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BMW PLANT MUNICH.

FLEXIBILITY. INNOVATION. PASSION.

The BMW Groups parent plant.


Production in the heart of a metropolitan city.

Plant Munich
PREFACE.
Dear Reader,

this is where it all began back in 1922: neighborhoods. We show every day perfect means to prepare the plant for
BMW Plant Munich is the birthplace anew that the large-series production a successful future.
of what has since grown to become of premium vehicles is actually possible
the BMW Groups global production in the midst of a major city. Sustain- But our number one success factor are
network with 31 sites in 14 countries. ability and good relations with our the approx. 8,000 people who work
For more than 90 years, the parent neighbors are among our top priorities. here at the plant. It is their expertise
plant has combined supreme engi- After all, the plant regards itself as an and experience, creativity and passion
neering and innovative strength with integral part of society, assumes social that allow us to create the perfect car
our peoples passion for the BMW responsibility and acts as a reliable to the delight of our customers
brand and the BMW Group. Given partner of the region. 1,000 times a day.
the complex plant structures and
innovative production processes, the As the global lead plant for the I hope you enjoy exploring
smooth cooperation of all production BMW 3 Series, Plant Munich has a BMW Group Plant Munich.
technologies in the most limited space special responsibility. To ensure the
is a major achievement in the global plants long-term competitiveness,
automotive industry. the BMW Group is investing a total
of over 700 million euros in the sites
Situated in the heart of Munich, in the innovative and sustainable production
direct vicinity of the Groups head- structures by 2018. The expansion
quarters, the BMW Museum and the of the body shop and the assem-
BMW Welt, the plant has developed bly as well as the construction of a
along with the surrounding residential resource-friendly paint shop are the Dr. Milan Nedeljkovic
Director, BMW Group Plant Munich
BASED IN MUNICH, AT HOME AROUND THE GLOBE.
Over the course of the past 100 years, continents. The same standards for than 10,000 individual parts are as- The smooth cooperation of production,
the BMW Group has transformed from quality, safety and the considerate use sembled into premium vehicles made logistics, transport and administration
a local Munich-based company to a of resources apply worldwide. by BMW. This also applies to BMW on premises of 400,000 square meters
global player. Today, its international Innovative production technologies Group Plant Munich. The companys in the heart of a metropolitan city is
production network comprises and the high level of expertise of the parent plant is one of the mainstays of a major achievement in modern-day
31 locations in 14 countries on four workforce at all sites ensure that more the global production network. automotive engineering.

Location: in the north of Munich, in the Milbertshofen Vehicle production BMW 3 Series Sedan, BMW 3 Series Touring,
neighborhood range: BMW 3 Series Plug-in Hybrid, BMW 4 Series Coup,
BMW M4 Coup
Total premises: 400,000 sqm
Engine production range: 3-, 4-, 8-, 12- cylinder petrol engines,
Dimensions: approx. 1,000 meters wide and 500 meters long
6- cylinder diesel engines, high- performance engines
Workforce: approx. 8,000 people with over for BMW M models
50 different nationalities
Daily production output: up to 1,000 vehicles and over 3,000 engines
Vocational training: more than 850 technical and commercial apprentices
Awards: Lean Award 2015, Ludwig- Erhard-Preis 2016,
in 14 different professions at the Munich site
Lean and Green Award 2016
Production areas: press shop, body shop, paint shop, assembly,
Investment: over 700 million euros between 2015 and 2018
engine production, equipment and seat production

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STRENGTH THROUGH TRADITION, FUTURE FROM PASSION.

1922 1923 1924 1948 1951 1955 1961 1975 198

Setup of Start of production Production of the Start of production Start of automotive Start of production Start of production The first 3 Series Start of pr
Plant Munich of aircraft engines first motorcycle, of series motorcycle production of the BMW Isetta of the BMW 1500 rolls off the of th
the R32 models after WWII (500 Series) assembly line (hand-

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HISTORY OF PLANT MUNICH.
Since 1922, the plant has been located in Munichs northern neighborhood of Milbertshofen.

