Munich. The BMW Group is consistently advancing the digitalisation and use of artificial intelligence in production. A key element in this effort is “Physical AI”, which combines digital artificial intelligence (AI) with real machines and robots. This enables intelligent systems such as humanoid robots to be integrated into real-world production processes.

For the first time, the BMW Group is now bringing Physical AI to Europe and launching a pilot project with humanoid robots at the Leipzig plant. The project aims to integrate humanoid robotics into existing series production of cars and to explore further applications in the production of batteries and components.

“Digitalisation improves the competitiveness of our production – here in Europe and worldwide. The symbiosis of engineering expertise and artificial intelligence opens up entirely new possibilities in production,” said Milan Nedeljković, Member of the Board of Management of BMW AG, Production.

Last year, the BMW Group successfully implemented a pilot project with humanoid robots at its Spartanburg plant in the United States. The insights gained from this project are being leveraged to further develop and scale Physical AI applications.

Unified IT and data model in the production system

Artificial intelligence is already an integral part of the BMW Group’s production system. From the virtual factory with digital twins and AI‑enabled quality controls to intralogistics with autonomous transport solutions, intelligent systems are used in almost all production steps.

A prerequisite for the effective use of artificial intelligence in production is a unified IT and data model across the entire production system. The BMW Group has consistently transformed isolated data silos into a unified data platform in its production system meaning that all data is consistent, standardised, and available at all times. This enables digital AI agents to take on increasingly challenging tasks autonomously and in complex environments while continuously learning and becoming available for additional areas of application. The introduction of intelligent and autonomous decision‑making agents marks a paradigm shift in production. In combination with robots, these digital AI agents are what make up Physical AI.

“Our aim is to be a technology leader and to integrate new technologies into production at an early stage. Pilot projects help us to test and further develop the use of Physical AI – that is, AI‑enabled robots capable of learning – under real-world industrial conditions,” said Michael Nikolaides, Senior Vice President Production Network, Supply Chain Management at BMW Group.

Digitalisation and artificial intelligence are core elements of BMW iFACTORY and are the foundation for future‑proof, flexible, and competitive production.

Humanoid robotics complements existing automation

The BMW Group is strategically expanding its automation portfolio to include Physical AI and humanoid robotics. Humanoid robots are viewed as a value‑adding complement to existing automation. Particularly, they demonstrate potential in monotonous, ergonomically demanding, or safety‑critical tasks. The goal is to relieve employees and further improve working conditions.

Center of Competence for Physical AI in Production consolidates expertise

Its consistent data platform in production makes the BMW Group an attractive partner for technology companies seeking to test the possibilities of Physical AI – particularly humanoid robotics – in an industrial environment under real-world conditions. By setting up the new “Center of Competence for Physical AI in Production”, the BMW Group is taking the next step in consolidating its expertise and ensuring that the full range of knowledge can be leveraged across the organisation.

The BMW Group is following a clearly structured approach. Technology partners are evaluated according to defined maturity and industrialisation criteria and tested in pilot projects under real-world production conditions. Following a theoretical assessment, an evaluation is carried out at the manufacturer’s site in the laboratory using real use cases from the BMW production system to test integration capability. If this phase is successful, it is followed by an initial test deployment under real-world production conditions at a BMW Group plant and subsequently the actual pilot phase.

First pilot project with humanoid robots in Europe

In collaboration with Hexagon, a long‑standing, established partner of the BMW Group in the field of sensor technology and software, the first pilot project in Europe is now underway. Hexagon’s organisational unit located in Zürich, Hexagon Robotics, specialises in Physical AI and presented its first humanoid robot, AEON, in June 2025. Following an initial theoretical evaluation phase and successful laboratory tests, there was an initial test deployment at BMW Group Plant Leipzig in December 2025. A further test deployment is planned from April 2026 to ensure full integration for the actual pilot phase starting in summer 2026.

The deployment in Leipzig is focusing on testing a multifunctional application of the robot. It is based on AEON’s design, whose human‑like body allows a wide range of hand and gripper elements or scanning tools to be flexibly attached and enables dynamic use on wheels. During testing and later in the pilot phase, the robot will be used in the assembly of high‑voltage batteries and in component manufacturing.

