BMW GROUP PLANT DINGOLFING. FLEXIBLE. EFFICIENT. SUSTAINABLE.

Plant Dingolfing 1 Plant 02.27

Plant 02.91

Plant 02.40 Plant 02.75 Plant 02.30

Plant 02.70 Plant 02.20

Plant 02.71 Plant 02.10 Plant 02.41

Plant 02.72

PLANT 02.30 PLANT 02.71 Training Center Spare parts logistics PLANT 02.10 BMW BKK, BMW Service Center Production of chassis and PLANT 02.72 drivetrain components PLANT 02.40 Production of chassis and Automotive production drivetrain components PLANT 02.20 Storage facility and production of PLANT 02.41 PLANT 02.75 chassis and drivetrain components Plant engineering Spare parts warehouse Bruckberg PLANT 02.27 PLANT 02.70 PLANT 02.91 Production of bodies-in-white for Rolls-Royce Dynamics Center (spare parts delivery) Spare parts warehouse Wallersdorf 2 SHAPING THE FUTURE – WITH EXPERTISE AND PASSION.

Dear Reader,

Over the past five decades, the In Dingolfing, we put the future BMW Group’s site in Dingolfing on the road. From 2021 on, we has gradually grown to a new will be producing the BMW dimension. Since the beginning iNEXT, the BMW Group’s all- of its success story back in 1973, new technological beacon for the plant has produced over ten e-mobility, autonomous driving, million cars. the interior of the future and intelligent lightweight construc- The strength of our site lies in tion. The new model will add the expertise of our team, the the next chapter to the success proximity to development, our story of BMW Group Plant experience with complex pro- Dingolfing. ducts and processes, and our distinct understanding of quality. Enjoy the read! In sum, these characteristics provide the best foundation for building new skills sets and knowledge in future techno- logies. At BMW Group Plant Dingolfing, outstanding people work together on shaping the mobility of the future with pride and passion. The BMW Group entrusts our site with its flagship Sincerely yours, Dr. Andreas Wendt models and technology carriers. Director, BMW Group Plant Dingolfing 3 288 HECTARES TOTAL PREMISES 1.600 VEHICLES A DAY 376.000 CARS PRODUCED IN 2017 6 MODEL SERIES 18.000 EMPLOYEES 800 APPRENTICES 48 NATIONALITIES

4 BMW GROUP PLANT DINGOLFING SITE – OVERVIEW.

Every day, about 1,600 cars Mastering this scale of complexi- the last couple of years, compre- roll off the assembly lines at ty requires maximum flexibility hensive preparations have been BMW Group Plant Dingolfing. and efficiency, two of Dingol- made to set up our assembly In 2017, more than 376,000 fing’s core strengths. In the area for the addition of e-mobili- vehicles were built here. With past few years, the production ty solutions, so that today we are its team of 18,000 employees site has drawn on the potenti- able to manufacture the plug-in and 800 apprentices, the site al of digitalization, optimized hybrid variants of the BMW 5 in Lower Bavaria is the BMW logistics structures and produc- and 7 Series on a single line Group’s Center of Excellence for tion processes, and invested in together with cars fitted with the large model series future technologies, primarily conventional engines. electrification and lightweight The production portfolio com- construction. Beyond the vehicle production, prises the BMW 5, 6 and 7 Se- BMW Group Plant Dingolfing ries as well as the BMW 3 Series LIGHTWEIGHT CONSTRUCTION is also the company’s Center of Gran Turismo and the BMW 4 AND ELECTRIFICATION Excellence for the production Series Gran Coupe. In 2018, the The plant has taken production of electric drive systems. In range will be complemented by to a new level with the innova- addition, Dingolfing is home to the new BMW 8 Series. tive and intelligent combination the plant engineering unit, the of aluminum, steel and carbon parts distribution center as well fiber (CFRP) used for the car as a separate body-in-white line body of the BMW 7 Series. Over for the Rolls-Royce models.