Up to 1951, the production range of In 1975, the plant in Munich started the Since the 1990s, the engine production been rolling off the plants assem-
Plant Munich was limited to aircraft production of the BMW 3 Series, which team in Munich has been building all bly lines. The BMW 4 Series Coup
engines and motorcycles. The automo- has remained the most successful mod- large-volume engines and high-perfor- followed in 2013, the BMW M4 Coup
tive production in Munich began with el series of the BMW brand to this day. mance drivetrains. Another highlight in 2014. The latest milestone: in 2016,
the BMW 501. Only four years later, It is currently produced at the plant in in the sites history is the exclusive Plant Munich built 700 BMW M4 GTS
the plant made the first BMW Isetta. its sixth generation. In 1987, BMW pre- Z8 roadster; 5,700 cars were made by cars, a limited edition based on the M4.
The summer of 1962 saw the produc- sented its Z1 roadster, a sports car with hand between March 2000 and July
tion launch of the first model front mid-engine that went into limited 2003. Since 2011, the now sixth
of the New Class, the BMW 1500. small-series production in 1988. generation of the BMW 3 Series has

88 1999 2008 2011 2012 2013 2014 2015 2016

roduction Assembly of the Production Start of Start of Start of Start of production Start of M4 GTS limited
he Z1 Z8 in a workshop of the production of the production of the production of the of the BMW M4 production of edition (700 cars)
-built) specifically installed MINI E series sixth generation fifth generation BMW 4 Series the BMW 330e
for this purpose BMW 3 Series BMW 3 Series Coup Plug-in Hybrid
Touring

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BMW GROUP PLANT MUNICH VEHICLE PRODUCTION RANGE.

BMW 3 Series Sedan BMW 3 Series Plug-In-

BMW M4 Coup

8
-Hybrid BMW 3 Series Touring

BMW 4 Series Coup BMW M4 GTS

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PRESS SHOP.
My name is Isuf Haxhosaj. I am a disposer and line inspector at the Munich press shop. I have been working for the BMW Group for two years.

The production of a car starts here in amount of steel in only twelve days
the press shop. Every day, we produce that was required to build the Eiffel
over 32,000 car body parts. In the press Tower.
lines, sheet steel passes through several
process steps to receive its final shape. The workforce of the press shop con-
We only use galvanized sheet metal, sists of about 400 highly qualified peo-
a first measure to protect cars from ple in production, quality assurance,
corrosion. The presses fully automati- maintenance, and logistics.
cally draw, bend and punch the sheet
steel in several steps to give it the Press lines are fully automated, and
desired shape. The car body of a a team of specialists electricians,
BMW 3 Series comprises over mechanics, toolmakers, logistics and
400 different pressed parts from the quality assurance experts takes care
tank cap to the side frame. 20 different of the facilities. My colleagues and I
kinds of steel, ranging in sheet steer, program and check the machines
thickness from 0.7 to 2.2 mm, are and tools as well as pressed parts and
processed. their quality. The entire process makes
highly efficient use of material, and the
At the heart of the press shop is a recycling rate stands at an impressive
state-of-the-art high-speed servo press 99 percent.
line which works at 17 strokes/minute.
This facility processes about the same
BODY SHOP.
I am Marek-Dariusz Turkiewicz. I work in the production of body and side frames and am responsible for electrical maintenance.
I have been with the company for 36 years.

In the body shop, we connect the manufactured at the plant on a single technology, as well as traditional test
individual steel parts produced at the line. methods using hammer and chisel.
press shop to form a body-in-white On top of that, we are responsible for
ready for painting. The result is a highly We apply different welding and joining maintenance and repair of the ma-
safe car body with the highest-possible techniques, such as spot welding, chines as well as a smooth production
reduction in weight. A car body weighs soldering, bolting and adhesive process.
about 442 kg and consists entirely of bonding as well as the innovative laser
zinc sheet. My 1,070 colleagues and I welding. Due to their sophisticated
produce about 990 car bodies a day for design, the intricate processing as well
the BMW 3 and 4 Series as well as the as the high and ultra-high strength
BMW M4 Coup. steels used, BMW car bodies are
among the safest in the global automo-
The procedures at the body shop are tive market.
almost fully automated. Our over 800
industrial robots carry out the highly My highly qualified colleagues and I
complex production tasks with constantly monitor the quality of
maximum precision and place more welding points and ensure the car bod-
than 6,000 welding points per vehicle ies dimensional accuracy and perfect
accurate to a tenth of a millimeter. surface quality. In quality assurance,
Thanks to the high level of automation, we apply state-of-the-art methods,
we can produce all vehicle types such as ultrasound, camera and laser
PAINT SHOP.
My name is Ayhan Firtin. I joined the BMW Group 18 years ago. I work in the paint shop, as a quality specialist in the area of microscopy fault detection.