Successful pilot at BMW Group Plant Spartanburg provides key insights for use of humanoid robots in production

The world’s first deployment of humanoid robots at a BMW Group plant took place at the Spartanburg plant in the United States in 2025, in collaboration with the technology company Figure AI. The results demonstrated that Physical AI can deliver measurable added value under real-world conditions. Within ten months, the robot Figure 02 supported the production of more than 30,000 BMW X3, working ten-hour shifts daily from Monday to Friday. Figure 02 handled the precise removal and positioning of sheet metal parts for the welding process – a task that is particularly demanding in terms of speed and accuracy while also being physically exhausting. In total, it moved more than 90,000 components and covered approximately 1.2 million steps in around 1,250 operating hours.

The pilot confirmed that humanoid robots can safely perform precise, repetitive work steps – such as positioning components with millimetre precision – and provided important insights for the further deployment of Physical AI in production.

During the initial test phases with Figure 02, it was essential to involve all areas of the production IT infrastructure, occupational safety, production process management, and shop floor logistics at an early stage.

One key finding was that the transition from the laboratory to the actual production environment was faster than expected. Motion sequences trained in the laboratory could be quickly transferred into stable shift operation. To ensure smooth coexistence with existing systems, integration into the BMW Smart Robotics ecosystem was implemented via standardised interfaces.

The body shop was deliberately selected for the test phase in Spartanburg, as it already has a high degree of automation. BMW Group employees in this area have extensive experience in integrating new technologies and processes. For example, material supply on the line is already carried out almost exclusively via automated smart transport robots (STR). The project team’s early communication ensured transparency from the outset and promoted acceptance. The deployment of humanoid robots was met with great interest among employees and quickly became a natural part of everyday work during the course of the project.

The BMW Group and Figure are currently evaluating additional use cases for deploying the Figure 03 robot.

Additional quotes for use:

Michael Nikolaides, Senior Vice President Production Network, Supply Chain Management at BMW Group:

“Our aim is to be a technology leader and to integrate new technologies into production at an early stage. Pilot projects help us to test and further develop the use of Physical AI – that is, AI‑enabled robots capable of learning – under real-world industrial conditions. The successful first deployment of humanoid robots at our BMW Group plant in Spartanburg in the USA proves that a humanoid robot can function not only under controlled laboratory conditions but also in an existing automotive manufacturing environment.”

Michael Ströbel, Head of Process Management and Digitalisation, Order to Delivery at BMW Group:

“We are delighted to deploy a humanoid robot for the first time in a pilot project at a plant in Germany. Following evaluation by our Center of Competence for Physical AI in Production, tests were carried out in the laboratory and at Plant Leipzig at the end of last year. This year, our focus is on step‑by‑step integration into our production system to explore a wide range of applications. The emphasis is on researching multifunctional use of the robot in various production areas such as battery manufacturing for energy modules and component production for exterior parts. With Hexagon, we have found a proven long‑standing partner with a highly innovative approach to humanoid robotics for this project.”

Felix Haeckel, Team Lead CoC Physical AI for Production:

“At our new Center of Competence for Physical AI in Production, we are pooling our expertise to make knowledge on AI and robotics widely usable within the company. In recent years, we have built up an international team of experts that, in addition to in‑house research and programming, is dedicated to the gradual integration of AI into the existing production system. At the same time, our team in Munich is driving its own robotics research to set up, support, and further develop pilot projects in the field of Physical AI at our plants.”

Arnaud Robert, President of Hexagon Robotics:

“We are very pleased to be working with the BMW Group to advance the use of humanoid robots in real‑world environments.”

Leipzig. On 1 March 2005 BMW Group Plant Leipzig went on stream – with series production of the fifth-generation BMW 3 Series Sedan. Its construction had been announced four years earlier, in July 2001, with the location chosen from among more than 250 applicants. Since then, some 3.75 million cars have rolled off the production lines, and the plant has been steadily extended and upgraded. The BMW Group has so far invested more than 5 billion euros in the site – and will continue to capitalise on its flexibility in the future.

BMW Group Plant Leipzig currently manufactures four models with three different types of drive by two different brands – all on the same production line: the BMW 1 Series, BMW 2 Series Active Tourer (including the plug-in hybrid version) and BMW 2 Series Gran Coupé as well as the MINI Countryman in both its fully electric and conventionally powered variants. When the plant was in planning, output was expected to total 650 units a day. Now, 20 years down the line, capacity stands at up to 1,300 units a day. Since 2005 there have been 20 different product launches of BMWs and MINIs Made in Leipzig.

