Bmw Group Plant Munich. Flexible
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BMW Group’s parent plant: Production in the heart of a metropolis. BMW GROUP PLANT MUNICH. FLEXIBLE. EFFICIENT. SUSTAINABLE. BMW GROUP PREFACE. Plant Munich is the BMW Group’s The smooth cooperation of all parent plant. It combines supreme production technologies and engineering and innovative support areas in the most limited strength with our people’s passion space is a major achievement in the for the brand and the company. The global automotive industry. plant is situated in the north of Munich, directly next to the Group’s In combination with the FIZ headquarters, the BMW Museum Research and Innovation Center, and the BMW Welt. BMW Group Plant Munich also serves as an in-house center of As early as 1922, the plant started excellence: From here, expertise to produce vehicles and engines. in processes and technologies The infrastructure of the site, which as well as the experience from developed at the same time as a 90 years of automotive engineering residential neighborhood in the are transferred also to other BMW immediate vicinity, is refl ected Group production sites. in complex plant structures and innovative production processes. Hermann Bohrer Director Plant Munich 3 4 BASED IN MUNICH, AT HOME AROUND THE GLOBE. The same standards for quality, Location: In the north of Munich, in the Milbertshofen neighborhood safety and the considerate use of Total premises: 400,000 m2 resources apply to the BMW Group’s Dimensions: Approx. 1,000 meters wide and 500 meters long entire international production network with its 28 locations in 13 Workforce: > 7,250 people (only core production of the BMW Group’s countries. Plant Munich) from over 50 nations working in about 300 different professions Innovative production technologies Vocational training: More than 800 technical and commercial apprentices and the high level of expertise of at the location Munich in 17 different professions the workforce at all sites ensure that more than 10,000 individual Production areas: Press shop, body shop, paint shop, assembly, parts are assembled into premium engine production, equipment and seat production vehicles ‘made by BMW’. This also Production range BMW 3 Series Sedan, BMW 3 Series Touring, applies to Plant Munich. Vehicles: BMW Active Hybrid 3, BMW 4 Series Coupé, BMW M4 Coupé Production range 3, 4, 8, 12-cylinder petrol engines, Engines: 6-cylinder diesel engines, high-performance engines for BMW M models Daily production flexible (depending on demand); output: more than 950 vehicles per workday 5 6 A TRADITION IN INNOVATION. The roots of the BMW production The 1980s were characterized by go back to the year 1917. Since the expansion of the production 1922, the plant has been located in network: Plants in Steyr, Munich’s northern neighborhood Regensburg and Wackersdorf were of Milbertshofen. In the beginning, put into operation. Following the the production range of the site transfer of the foundry to Landshut was limited to aircraft engines and and the construction of the motorcycles. Research and Innovation Center in the north of Munich, Plant Munich The automotive production in started to focus entirely on the Munich began with the BMW 501 in production of automobiles and 1951. Only four years later, the plant drivetrains from the mid-1980s on. made the first BMW Isetta, securing additional jobs for the site. One key decision in the 1990s was to build all large-volume engines The summer of 1962 saw the and high-performance drivetrains production launch of the first model of the BMW Group at the Munich of the ‘New Class’, the BMW 1500. site. In the late 1960s, the company moved certain production scopes The environmentally friendly from Milbertshofen to Dingolfing. production in the heart of the city To reduce the load on the parent has always been a major concern plant further, the motorcycle to BMW Group. In 1994, a production moved to Berlin in 1969. neighborhood forum was founded. In 2003, the plant received the In 1975, Plant Munich started Environmental Award of the City of the production of the BMW 3 Series, Munich. which has remained the most suc- cessful model series of the BMW brand to this day. 7 PRESS SHOP. The production of a car starts in The starting point for the produc- At the heart of the press shop is a the press shop. Every working day, tion of body parts are the so-called state-of-the-art high-speed servo more than 130,000 body parts are coils of high-quality galvanized pressing line with a press force made using huge sheet steel and sheet steel/deep-drawing sheet of over 9,000 tons and 17 strokes/ aluminum coils. steel. These coils can contain up minute. At a material consumption to 3.5 kilometers of sheet steel and of 600 tons of steel per day, this Each BMW car body consists of weigh up to 30 tons. On the pressing facility processes the same amount several hundred individual parts: lines, the sheets are given their final of steel in only twelve days that was from the tank cap to the side frame. shape in a multi-step process. required to build the Eiffel Tower. 