5 THERE IS NO FUTURE WITHOUT A PAST.

BMW Group Plant Dingolfing’s success story began more than half a century ago. Some milestones from six decades:

1967 1996 2014 BMW AG takes over The new paint shop is put Completion of a new body shop Hans Glas GmbH. into operation and the and CFRP production facility as The Dingolfing site has a work- 4-millionth vehicle is part of the west extension. force of approx. 2,600 people. produced in Dingolfing. Plant extension with commissio- ning of a high-speed servo press, 1973 2000 a new door pre-assembly and a The first BMW made in 5 million BMW cars new assembly supply center. Dingolfing – a red BMW 520 made in Dingolfing. Symbolic start of production of – rolls off the line at the new The new Training Center electric drive components for vehicle plant 02.40. is inaugurated. plug-in hybrids at Plant 02.20.

1987 2005 2017 Production anniversary: Commissioning of the The site celebrates its 50th 2 million BMW cars Dynamics Center (Plant 02.70). anniversary and 10 million made in Dingolfing. cars made in Dingolfing. For the first time, the 2013 BMW 7 Series is offered Start of production of BMW i with a 12-cylinder engine. components at Plant 02.10.

6 7 HOW A BMW IS MADE. PRESS SHOP.

Every day, huge steel and alu- Several test units control the minum sheet rolls are converted impeccable quality of pressed into up to 1.6 million body parts parts – ranging from the visual for the Dingolfing plant and the surface check carried out by production network. The Din- workers up to the robot-based golfing press shop is the largest measuring procedures. facility of its kind within the BMW Group. Special technologies applied at the Dingolfing press shop Over 40 press systems produce include the production of about 2,500 different parts – components made of carbon from fuel tank caps to side fiber (CFRP), hydroforming and frames. With the commissioning press hardening. The facility of two high-speed servo presses also contains the die-cutting unit for the production of large-scale were 15 die-cutting machines body parts in 2015, Dingolfing’s produce about one million press shop has further increased smaller components a day for its efficiency and resource- all vehicles in the BMW Group’s friendliness. The facility has a portfolio. press force of 10,300 tons. To put this figure into perspective: The Eiffel Tower weighs 7,300 tons. HOW A BMW IS MADE. BODY SHOP.

The body shop at BMW Group Lightweight construction has Plant Dingolfing is a high-tech reached a new level with the lightweight construction facility. introduction of the ‘carbon Here, approximately 2,000 core’ in the new BMW 7 Series, industrial robots turn the meaning the use of structural sheet metal parts produced at components made of CFRP the press shop into paintable around the passenger compart- bodies-in-white. ment, and the increasing use of die-cast aluminum. The new, Up to 600 steel, aluminum and state-of-the-art body shop for plastics components are com- the BMW 7 Series is prepared to bined in an intelligent mix of accommodate the latest joining materials; the joining techniques technologies and combination applied range from welding to of materials. Also in the BMW adhesive bonding and riveting. 8 Series aluminium, plastics The result is a very safe car body (SMC), steal and CFRP are com- with minimal weight. bined in an intelligent mix.

The body shop in Dingolfing is the BMW Group’s Center of Excellence for aluminum. This is why the plant also manufac- tures bodies-in-white for the Rolls-Royce models in an exclu- sive small series production. HOW A BMW IS MADE. PAINT SHOP.

In the paint shop, the body- This coating is the basis for in-white is given its color and lasting corrosion protection. shine. Moreover, it is protected After that, four further paint against corrosion, sealed and layers are applied, protecting the given a perfect surface. BMW car against external impacts and customers can choose from a giving it permanent color and range of more than 300 series shine. The Dingolfing paint shop and special colors. is one of the world’s most en- vironmentally friendly facilities: When they arrive at the paint Over the course of the past years, shop, the car bodies are cleaned wastewater and solvents were in dip tanks, degreased and reduced significantly. covered with a zinc-phosphate coating. HOW A BMW IS MADE. ASSEMBLY.

In assembly, over 6,000 workers Approximately 1,000 external fit the painted car bodies with and internal suppliers provide the equipment selected by the plant with parts, which are the customers; the complete always fed into the line in the premium vehicle is a three- right sequence (just-in-sequen- dimensional puzzle of up to ce) and at the right time (just- 20,000 parts. About 1,600 in-time). Customers can change BMW cars are created on the their orders up to six days prior two assembly lines every day. to the start of assembly.

Complexity, flexibility and effi- High ergonomic standards and ciency are particularly apparent tools such as handling devices, in assembly: Up to four different pivot mounts and exoskeletons, model series roll off the same a flexible support device for the assembly line. Both assembly body, make work steps as easy halls can produce various model and ergonomic for workers as series as well as a mix of models possible. with combustion engines and plug-in hybrid drives. HOW A BMW IS MADE. FOCUS ON CUSTOMER SATISFACTION.