Extraordinary architecture and flexible structures

In its 20 years of existence, BMW Group Plant Leipzig has set standards time and again and clocked up a succession of milestones. The architecture of the central building alone remains impressive to this day. Designed by the renowned Iraqi-British architect Zaha Hadid, it was awarded the German Architecture Prize in 2005, the year it opened. As the centrepiece and linking element of the plant, it provides the backdrop to the spectacular procession of vehicles that pass overhead through the offices on their way through the production process.

The flexible structures of the plant halls have also proven their worth to this day, throughout the various expansion stages of the facility. Leipzig was the first assembly plant in the world to feature a ‘finger’ arrangement in the production hall, for example, which offers ideal logistics solutions and can be flexibly adapted as needed. Developed specifically for this site, the finger layout allows trucks to deliver parts and preassembliesstraight to the production line. It also means extensions can be added as needed and new assembly stations integrated easily without having to rebuild the line from scratch. At the moment various further extensions are being added on the 240-hectare site.

For the last 20 years, BMW Group Plant Leipzig has demonstrated tremendous flexibility and adaptability, accommodating new products, processes and technologies. It has often played a pioneering role within the BMW Group production network. Its first upgrade consisted of the addition of a new press shop. This went into operation in 2009 and incorporated the first high-speed servo press in the world, able to produce pressed parts with unprecedented speed and efficiency. By 2014 three additional large-scale presses and two coil systems for body panels had also been installed, completing the press shop upgrade.

Pioneer in electromobility 

One particularly defining moment for Plant Leipzig was the decision to produce its first fully electric vehicle there, making it the birthplace of electromobility at the BMW Group. Between 2013 and 2022 more than 250,000 all-electric BMW i3 vehicles rolled off the production lines. Their carbon bodies were a world first in series production. In 2014 the BMW i8 followed: the first plug-in hybrid by the BMW Group, it featured an award-winning, futuristic design and progressive technologies, which together made it an icon among sportscars. With 20,500 units made – including the BMW i8 roadster launched in 2018 – the era drew to a close in 2020.

But the team’s expertise in electromobility continues: in 2021 BMW Group Plant Leipzig launched e-component manufacturing for high-voltage battery production. Having started with the production of battery modules for the BMW Group production network, facilities were expanded within four years to include further stages of manufacturing and additional production lines. Since the start of MINI Countryman Electric production in March 2024, Plant Leipzig has carried out the entire process of high-voltage battery manufacturing for the fifth generation of batteries, with its five cell-coating lines, three module assembly lines and two lines for high-voltage battery assembly. The batteries are used in the MINI Countryman Electric and fully electric BMW models at various BMW Group sites.

From rear-wheel to front-wheel drive 

It’s not just the BMW i8 that made 2014 a landmark year: it was also the year production of the first generation of BMW 2 Series Active Tourer began. This brought fundamental change to BMW Group Plant Leipzig: it was the first ever BMW with a front-wheel drive architecture and paved the way for this drive technology to become integrated into Plant Leipzig’s production lines. Thanks to Leipzig’s flexibility, the sports activity tourer was able to roll off the same line as the BMW 1 Series, 2 Series and first-generation BMW X1, all of which are rear-wheel drives.

Integrating the BMW 2 Series Active Tourer required just a few minor adjustments to the paintshop and assembly, but in the bodyshop, its new front-wheel drive concept and vehicle architecture meant a whole new production area was needed. About a year and a half later, production of a plug-in hybrid model was launched: the BMW 225xe. Like the BMW i8, this featured a combined combustion-engine and electric drive. Its successor, the second-generation BMW Active Tourer, in production since 2021, is also manufactured with either a plug-in hybrid drive or an internal combustion engine. In 2021, Leipzig’s rear-wheel drive era came to an end when the BMW 2 Series Coupé, BMW 2 Series Convertible and BMW M2 were phased out.

Production of the MINI Countryman is another USP of Plant Leipzig within the production network: it is the only full vehicle production facility in the BMW Group to produce BMW- and MINI-badged cars on one and the same production line.

