[Report] BMW Electric and Internal Combustion Vehicles Assembled on One Line... "Active Response to Demand Changes"

At the Forefront of Electrification Strategy, Visiting the German Dingolfing Plant
Real-Time Integration System with Partners
Enhanced Quality Inspection through Final Assembly

The new 7 Series electric vehicle i7 is being assembled at the BMW Dingolfing plant.

[Asia Economy Reporter Choi Dae-yeol] Dingolfing, located about 100 km northeast of Munich, Germany, is a small town with a population of less than 20,000 and is home to BMW's largest factory in Europe. On the assembly line of this factory visited on the 14th, robots were precisely moving and combining the body and chassis of the electric large sedan i7. After a task lasting just over a minute, the process moved to the next step, followed by a vehicle of the same 7 Series but with an internal combustion engine. The electric sports utility vehicle (SUV) iX and gasoline/diesel 5 Series were also mixed in at various points along the same line.

Not only different models but also models with different powertrains are assembled on the same line. Instead of dedicating each line to a specific model or vehicle type, the system allows production of all vehicle types of this factory on any line. In the case of electric vehicles, the structure differs from conventional internal combustion engines, with the battery filling the lower part of the vehicle.

Mixed production of various vehicle types on a single line has been done by several manufacturers, but it is rare to produce heterogeneous internal combustion and electrified vehicles in the same place. Usually, companies respond by having separate electric vehicle production lines or building dedicated factories.

The body and chassis of a BMW vehicle about to undergo assembly. Robot arms over 2 meters tall precisely align the body and chassis moving on different conveyor belts. According to a company official, different vehicles have been mixed on the same line for the past two years without causing any issues.

Josef Brumm, a BMW employee in charge of the factory tour, said, "In the past, the process was simple, assembling sedans and wagons on one line, but now we have a system that is organically linked in real time with parts suppliers and others," adding, "The idea of finally assembling various vehicle types and models on a single line was a considerable challenge."

This production system, capable of actively responding to changes in demand, is part of BMW Group's electrification transition. The company has committed to having more than half of its total vehicle sales be electric vehicles by 2030. The key issue is the market flow, which has many variables.

In Germany, electricity prices have risen due to the war's aftermath, and electric vehicle purchase subsidies are being reduced. Since market demand can change at any time due to unexpected variables or policies, the company has prepared to respond flexibly.

BMW Dingolfing Plant in Germany. It is the largest BMW factory operating in Europe. The Munich plant, where the headquarters is located, is in the city center, making expansion difficult, so BMW acquired a factory in a nearby suburban area, leading to the current situation. The plant covers an area of 1.8 million square meters and employs about 17,000 people. It produces large vehicles such as the 4 and 8 Series, as well as electric vehicles like the iX. The new 7 Series, which will be launched domestically at the end of this year, will also be produced here.

An employee is inspecting the interior of a vehicle at the BMW Dingolfing plant.

Another notable aspect throughout the process from initial pressing to final assembly is the obsession with quality. The system collects information through cameras and sensors, inspects quality, and uses artificial intelligence to analyze and deliver real-time feedback to employees on the line. This system has been applied in 40 areas of the new 7 Series, which has been in production since July. Areas missed by machines are inspected directly by people at various stages of the process.

Brumm said, "Developing equipment for quality inspection and employing many people inevitably increases costs, but if defects are found after a certain process or if there are problems with the quality of the final product, the losses are much greater."

An employee is assembling an electric powertrain at the Electric Drive Production Competence Center within the BMW Dingolfing plant.

After the BMW vehicle completes final assembly, noise and vibration inspections are conducted in the rolling test room.

Dingolfing (Germany) = Reporter Choi Dae-yeol dychoi@asiae.co.kr