20 different kinds of steel, ranging in sheet thickness from 0.7 to 2.2mm, are processed. 8 BODY SHOP. In the body shop, the individual steel parts are connected via different joining technologies such as welding, adhesive bonding and riveting to form a body-in-white ready for painting. The result is a highly safe car body with the highest-possible reduction in weight. The procedures at the body shop are almost fully automated. Robots carry out the highly complex production tasks with maximum precision and place more than 6,000 welding points per vehicle accurate to a tenth of a millimeter. Thanks to the high level of automation, different car body models – BMW 3 Series Sedan, BMW 3 Series Touring, BMW 4 Series Coupé, BMW M4 Coupé in different variants (rear-wheel drive, all-wheel drive, hybrid; with or without sunroof) – can be manufactured on a single line. 9 PAINT SHOP. A brilliant color, maximum It serves as a primer for the follow- corrosion protection and a supreme ing four paint layers. appearance: The car bodies receive their color and shine in The altogether five functional paint the paint shop. A priority here coat layers are about ten times is the application of eco-friendly the diameter of a human hair and processes, such as the use of water- protect the car body against corro- based paint coats and state-of-the- sion and environmental damage. art application procedures. After the paint process, the car Following the pre-treatment, in bodies are stored in a fully auto- which the car bodies are thoroughly mated high-bay storage area, where degreased and treated with alkaline they remain until they are called up cleaner in a dip basin, a zinc phos- by assembly in the predetermined phate layer is applied. order. 10 ASSEMBLY. In assembly, workers complete high-bay storage unit. The vehicle the painted car bodies by adding now receives its identification the equipment selected by the number and is allocated to the customer. The result is a finished specific customer. The order-based premium vehicle. The top priorities production with a multitude of here are the customer’s wish and variants is about to begin. All individualization options. required parts are provided to the assembly line just-in-sequence and Only a few days before the start of just-in-time. assembly, the assembly receives the customer order, establishes High ergonomic standards and tools the assembly sequence and such as handling devices, roller automatically sends material call- stools and swiveling assemblies ups to the suppliers. Depending on provide employees with the easiest the customer order, assembly calls and healthiest options to do their up the painted car bodies from the jobs. 11 12 ENGINE PRODUCTION. For decades, the production of For all BMW drivetrains, parts engines has been a core competence are machined with a precision of of BMW Group, the ‘Bavarian 0.001 mm and mounted. Before it Engine Works’. They are a vital is fitted in the vehicle, each engines element of the proverbial ‘sheer has to pass through certain test driving pleasure’, combining cycles, such as the cold test, a full outstanding driving characteristics functional test that can be run very with minimum fuel consumptions quickly and does not require any and CO2 emissions. fuel. The supreme running behavior and driving pleasure are based on most demanding production technologies. The teams in engine production of BMW Plant Munich build the entire range of BMW Group engines, from the 3-cylinder to the high-performance engines for the current BMW M models, as well as the 12-cylinder drives for Rolls-Royce and BMW automobiles. 13 14 NATURALLY SUSTAINABLE. To demonstrate sustainability in all BMW Group Plant Munich actions and economic activities is considers itself a responsible a success model the BMW Group partner of the City of Munich and has applied for many years. The sets great store by the harmonious company’s Clean Production cooperation with its neighbors. Strategy is an inherent part of the BMW Group’s global production The protection of local residents network. The teams at Plant from production-related noise is Munich constantly work on a key consideration at the plant, developing innovative, sustainable which is met by the reduction of production processes as well; noise emissions, the application these help to avoid air pollution, of innovative sound absorbers, to conserve resources and to reduce ventilators and soundproofing, energy consumption. as well as the optimization of transport logistics.