Skilled workers and state-of- to complement its testing and the-art measuring and testing break-in courses; before being systems ensure that all cars that dispatched to customers, all leave BMW Group Plant Dingol- cars must pass the test without fing are of the premium quality reservations. customers expect. US-based market researcher J.D. Power, The plant’s own Analysis and among others, has repeatedly Launch Center serves as the attested to the plant’s top quality interface for the Research and standards. Innovation Center (FIZ) in Munich. It ensures the produc- Dimensional accuracy and tion feasibility of vehicle series, quality are guaranteed thanks launch preparations as well as to the in-line measuring systems the functioning and perfect that are applied from the very interaction of all electronic beginning of production. In mid- vehicle systems. It also handles 2014, the Dingolfing site com- the launch preparation for new missioned a new short test track models. OVERVIEW OF CURRENT PRODUCTS MADE IN DINGOLFING. 3 4 BMW 3 SERIES GRAN TURISMO BMW 4 SERIES GRAN COUPE 5 BMW 5 SERIES SEDAN BMW 5 SERIES TOURING BMW 530e iPERFORMANCE BMW M5 6 BMW 6 SERIES GRAN TURISMO 7 BMW 7 SERIES SEDAN BMW 7 SERIES LONG VERSION BMW 740e iPERFORMANCE 8 BMW 8 SERIES COUPE 13 14 MORE THAN JUST A CAR FACTORY.

The Dingolfing site is much manufacture unit. These exqui- county), respectively, both put more than just a car factory. site interiors are primarily fitted into operation in 2016. Overall, It also produces chassis and in the BMW 7 Series models ZTA stores more than 300,000 drive parts at its Plant 02.10 made in Dingolfing but also different product items on a and Plant 02.20 as well as delivered to other production total floor space of 800,000 sqm. eDrive components for BMW i sites as the Dingolfing individual Each day, 45,000 parts are ship- and plug-in hybrid models. manufacture unit is a unique ped to destinations all around feature in the BMW Group pro- the world. The site also provides vital duction network. components to Rolls-Royce: The Dingolfing site also has tool- Due to the expertise of the DINGOLFING – THE HEART making and plant engineering Dingolfing-based specialists in OF AFTERSALES LOGISTICS facilities – in-house partners that processing aluminum, they are The Dingolfing site is also home operate as ‘companies within responsible for producing the to the BMW Group’s Central the company’, manufacturing bodies-in-white for all models Parts Delivery (ZTA), called industrial tools and facilities for of the British ultra-luxury brand. the Dynamics Center, at Plant automotive production. At the remote location in Unter- 02.70. This unit supplies the hollerau, Plant 02.27, highly global BMW and MINI retail specialized workers manufacture organizations with original parts the sophisticated aluminum and equipment. Aftersales is car bodies in an exclusive small growing in sync with the increa- series production. se in the number of models and vehicles produced. The latest Special vehicle interiors made addition to the ZTA are two new of superior quality materials are large-scale warehouses in Bruck- also hand-built by Dingolfing’s berg (Landshut county) and specialists in the individual Wallersdorf (Dingolfing-Landau 15 ELECTRO-MOBILITY FROM BMW GROUP PLANT DINGOLFING.