A brilliant color, maximum corrosion sioned a new, highly innovative and, matte paints. In areas that require
protection and a supreme appearance: most importantly, resource-friendly manual tasks, the ergonomic design of
in the paint shop, the car bodies paint shop. the workstations is a top priority.
receive their color and shine. A
priority here is the application On a total of 13,500 square meters, The new facility sets new standards, in
of eco-friendly processes, we paint about 1,000 car bodies of the particular when it comes to resource
such as the use of water- BMW 3 and 4 Series every day. conservation, sustainability and
based paint coats and Innovative six-axle robots give us environmental protection. It applies
state-of-the-art appli- maximum flexibility in terms of paint the innovative, highly efficient IPP
cation procedures. technology and thus allow us to (Integrated Paint Process) technology
In early 2017, respond flexibly to customers special another important step toward the
we commis- wishes, such as for special colors or sustainable production right in the
heart of Munich. Compared to the
previous facility, natural gas con-
sumption and exhaust emissions have
dropped by nearly 50 percent. Energy
consumption is also down 25 percent
the equivalent of the average annual
energy consumption of 4,000 two-
person households.
ASSEMBLY.
I am Agnieszka Ruda and I work in the finish area of the vehicle assembly. My tasks focus on the car wash, the short test track and the test facility.
I have been with BMW for five years.

In the assembly at Plant Munich, we from the individual parts in separate


complete about 1,000 cars daily in assembly spaces first before delivering
about 335 work cycles. The top priori- them at the right time and in the right
ties here are the customers wishes and order just in sequence to the main
individualization options. line where some of these modules can
be fitted fully automatically. At a
Depending on the customer order, as- conveyor belt of about 3,5 kilometers
sembly calls up the painted car bodies in length, we can work on 535 cars
from the high-bay storage unit. This is at the same time. High ergonomic
when the order-based production of standards and tools such as handling
the car begins, in line with the devices, roller stools and swiveling
customers individual vehicle config- assemblies provide us with the easiest
urations. A challenging aspect of our and healthiest options to do our jobs.
work is the high number of variants: Fitting the engine, transmission and
for the BMW 3 Series alone, we offer chassis to the car body a process
approx. 20,000 interior options. known as the marriage is the high-
light in assembly: the drivetrain gives
To ensure a safe production process the individually fitted car body its heart
despite this huge number of variants, and soul, turning it into a real car.
we assemble modules like the cockpit, And soon it will be a finished BMW.
front end, seats, doors and drivetrain

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SEAT PRODUCTION.
My name is Astrit Ahmeti. I work in seat production where I mount front seats. I joined the company two years ago.

In seat production, we make all seats either mechanical seat adjusters or


for the vehicles produced at the power seats. A wide range of uphol-
Munich vehicle plant several hundred stery options is available as well so that
different types in total that vary customers can select their personal
depending on customer requirements favorites from among numerous colors
and country specifications, ranging and materials, such as fabric or leather.
from the base model to various special
equipment options and ultimately We apply polyol and isocyanate
to a completely customized seat. (polyurethane) to produce the foam
Customers can choose between parts used to pad the seats; these
different seat options, such materials are merged in a high-pressure
as regular or sports seats, procedure. Depending on the exact
with or without lumbar mix of these two materials, the result
support, and with is a softer or firmer foam part. This
allows us to achieve the ideal firmness
for each section. The completed seats
are assigned consecutive numbers and
provided to the assembly line just-in-
sequence as car sets of two seats each.

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FINISHED VEHICLE AND QUALITY MANAGEMENT.
I am David Jobst, Ph. D. I have been with the BMW Group for seven years now and am responsible for the validation of the finished vehicle
in the area of driver assistance systems.

The area of finished vehicle and quality development and ensure the smooth An efficient and effective problem-
management focuses on the vehicle in its integration of a new vehicle or new solving process makes sure that iden-
entire complexity. In the early phase of special equipment in the plants tified solutions are always sustainable.
the product development process, we production processes. Zero faults in Changes in series production are
are an important driver in matters production are our top priority. We are smoothly transferred to the production
of product and process design, also responsible for validating all vehi- process. In doing so, we apply a quality
the basic prerequisite for an cle characteristics and its suitability for management system which is always
excellent product. We are production. We guarantee a products up to certification levels. We see our
the interface between flawlessness, especially in the case of a efforts as successful when we manage
our plant and our new model launch, and allow no errors to exceed our customers expectations.
colleagues in to slip through.

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LOGISTICS.
My name is Athanassios Triantafillidis. I have worked for BMW for 21 years now. I work in logistics where I drive the tugger train
from the westward plant expansion to assembly.

