In February, I had the uncommon alternative to witness firsthand probably the most bold transformations in BMW’s historical past. Hidden behind the model’s iconic headquarters and museum, the Munich plant is present process a large modernization effort that can fully reshape how BMW builds automobiles within the coronary heart of its hometown. This manufacturing facility—certainly one of BMW’s longest-running manufacturing websites—has been in operation since 1922, and by 2027, it’s going to produce solely totally electrical automobiles, making it one of many firm’s first crops devoted fully to Neue Klasse manufacturing.
In contrast to BMW’s brand-new manufacturing facility 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. Each day, 1,000 automobiles roll off the road whereas cranes, vehicles, and employees function round them. The manufacturing facility just isn’t increasing outward because of house limitations—it’s rising vertically, with three-story manufacturing buildings changing older constructions.
“We aren’t reworking this plant simply because we’re transitioning to electrical automobiles. The plant can already produce electrical automobiles, just like the i4, which makes up 40% of its present manufacturing. The reconfiguration is occurring as a result of the plant is 100 years outdated. Sometimes, it’s important to rethink manufacturing and develop a brand new construction,” defined Dr. Mohan Noronha, Challenge Lead for the Structural Transformation of BMW Manufacturing unit Munich.
Constructing a New Manufacturing unit Whereas Conserving the Previous One Working
The transformation of the Munich plant isn’t just about introducing new expertise—it’s about doing so whereas preserving the manufacturing facility operational. In contrast to many automotive crops that shut down for intensive retooling, BMW has no such luxurious right here. Town’s dense city setting makes large-scale enlargement unattainable, so the automaker is demolishing and rebuilding sections of the manufacturing facility in phases whereas manufacturing continues.
This course of requires cautious planning and exact logistics. BMW has initiated 13 main relocation tasks to clear house for the brand new constructions. Whole 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 top 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. Laws require BMW to research and course of this materials earlier than transferring it off-site, that means giant parts of the manufacturing facility grounds should be used for short-term storage. In the meantime, 400 vehicles transfer out and in of the plant each single day, delivering elements for manufacturing and hauling away dismantled constructions.
New, Extra Power Environment friendly Buildings
When accomplished, the transformation will introduce 70,000 sq. meters of recent manufacturing flooring house, 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 flooring house. These new constructions shall be 40% extra vitality environment friendly than those they substitute, aligning with BMW’s broader sustainability targets.
“We needed to rethink every thing. There’s no room to increase outward, so we’re constructing vertically. The brand new Last Meeting Corridor has three flooring, every 9 meters excessive—the footprint alone is the dimensions of six soccer fields. And once you step inside, you understand simply how briskly issues are altering. Should you go away for 2 weeks and are available again, new partitions have already gone up,” Dr. Noronha advised us throughout our go to.
Know-how, AI, and Workforce Transformation
Past its structural adjustments, the Munich plant can also be adopting new expertise 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 automobiles in real-time, minimizing defects and enhancing effectivity. Moreover, automated logistics programs will substitute conventional forklifts, lowering human labor in elements transportation.
Regardless of this shift towards automation, BMW just isn’t lowering its workforce. The plant at the moment employs 6,500 individuals from over 60 nationalities, and as a substitute of layoffs, BMW is retraining and repositioning workers for brand new roles in EV manufacturing. A brand new Expertise Campus is being constructed to offer steady coaching, making certain that workers stay on the forefront of contemporary 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 also be pushed by sustainability and neighborhood integration. Given the manufacturing facility’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 facility extra accessible to the general public.
Moreover, logistics are being optimized to reduce pointless transportation, with elements being delivered on to manufacturing traces as a substitute of passing via a number of places. These efforts will cut back visitors across the plant and decrease emissions, making the power extra appropriate with the encircling city setting.
An Spectacular Achievement in Only a 12 months
Strolling via the plant, it was clear—this isn’t only a easy manufacturing facility 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 outstanding half? BMW is doing all of this with out stopping.