The era of e-mobility has be- E-DRIVES AND PHEV models are powered by gun – and BMW Group Plant HIGH-VOLTAGE BATTERIES a combustion engine and an Dingolfing is at the forefront of As part of Plant Group 2, a electric drive with a high-voltage the development. This is where new remote location in Nie- battery that can be charged at key components for the BMW derviehbach has been created a wall socket. Shorter distances i and plug-in hybrid models as a production site for chassis can be covered in electric mode; come from, as well as electrified and drivetrain components. for longer distances, the cars vehicle variants of the BMW 5 This is where chassis scopes for usually switch to mixed-mode and 7 Series. the BMW i8 are manufactured, operation. among other things. Plant 02.10 makes the high-vol- In 2021, the BMW Group will tage battery as well as the Following the launch of the launch its first all-electric car, e-transmission and the Drive BMW i models, the company is the BWM iNEXT. This model structure for the BMW i3, which currently introducing the eDrive will be made in Dingolfing. A is the ‘chassis’ of the BMW i3, technology step by step to the year earlier, the Dingolfing site an aluminum composite frame traditional product line-up. To is scheduled to start the pro- construction. In assembly of this end, two production lines duction of the fifth generation the Drive module, the battery for the production of high- of e-drives, which will further is integrated and the drivetrain voltage batteries and electric optimize the interaction between transmission unit fitted. motors were commissioned at the electric motor, transmission, Plant 02.20 in 2014. In 2016, power electronics and battery. In producing the e-transmission, the Dingolfing plant started to Another important milestone for BMW Group Plant Dingolfing produce its first plug-in hybrid BMW Group Plant Dingolfing benefits from its significant model, the BMW 740e iPerfor- as the Center of Excellence for process expertise in the fields of mance, which was followed by the production of electric drive mechanical processing, linking the BMW 530e iPerformance in systems. and assembly technologies. March 2017. 16 17 WORKING WORLD 4.0.

To improve efficiency, quality Another example: Sensitive and customer orientation even lightweight robots support further, BMW Group Plant Din- workers by taking on physically golfing draws on the potential of demanding tasks. They operate digitization in production. in an environment without protective fences alongside their Areas of application range from human colleagues. Lightweight virtual process validation to in- robots are utilized in several telligent, self-controlling systems areas, including door pre- and advanced robotics, namely assembly, 3D measuring of gap the increased use of lightweight sizes in the body shop’s quality robots. This development control area and the assembly of toward Vehicle Production 4.0 axle differentials. entails a modernization of the working world, in which people, Industry 4.0 applications also data and technologies become include clever inventions such more and more connected, and as the ProGlove, a glove with complex workflows in producti- an integrated scanner that on can be made more efficient logistics and assembly workers and reliable. For instance, wor- wear instead of having to use kers have been qualified for the a hand scanner. ProGlove was production of the BMW 8 Series developed to series maturity by using virtual reality devices. together with members of the BMW logistics team and initially applied at the Dynamics Center in Dingolfing. THE PATH TOWARD AUTONOMOUS DRIVING.

The mobility of the future is their attention away from the connected, with cars communi- road entirely at times. At level cating both with each other and 4, the driver could even take their environment. We are on the a nap, provided that they are path toward self-driving cars. generally fit to drive. Self-driving will be introduced with level As the production site for large 5 when the driver turns into a model series, BMW Group Plant passenger. The Munich-based Dingolfing is well prepared for Research and Innovation Center mastering the challenges of fu- (FIZ) is already running tests on ture mobility. The BMW 8, 7 and the autonomous driving of the 5 Series are considered techno- future. Since mid-2017, about 40 logy leaders in their respective self-driving BMW 7 Series cars segments, not least on account have been cruising on public of their driver assistance systems roads in the U.S. and Europe. and comprehensive connectivity features. The lighthouse project in these efforts is the BMW iNext, an- The BMW Group is implemen- nounced for 2021, which will be ting autonomous driving in five built at BMW Group Plant Din- development steps. Today, we golfing. This model will combine have reached level 2, where the all future technologies, namely driver is supported by assistan- an e-drive, lightweight const- ce systems and can take their ruction, artificial intelligence, hands off the steering wheel for autonomous driving, the interior a short period of time. At level of the future and connectivity. 3, the driver will be able to turn 20 COMMITTED TO SUSTAINABILITY.

Environmentally friendly pro- There are many aspects to ap- One of many examples is the duction is a top priority for the plying environmentally friendly innovative press technology that Dingolfing site. The plant meets technologies in production: For has reduced energy consumption its environmental responsibility instance, the Dingolfing paint by about five million kilowatt with activities on air purificati- shop recycles up to 25,000 liters hours a year. Thanks to the on, resource conservation and of water per hour and feeds constant efforts to reduce waste energy saving. them back into the production for disposal, the recycling rate process. Emissions of organic at BMW Group Plant Dingolfing The reduction of traffic cuts car- solvents are also down consi- stands at 99.7 percent. bon emissions. With its unique derably, and over the past few commuter bus system – 300 years, the site has managed to In late 2017, the Dingolfing site buses, used by 10,000 employees significantly reduce water and commissioned a new power plant – the plant makes an important energy consumption per vehicle at Plant 02.40, increasing its com- contribution: Compared to peo- produced. The application of the mitment to highly efficient power ple using their own cars to drive innovative LED technology alo- and heat generation even further to work, the buses account for ne has resulted in annual energy with cogeneration systems. Four a reduction in CO2 emissions of savings of 50 percent for lighting state-of-the-art facilities increase about 7,000 tons annually. production halls. the share of power produced on Almost 70 percent of all vehicles site. Thanks to the new technolo- produced at BMW Group Plant HIGH ENERGY EFFICIENCY gy, about 34,000 tons of CO2 are Dingolfing are dispatched by BMW Group Plant Dingolfing saved annually. rail, cutting the number of applies energy-efficient instal- trucks used by 100. lations and resource-optimized processes.

