW Group’s

production network is suficiently lexible to build different models

and versions at every plant. An important feature in this context is

the universal main assembly line in production, allowing assembly

of various models in any sequence on one and the same production

line. This enables the BMW Group to respond lexibly to luctuations

in the market and individual customer wishes, working to optimum

capacity at all plants.

Qualiied and committed

Each and every associate contributes to the quality of our products. A high level

of individual responsibility, constant supervision of one’s own quality at work,

and the wish to obtain even higher qualiications for new tasks all are part of the

corporate culture lived out consistently by all associates of BMW. Forming an

integral part of the BMW Group’s worldwide network, this corporate culture

ensures an eficient transfer of knowledge beyond the borders and conines of the

individual plants. And through their commitment and hard work at all new plants

and in the launch of new models, BMW Group associates ensure a punctual start

of production in each case, maintaining a high level of product quality right from

the beginning.

Flexible working times

More than 300 working time models are used within the BMW Group, enabling

the company to respond lexibly to luctuations in the market and ensure

optimum use of machinery and funds, while at the same time catering to the

individual needs of the company’s associates. This lexibility is achieved by

separating personal working hours from machine operating times: while weekly

working hours remain the same on average throughout the year, machine

operating hours can vary considerably.

virtual testing for a smooth start to serial production

The development of a new vehicle and the production facilities

required would be quite inconceivable today without the use of

virtual tools such as computer-based design programs and complex

simulation models. Using 3D simulations and computer models of

a virtual factory, BMW specialists are able to replicate the entire

low of production and simulate production conditions very close to

subsequent reality. In the production of automobiles, over 80 per cent

of all processes are now veriied and conirmed in virtual reality in

advance, long before the irst production facilities are actually in place.

Since it is impossible for a car-maker to manufacture all of the up

to 20,000 individual components of each model in-house, close

cooperation with partners is absolutely essential. These include

conventional supply companies as well as small, eficient high-tech

companies. Outsourced production of the MINI Countryman in Graz,

Austria, shows how complete production by a partner can intelligently

supplement the capacities of the BMW Group, thereby increasing

lexibility.

responsible personnel policy

From an international perspective, the BMW Group is one of the most popular

employers in the world. One of the reasons is that the company takes its social

responsibility towards associates very seriously.

What is more it offers lexible working hours, part-time models, job-sharing,

sabbaticals, temporary periods of employment abroad and a range of initial and

further training programs.

origin

Production of a car starts with the steel

and aluminium plates cut out of huge

coils weighing several tons.

dies and tooling

Tools and dies are constructed and produced

for the press plant and body shop.

Modules

Seats, cockpits, front ends and customer-

speciic components are completed in

advance and fed into the assembly line

just-in-sequence.

engine production

Precise craftsmanship, experience and

state-of-the-art plant technology provide

the foundation for engines of the very

highest standard.

light alloy foundry

Various materials are used for various

requirements. As one would expect, the

casting methods used are highly versatile

and innovative.

auToMobile

ManuFacTurinG

Press plant

Here the crude panels cut into shape are

pressed into the right form by means of

high-performance presses.

body shop

Industrial robots put together some 500 metal

components to form the body of a car. In the

process they use joining methods such as spot

and laser welding as well as riveting and bonding.

Paint shop

Up to four layers of paint protect the car from

environmental effects and give the vehicle a

lasting, brilliant gloss.

assembly

Experienced, well-trained associates then

complete the painted body shells to produce

premium cars tailored to each individual

customer.

The “marriage”

During the inal assembly stage, the customer-speciic body is bolted to

the drivetrain, consisting of the engine, gearbox and chassis: this is

referred to as the “marriage”.

Final assembly

Now the car stands on its own wheels.

The inal parts and body components are

itted in position and the engine is started

for the irst time.

Finish

In a inal functional and visual inspection,

specially trained associates ensure that every

car comes off the assembly line meeting the

customary premium quality standards.

Main processes

supreme lexibility for the customer

The BMW Group has optimised its internal processes to such an extent that wishes expressed by the

customer to alter the engine, paint inish, upholstery or special equipment of the car ordered can be taken

into account just six days prior to the start of assembly – without any effect on the delivery date of the car.

Production of axles

Aluminium chassis and suspension

components guarantee excellent

driving qualities but also demand a

high level of production expertise.

delivery

Carefully prepared for their journey, the

vehicles then leave the plant by train, truck

or ship to customers in more than 140

countries all over the world.

Components and

pre-assembly

The painted body shells are not assigned to a speciic customer order until the start of assembly, when

the cars receive their „identity“ – the individual chassis number. Considering the mathematically possible

number of some 5 x 10 32 versions – that is a igure with 32 zeros – which can be conigured within the

BMW Group’s product range, one can appreciate the individual and demanding character of the so-called

Customer-Oriented Sales and Production Process (or KOVP in short, to use the German abbreviation).

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