About 800 people at BMW and at Ecological sustainability is becoming


service providers make up the physical increasingly important as well in an
logistics team, and we are responsible urban environment. This is why we
for the smooth supply to the vehicle have commissioned a fully electric
production. e-truck to deliver parts at the plant.
Our experiences with this truck have
We provide all materials in the right been so positive that we are now
quality to the right place in assembly at planning to expand the pilot project.
the right time. Every day, about
1.3 million parts in close to 9,000
containers are provided. To be able to
supply the lines, we have to unload 300
trucks at the plant in two shift opera-
tions. We sort parts, arrange them in
sequence and transport the respective
containers just-in-sequence to assembly
by forklift, pallet truck or tugger train.

Sustainability is an important issue for


us, and not only when it comes to the
ergonomic design of our workstations.

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BMW GROUP PLANT MUNICH ENGINE PRODUCTION PROGRAM.

3-cylinder petrol engines 4-cylinder petrol engines 8-cylinder petrol engines

6-cylinder high-performance engines 8-cylinder high-performance engines 12-cylinder petrol engines

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ENGINE PRODUCTION ASSEMBLY.
My name is Rafal Nierada. I joined the company four years ago and work in engine production, more specifically in the assembly of modular engines.

For decades, the production of engines Before being fitted into the vehicle, each
has been a core competence of BMW, engine undergoes specific test cycles,
the Bavarian Engine Works. Engines such as the cold test that allows for a
are a vital element of the proverbial full function test in close to no time and
sheer driving pleasure, combining without the use of fuel. The throughput
outstanding driving characteristics time for an engine is between six and
with minimum fuel consumption and twelve hours. The approx. 450 individual
CO2 emissions. parts needed to make an engine are
finely machined with a precision of a
Plant Munich is BMWs only site that thousandth of a millimeter and then
combines automotive core production mounted. We supply our engines to the compared with its
with engine production. At the same vehicle plants in the global production predecessor model,
time, the Munich-based engine network. namely 30 kilograms
production has the longest history of for the 3-cylinder and
the companys facilities of this kind. State-of-the-art modular 3- or 4-cylinder 20 kilograms for the
We manufacture the entire range of engines are equipped to meet the 4-cylinder drive. This way, the
BMW Group engines, from 3-cylinder constant changes in legal requirements modular engine concept makes
engines to the high-performance drive- regarding CO2 emissions as well as the a valuable contribution both to
trains for the current BMW M models, increasing electrification. A remarkable minimizing an individual cars fuel
as well as the 12-cylinder drives for achievement is the significant reduction consumption and to reducing overall
Rolls-Royce and BMW automobiles. in weight of this engine generation fleet consumption.

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ENGINE PRODUCTION LOGISTICS.
I am Remziye Demircan and I have been working for the BMW Group for three and
a half years. I am responsible for parts picking for the 3- and 4-cylinder engines.

My about 340 colleagues in physical are directly provided to the respective


logistics and I cooperate very closely line. Variant-specific parts, however,
with the engine assembly and me- are prepared on the lower floor and
chanical production. Logistics applies delivered to the engine assembly line
the just-in-sequence supply principle. via conveyor belts in so-called engine
Contrary to mechanical production, sets, boxes that resemble shopping
assembly is provided with engine parts carts.
on two floors. Attachment parts that
are identical for all engine variants

ENGINE PRODUCTION MECHANICAL PRODUCTION.


My name is Manuel Nagel. I joined the BMW Group five years ago and work in the production area
for cylinder heads.

We are a total of about 600 colleagues components, which we subsequently 8- and 12-cylinder V engines on two
in mechanical production. deliver to assembly. lines.
All common techniques to process One of these components is the cylin- On two other lines, we make aluminum
blanks are used here, including der head: our cylinder heads consist of crankcases for 8-cylinder engines. The
drilling, machining, milling, honing a firm but lightweight aluminum alloy. fifth line makes steel crankcases for the
and sanding. At our five production We manufacture cylinder heads for 3-, 12-cylinder drives.
lines, we process three different engine 4- and 6-cylinder engines as well as
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INNOVATION.
The BMW Group is continuously developing its production network further, applying innovative technologies in the fields of digitalization, ergonomics and sustaina-
bility. These innovations offer a multitude of new possibilities in production. The goal is to operate a production system with stable, efficient and flexible processes
and a strong focus on top quality.

