OPERATIONS MANAGEMENT

ASSIGNMENT
INNOVATIVE PRACTICES USED IN
PRODUCTION INDUSTRY
“BMW”
TEAM MEMBERS:
SANJAY.H
POOJA
VETRIVEL.B
SRINITHY.J

INTRODUCTION:
Bayerische Motoren Werke AG, translated in English as Bavarian Motor
Works, often referred to as BMW. The company was founded in 1916 as
a manufacturer of aircraft engines, which it produced from 1917 until
1918 and again from 1933 to 1945.Automobiles are marketed under the
types BMW, Mini and Rolls-Royce, and motorcycles are marketed under
the types BMW Motorrad. In 2015, BMW was the world's twelfth-largest
producer of motor vehicles, with 2,279,503
vehicles produced.BMW is headquartered in Munich and produces
motor vehicles in Germany, Brazil, China, India, South Africa, the
United Kingdom, the United States and Mexico. BMW has significant
motorsport history, especially in touring cars, Formula 1, sports cars
and the Isle of Man TT

TRANSFORMING DIGITAL MANUFACTURING

BUSINESS.
Open
Manufacturing created Platform permit industrial manufacturers to
work together to break down data silos and overcome the challenges of
complex, propriety systems that slow down production optimization. By
leveraging existing proven solutions, manufacturers can unlock the
potential of their data, integrate industrial solutions more quickly and
securely and benefit from the contributions of other community
members while owning their own IP and data.

• The Open Manufacturing Platform is an open

industrial IoT platform to accelerate production and logistics
optimization efforts.

• Data standardization across data producers for

faster insights correlation

• Central auditability and dashboards also

• Data monetization chance through controlled

sharing and ownership
 • Open source for OMP components are made

Community approach ensures requirement prioritization. All partners

give and can shape the future of the platform, focusing on common
industrial use cases and challenges.

JOINT DIGITAL TRANSFORMATION: Future controlled product

vision that augments members’ unique domain skills.
 JOINT INNOVATION: Aligning technology visions to make industry-
leading competitive advantage
including joint deliverables and resources.

JOINT ACCOUNTABILTY: Together, execute on

detailed integration plans to deploy the solutions under
controlled risk.

1.How does a hydrogen engine work?

Hydrogen fuel cell cars are powered by an electric motor and are
therefore classified as e-cars and common abbreviation is FCEV, short
for “Fuel Cell Electric Vehicle,” in contrast to a BEV or “Battery Electric
Vehicle.”

There is one crucial difference between hydrogen fuel cell cars and
other electric vehicles – hydrogen cars produce the electricity
themselves. So, unlike in fully electric or plug-in hybrid vehicles,
vehicle doesn’t get its power from a built-in battery that can be
charged from an external power source. Instead, hydrogen cars
effectively have their own efficient power plant on board: the fuel cell.
In the fuel cell of an FCEV, hydrogen and oxygen generate electrical
energy. This energy is directed into the electric motor and/or the
battery, as needed.

In fuel cell technology, process is known as reverse electrolysis takes

place, in which hydrogen reacts with oxygen in the fuel cell. The
hydrogen enters from one or more tanks built into the FCEV, while the
oxygen comes from the ambient air. The only results of this reaction
are electrical energy, heat and water, which will emitted through the
exhaust as water vapor. So hydrogen-powered cars are locally
emission-free – more about that in a minute.

The electricity generated in the fuel cell of a hydrogen engine can take
two routes, depending on the demands of the specific driving situation.
It either flows to the electric motor and powers the FCEV directly or it
charges a battery, which stores the energy until it’s needed for the
engine. This battery, known as a traction battery, is significantly smaller
and therefore lighter than the battery of a fully electric car, as it’s being
constantly recharged by the fuel cell.

Like other e-cars, hydrogen vehicles can also recover or “recuperate”

braking energy. The electric motor converts the car’s kinetic energy
back into electrical energy and feeds it into the back-up battery.

2.The pros and cons of hydrogen-powered cars for users

The pros and cons of a particular propulsion technology can be

seen from two main perspectives: that of the user, and that of the
environment. If any technology is to succeed as an alternative to the
combustion engine, it must be user-friendly and significantly reduce the
emission of pollutants. We’ll start by examining the key benefits and
disadvantages for drivers/owners of hydrogen fuel cell cars – with the
help of Axel Rücker, Program Manager Hydrogen Fuel Cell at the BMW
Group.

