In February, I had the uncommon alternative to witness firsthand some of the bold transformations in BMW’s historical past. Hidden behind the model’s iconic headquarters and museum, the Munich plant is present process an enormous modernization effort that can fully reshape how BMW builds automobiles within the coronary heart of its hometown. This manufacturing unit—one in every of BMW’s longest-running manufacturing websites—has been in operation since 1922, and by 2027, it is going to produce solely absolutely electrical autos, making it one of many firm’s first vegetation devoted fully to Neue Klasse manufacturing.
In contrast to BMW’s brand-new manufacturing unit in Debrecen, Hungary, which was designed from the bottom up for the Neue Klasse EV platform, the Munich facility should be rebuilt from inside, whereas sustaining full-scale manufacturing. The problem is gigantic: BMW is tearing down and rebuilding one-third of your entire plant with out stopping manufacturing. Day-after-day, 1,000 automobiles roll off the road whereas cranes, vans, and employees function round them. The manufacturing unit will not be increasing outward resulting from area limitations—it’s rising vertically, with three-story manufacturing buildings changing older buildings.
“We aren’t remodeling this plant simply because we’re transitioning to electrical autos. The plant can already produce electrical automobiles, just like the i4, which makes up 40% of its present manufacturing. The reconfiguration is going on as a result of the plant is 100 years previous. Occasionally, it’s a must to rethink manufacturing and develop a brand new construction,” defined Dr. Mohan Noronha, Venture Lead for the Structural Transformation of BMW Manufacturing facility Munich.
Constructing a New Manufacturing facility Whereas Holding the Outdated One Operating
The transformation of the Munich plant is not only about introducing new know-how—it’s about doing so whereas conserving the manufacturing unit operational. In contrast to many automotive vegetation that shut down for intensive retooling, BMW has no such luxurious right here. The town’s dense city setting makes large-scale growth unattainable, so the automaker is demolishing and rebuilding sections of the manufacturing unit in phases whereas manufacturing continues.
This course of requires cautious planning and exact logistics. BMW has initiated 13 main relocation initiatives to clear area for the brand new buildings. Complete departments, together with engine manufacturing, wastewater therapy, and axle pre-assembly, have been moved to different places to make means for the brand new meeting traces. The engine manufacturing division has been relocated to Austria and the UK, marking the tip of combustion engine manufacturing in Munich.
With these large shifts, 600,000 tons of fabric should be dismantled, examined, and both disposed of or repurposed. Rules require BMW to investigate and course of this materials earlier than shifting it off-site, which means giant parts of the manufacturing unit grounds should be used for non permanent storage. In the meantime, 400 vans transfer out and in of the plant each single day, delivering elements for manufacturing and hauling away dismantled buildings.
New, Extra Power Environment friendly Buildings
When accomplished, the transformation will introduce 70,000 sq. meters of recent manufacturing ground area, making the plant extra environment friendly and higher fitted to EV manufacturing. Three new manufacturing buildings are being constructed for meeting and physique store operations, every with three full tales to optimize ground area. These new buildings will likely be 40% extra power environment friendly than those they exchange, aligning with BMW’s broader sustainability targets.
“We needed to rethink every little thing. There’s no room to broaden outward, so we’re constructing vertically. The brand new Last Meeting Corridor has three flooring, every 9 meters excessive—the footprint alone is the scale of six soccer fields. And if you step inside, you understand simply how briskly issues are altering. When you go away for 2 weeks and are available again, new partitions have already gone up,” Dr. Noronha advised us throughout our go to.
Expertise, AI, and Workforce Transformation
Past its structural adjustments, the Munich plant can be adopting new know-how to streamline manufacturing. The brand new physique store will combine 900+ robots, considerably lowering the necessity for guide labor in welding and meeting processes. AI-powered high quality management programs will examine autos in real-time, minimizing defects and enhancing effectivity. Moreover, automated logistics programs will exchange conventional forklifts, lowering human labor in elements transportation.
Regardless of this shift towards automation, BMW will not be lowering its workforce. The plant presently employs 6,500 individuals from over 60 nationalities, and as an alternative of layoffs, BMW is retraining and repositioning workers for brand new roles in EV manufacturing. A brand new Expertise Campus is being constructed to supply steady coaching, guaranteeing that workers stay on the forefront of recent automotive manufacturing.
“We aren’t lowering jobs; we’re coaching our individuals for the long run,” mentioned Dr. Noronha.
Sustainability and the Way forward for City Manufacturing
The transformation can be pushed by sustainability and group integration. Given the manufacturing unit’s location within the coronary heart of Munich, BMW has dedicated to lowering emissions, noise, and visitors congestion whereas enhancing the plant’s visible and environmental footprint. The brand new design incorporates inexperienced areas, and BMW is exploring methods to make elements of the manufacturing unit extra accessible to the general public.
Moreover, logistics are being optimized to attenuate pointless transportation, with elements being delivered on to manufacturing traces as an alternative of passing via a number of places. These efforts will scale back visitors across the plant and decrease emissions, making the ability extra suitable with the encompassing city setting.
An Spectacular Achievement in Only a Yr
Strolling via the plant, it was clear—this isn’t only a easy manufacturing unit improve. This can be a historic transformation. For over a century, BMW’s Munich plant has been the beating coronary heart of the model’s manufacturing. Now, it’s evolving right into a state-of-the-art EV manufacturing hub, setting the stage for the Neue Klasse fashions that can outline BMW’s future.
Essentially the most exceptional half? BMW is doing all of this with out stopping.