21 THE HUMAN SUCCESS FACTOR.

Each year, more than 260 Plant Dingolfing offers young apprentices begin their profes- people who have not succeeded sional training at BMW Group in finding an apprenticeship Plant Dingolfing. In total, the position a long-term internship plant is currently training about – and the possibility to secure an 800 young people in 14 different apprenticeship contract after- professions. wards.

Since the plant was opened, The site’s WORK HERE! initiati- Dingolfing has trained about ve supports the integration of re- 10,000 young people. Innovative fugees. Since its launch in 2016, training concepts, such as the more than 100 refugees have dual apprenticeship with a col- participated in the six-week on- lege entry qualification (DBFH), the-job training course. About complement the offering. In half of them have since found the three-year program, the site employment in the German trains electronics technicians, labor market. industrial mechanics and auto- motive mechatronics specialists. In light of future technologies, The BMW Group’s ‘Speed up’ continuous further education program gives graduates the op- is vital. The BMW Group’s portunity to follow up on their comprehensive training course DBFH program with studies at a offering, also at the Dingolfing partner college. site, helps employees acquire the With its ‘entry qualification’ necessary skills sets. (EQ) program, BMW Group 23 24 WORKING ERGONOMICALLY, LIVING HEALTHILY.

The BMW Group is countering The BMW Group’s health the demographic change with its management (‘Initiative Health’) integrated health management focuses on raising people’s and the ‘Today for Tomorrow’ health awareness and behavi- project. or. Attractive offerings in the fields of health promotion and The ‘Today for Tomorrow’ preventive action encourage the program supports production workforce to take responsibility in aligning with the require- for their health – at the workpla- ments of an aging workforce. ce and at home. One example: Age-appropriate workplaces are Dingolfing’s PROAKTIV center created through the introducti- offers physiotherapy, fitness on of load-optimized workplace and strength training, as well as rotation as well as a variety of relaxation, sport and smoking ergonomic measures. From the cessation classes. early planning stage, company physicians and ergonomics specialists are involved in the design of new facilities and workstations to make sure that ergonomic requirements are met optimally, ensuring a healthy work environment.

25 BEING A GOOD NEIGHBOR.

BMW Group Plant Dingolfing Half Marathon. The plant is also considers itself a reliable key a partner of the ‘Dingfest’, a festi- partner in the region of Lower val that takes place in Dingolfing Bavaria and as such assumes every two years, and hosts the social responsibility to make a annual ‘Jugend forscht – Schüler lasting positive contribution to experimentieren’ student STEM the region’s development. research competition.

Its commitment ranges from BMW Group Plant Dingolfing vehicle donations to educational frequently enters into a dialog institutions or charities to the with stakeholders. This is how sponsoring of social projects. the site emphasizes its role as a BMW Group Plant Dingolfing good neighbor and partner of the has supported various events region. hosted in the region for many years, including the Dingolfing FASCINATION PRODUCTION – EXPERIENCE IT LIVE.

Take a look behind the scenes of the BMW Group’s production site in Lower Bavaria and visit BMW Group Plant Dingolfing.

Tours through the production area are offered to both groups and individuals.

INFORMATION AND i REGISTRATION AT www.bmw-besuchen.com +49 89 382 15750 [email protected] Further information: BMW Group Plant Dingolfing BMW Group Plant Dingolfing Karl-Dompert-Straße 7 Corporate Communications 84130 Dingolfing Not to be reproduced (in full or in parts) Germany without permission. Phone: 08731/76-0 © Bayerische Motoren Werke Aktiengesellschaft www.bmw-werk-dingolfing.de Last updated 06/2018 28