Advantages for users:

• The propulsion in hydrogen fuel cell cars is purely electrical.

When you drive one, it feels similar to driving a regular electric car.
What does that mean? Virtually no engine noise and a lively start,
because electric motors provide full torque even at low speeds.

• Another advantage is the quick charging time. Depending on the

charging station and battery capacity, fully electric vehicles currently
require between 30 minutes and several hours for a full charge. The
hydrogen tanks of fuel cell cars, on the other hand, are full and ready
to go again in less than five minutes. For users, this brings vehicle
availability and flexibility into line with those of a conventional car.

• For the time being, hydrogen cars still have a longer range than
purely electric cars. A full hydrogen tank will last around 300 miles
(approx. 480 kilometers). Battery-powered cars can match this with
very large batteries – which in turn will lead to an increase in both
vehicle weight and charging times.

• The range of fuel cell vehicles is not dependent on the outside

• temperature. In other words, it does not deteriorate in

cold weather.
Current disadvantages for users:

Currently, the biggest shortcoming of hydrogen fuel cell cars is the

sparsity of options for refueling. A hydrogen engine is refueled at
special fuel pumps, which in the future will probably find their way into
ordinary service stations. As things stand, however, there are still very
few refueling stations for hydrogen-powered cars. At the end of 2019
there are only around 40 in the U.S., as compared to approx. 80 in
Germany.

“We have a chicken and egg problem with hydrogen fuel cell
technology,” explains BMW expert Rücker. “As long as the network of
refueling stations for hydrogen-powered cars is so thin, the low
demand from customers will not allow for profitable mass production
of fuel cell vehicles. And as long as there are hardly any hydrogen
cars on the roads, the operators will only hesitantly expand their
refueling station network.”

BMW’s homeland of Germany leads the way in terms of

infrastructure for hydrogen fuel cell cars. In order to promote the
expansion of refueling infrastructure there, vehicle manufacturers like
BMW have joined forces with hydrogen producers and filling station
operators in the Clean Energy Partnership initiative, which plans to
expand the hydrogen fueling station network to 130 stations by 2022.
That would allow the operation of about 60,000 hydrogen cars on
Germany’s roads. The next target, with a corresponding increase in
fuel cell vehicles, will be 400 stations by 2025. More fueling stations
are also needed in neighboring countries to actually make it possible
to travel outside Germany via FCEV, according to Rücker.
3.How much do hydrogen-powered cars cost – and why?

In adding to the thin fueling station network, there is a another reason

for the as of yet low demand for hydrogen fuel cell cars: they are
relatively expensive to buy. The few models of fuel cell vehicles already
available on the market cost around USD 80,000 for a mid- or upper-
mid-range vehicle. That’s almost twice as much as comparable fully
electric or hybrid vehicles.

There are a range of reasons why hydrogen fuel cell cars are still
expensive. In addition to small volumes, which means that production
is still to be industrialized, there’s also the question of the need for
the precious metal, platinum, which acts as a catalyst during power
generation. The amount of platinum needed for vehicle fuel cells has
already been greatly reduced. “The general goal is to bring down the
price of hydrogen-powered cars to a similar level to that of other
electric cars,” explains Rücker.

Another reason for the high purchase price is that hydrogen fuel cell
cars tend to be quite large because the hydrogen tank(s) take up a lot
of space. The drive unit for a purely battery-driven electric vehicle, on
the other hand, also fits into small cars. That’s why classic electric
cars can currently be found in all vehicle classes.

In addition to the cost of purchase, operating costs also play an

important role in the cost-effectiveness and acceptance of a propulsion
technology. In hydrogen fuel cell cars, these costs are not least
dependent on the price of the fuel. At present, 1 lb (0.45 kg) of
hydrogen costs around USD 14 in the U.S., as compared with USD 4.80 in
Germany (this is the price the H2 Mobility partners have agreed on). An
FCEV can drive about 28 miles (45 km) on 1 lb (0.45 kg) of hydrogen.

The cost per mile of running hydrogen cars is therefore currently almost
twice as high as that of battery-powered vehicles charged at home.
Rücker expects these operating costs to converge: “If the demand for
hydrogen increases, the price could drop to around USD 2.50/lb (USD
5.60/kg) by 2030.”