Complex processes in production can and reliability issues under the condi-
be made even more efficient by apply- tions of large series production.
ing new technologies. In the long term,
these developments will modernize the
work environment even further.
However, not everything that is techni-
cally feasible makes sense when taking
into consideration the economic, safety

Digitalization gives us new leeway and greater


efficiency in numerous processes, and this will
provide a sustainable benefit to our workers. In
the future, people in production will be creators
of their work environment to an even greater
extent than they are today. On top of that, they
will benefit from the declining share of physically
strenuous, non-ergonomic tasks thanks to the
application of innovative robot systems.
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NATURALLY SUSTAINABLE.
To demonstrate sustainability in all actions and economic activities is a success model the BMW Group has applied for many
years. The companys Clean Production strategy is an inherent part of the BMW Groups global production network. The
teams at BMW Group Plant Munich constantly work on developing innovative, sustainable production processes as well;
these help avoid air pollution, conserve resources and reduce energy consumption.

The BMW Group is one of the worlds of noise emissions, the application of
most sustainable automakers. Especial- innovative sound absorbers, ventilators
ly given its location in the midst of a and soundproofing, as well as the
city, the Munich site has always been optimization of transport logistics.
known for its particularly eco-friendly
and sustainable production. Today, production at the site causes
BMW Group Plant Munich considers almost no non-recyclable waste. Waste,
itself a responsible partner of the wastewater and emissions have been
City of Munich and sets great store reduced almost to zero, and noise
by the harmonious cooperation with emissions and vibrations have been
its neighbors. The protection of local reduced to a minimum. The total
residents from production-related amount of waste for disposal per
noise is a key consideration at the vehicle produced is 200 grams, the
plant, which is met by the reduction recycling rate stands at 99 percent.

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The plant has a rail link via which The vehicles are powered exclusively
about two thirds of all the vehicles with electricity from renewable
produced here are dispatched in the sources. Combined with the alterna-
most eco-friendly manner. On top of tive drivetrain, this makes the 40-ton
that, this method of transport keeps e-truck carbon-free and very quiet; the
noise emissions that could bother particulate pollution is also negligible.
people in the surrounding neighbor- Compared to a diesel truck, the e-truck
hood to a minimum. saves 11.8 tons of CO2 annually,
corresponding to almost three trips
Plant Munich is also a pioneer in around the world in a BMW 320d
matters of eco-friendly city logistics: Efficient Dynamics.
as the first car factory worldwide, the
site uses two fully electric trucks for
parts deliveries in public road traffic.

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FOCUS ON THE PEOPLE.
The success of BMW Group Plant Munich is first and foremost based on its people. Their commitment, their identification with the company and most of all
their expertise have a significant share in the success of Plant Munich.

Each employee is an important element control of ones work quality, and the top product quality right from the of female workers in the automotive
of the complex production network willingness to undergo training for new word go. industry are only a few examples for
and thus ultimately responsible for the tasks. the BMW Groups sustainable HR
outstanding product quality. Over 300 working time models, a strategy.
As part of an intelligent network, our consistent profit-sharing scheme, the
The corporate culture, which is fully employees ensure the transfer of knowl- possibility of accepting work assign- In order to ensure the high qualifica-
incorporated in the mindset of the edge across plant boundaries. ments abroad, the cooperation with tion level of the workforce also for the
workforce at BMW Group Plant In addition, their commitment ensures colleges and universities, comprehen- years to come, the BMW Group trains
Munich, strongly builds on own that when a new model is introduced sive on-the-job and advanced training more than 850 young people in
initiative and responsibility, continuous production starts on schedule and at programs, as well as the highest share 14 different professions in Munich.
DIVERSITY, AN INHERENT PART OF OUR SELF-IMAGE.
Diversity at the BMW Group is a triad consisting of a mix of different nationalities and ages as well as an appropriate mix of male and female staff.

This is how, in the future, the


BMW Group as a global player
will be able to maintain the skills
needed to perfectly serve existing sales
markets, tap new markets and chang-
ing customer groups, as well as make
best use of our peoples skills in light
of the demographic change.
Workers at BMW Group Plant Munich
come from over 50 different countries.
The age average is 42.5 years.

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A VIEW BEHIND THE SCENES.
Experience the fascination of production at BMW Group Plant Munich up close and let one of our guides introduce you to the world of industrial production.

The plant tour program is as versatile as the interests of our visitors.


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

We are looking forward to your inquiry:


Phone: +49-89-1250-160001
Email: infowelt@bmw-welt.com
Website: www.bmw-werk-muenchen.de

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Imprint:
Stammwerk der BMW Group:
Produktion in Herzen einer Metropole.
BMW Group Plant Munich
Communications Production Network BMW Group
Not to be reproduced (in full or in parts) without permission.
Bayerische Motoren Werke Aktiengesellschaft; Last updated: 03/2017