4.How environmentally friendly and sustainable

is hydrogen fuel cell technology?
A car that uses only renewable energy and produces no harmful
emissions would be ideal from an environmental point of view. Let’s
take a look at how close fuel cell cars are to this goal in comparison
to other types of propulsion:

• Alternative propulsion systems are designed to reduce the

emission of pollutants, in particular climate-harming CO2, but also
other noxious gases such as nitrous oxide. The exhaust gas from a
hydrogen engine consist of pure water vapor. Hydrogen fuel cell
technology is therefore locally emission-free. This means it keeps the
air clean in cities, but does it protect the climate at the same time?

• That depends on the conditions under which the hydrogen for the
fuel cell vehicles was produced. Hydrogen production requires electrical
energy. This electrical energy is used to break water down into its
constituent elements, hydrogen and oxygen, via the process of
electrolysis. If the electricity used comes from renewable energy
sources, the hydrogen production has a neutral carbon footprint. If, on
the other hand, fossil fuels are used, this will ultimately have a knock-
on effect on the carbon footprint of the fuel cell cars using the
hydrogen. How strong that effect is depends on the energy mix used. In
this respect, hydrogen fuel cell cars are no different from other electric
vehicles.

• However, one disadvantage of producing hydrogen is the losses

during electrolysis. The overall efficiency in the “power to vehicle drive”
energy chain is therefore only half the level of a BEV.

• However, hydrogen can be produced at times when there is an

oversupply of electricity from renewable energy sources when the
wind or solar energy currently produced is not otherwise used. The
potential for this is huge.

• Hydrogen is also a by-product of many industrial processes,

where all too often it is treated as waste with no further use. The fuel
cell battery offers a way to upcycle this hydrogen, although it must be
cleaned first.

• energy stabilize sheet for hydrogen fuel cell cars also has to attach
the transportation and storage of the hydrogen. Depending on the
transportation technology used (liquid or gaseous), different costs for
compression, cooling, transport and storage arise. Due to its better
transportability and storage ability, the trend is towards liquid
hydrogen. Nevertheless, the transportation and storage of hydrogen
are – at this stage – still a good deal more complex and energy-
intensive than for gasoline or diesel.
In conclusion, hydrogen fuel cell technology in the potential to make
ecologically sustainable mobility possible. However, according to
BMW’s expert Axel Rücker, this would above all require the use of
renewable energy sources when producing the hydrogen used, as
well as an expansion of the technological infrastructure in order to
shorten transportation distances

DESIGN INNOVATION:

INTELLIGENT LASER LIGHT AND OLED.

The BMW i8 is the future of the sports car – and Laserlight, the future
of automotive lighting technology. Both offer unprecedented
performance wand top efficiency. In the BMW i8, this is the first time
that Laserlight headlights have been offered in a series-production
vehicle worldwide. BMW Laserlight offers more than double the
range of conventional headlights (up to 600 metres), providing
increased safety for night-time driving.

BMW Organic Light.

Organic light-emitting diodes (OLEDs) are innovative, efficient and
sustainable light sources used as part of BMW Organic Light. OLEDs use
very little energy, which also helps lower CO2 emissions.The
sustainability of the technology is also evidenced by the fact that
production does not involve any expensive or rare materials or “rare
earths”. Unlike regular LEDs, OLEDs produce a light that is dissipated
more evenly.

BMW EDRIVE ZONES – AUTOMATICALLY

EMISSION-FREE IN THE CITY.
The BMW eDrive Zones digital service is now available as standard in
various BMW Group plug-in hybrid models. BMW eDrive Zones
trigger an automatic change to the purely electric operating mode as
soon as the vehicle enters a designated area, e.g. low emission zones.

The BMW eDrive Zones service uses geo-fencing technology via GPS.
Switching to the purely electric driving mode is automatic. When the
service is activated, each available eDrive Zone on the navigation map is
graphically highlighted in the Control Display.

In addition to reducing emissions, the increasing share of the electric

driving also contributes a reduction in operating costs for the driver. A
purely electric trip results in significantly lower energy costs than using
the combustion engine as is shown by comparative calculations for
current plug-in hybrid models. This applies particularly to city traffic,
where electric power consistently achieves a higher level of efficiency
than a petrol or diesel engine.
THE BMW GROUP AS THE DRIVING FORCE FOR
MOBILITY RESEARCH.