Important employer in the region

With some 6,800 BMW employees and more than 11,000 people based locally, the BMW Group plant is a major contributor to the economy and a key employer in the region. When it first went on stream, it had roughly 2,600 BMW employees, with plans for around 5,500 jobs over the medium term.

In 2001, when Leipzig was chosen as the site for a new plant, the enthusiasm and welcome across the region were huge. Job applications poured in. On the day of the announcement alone, the specially established call centre took more than 4,000 calls. Over the next few days, the post bags were full, and by September 2001 thirty-five apprentices had become the first cohort to receive an employment contract with BMW Group Plant Leipzig. Since then, Leipzig has trained some 1,100 apprentices.

Last year Plant Leipzig opened its Talent Campus. This accommodates training and development spaces in a single new building on the plant premises, offering the perfect conditions for employee training.

In 2024 the MINI Countryman meant production volumes increased, marking another first for Leipzig: the introduction of nightshifts – unprecedented in the history of the plant.Today, BMW and MINI vehicles are manufactured round the clock, in three shifts. The additional shift has created jobs for another 900 employees.

Progressive energy management

Planning the BMW plant in Leipzig, efficient and sustainable processes played a crucial role – not just in vehicle production but in energy supplies as well. Visible from afar, the plant’s four wind turbines are among its landmark features and have been powering production with green energy since 2013. With a total capacity of 10 megawatts, they generate 26 gigawatt hours a year of electricity from wind energy – enough to cover about 15 percent of the plant’s total energy needs.

In addition, BMW Group Plant Leipzig is equipped for interim energy storage, with a battery storage farm that went into operation in 2017. This comprises up to 700 second-life high-voltage batteries from BMW i3 cars, enabling us to optimise local energy management and help stabilise the electricity network.

Looking to the future, BMW Group Plant Leipzig attaches great importance to hydrogen as a fuel. In pursuit of its vision of largely decarbonising production – by replacing fossil fuels with hydrogen – it will need sufficient supplies from a grid. A regional hydrogen network is currently under construction, and Plant Leipzig plans to tap into it.

BMW Group Plant Leipzig has extensive experience of working with hydrogen, having already used it for in-house plant logistics for more than a decade. A pioneer in the automotive industry, it opened Germany’s first indoor hydrogen filling station in 2013. It now operates five such facilities for refuelling forklifts and tug trains in intralogistics. Its hydrogen fuel cell-powered fleet currently consists of over 200 vehicles and is one of the largest in Europe.

Plant Leipzig was also the first car plant in the world to introduce a brand-new bivalent burner technology that can run on either natural gas or hydrogen. It can even switch between the two while operations are ongoing. In the paintshop, five such gas- and hydrogen-capable burners are currently used to dry the contrast roofs of the MINI Countryman, BMW 1 Series and BMW 2 Series Gran Coupe, and another six have replaced the previous systems in the PVC drying section.

BMW Group Plant Leipzig is currently undergoing further extensions and upgrades in preparation for forthcoming models – and for the next 20 years in its history.

BMW Group Plant Leipzig – Key milestones:

• 2001 Leipzig is chosen as the location for the new plant
• 2002 Zaha Hadid’s design is selected for the central building. The ground-breaking is celebrated
• 2003 The foundation stone is laid for the central building, and the topping-out ceremony is celebrated later that year

• 2005 Series production is launched with BMW 3 Series. Plant Leipzig is inaugurated. The central building wins the German Architecture Prize
• 2007 Production of the three-door BMW 1 Series and the BMW 1 Series Coupé begins
• 2009 Leipzig produces its 500,000^th car. Production of the first generation of BMW X1 begins. The press shop opens with the world’s first high-speed servo press
• 2011 Plant Leipzig delivers its 1,000,000^th BMW

• 2013 Four wind turbines go on stream. Production of the BMW i3 begins. Carbon is used in series production – a world first
• 2014 Production of the BMW i8 begins. Plant Leipzig is extended for production of the BMW 2 Series Active Tourer (the first front-wheel drive BMW). The press shop is upgraded
• 2016 Plant Leipzig delivers its 2,000,000^th BMW
• 2018 The plant is upgraded
• 2021 Plant Leipzig delivers its 3,000,000^th BMW. Battery module production begins
• 2022 The BMW i3 is phased out
• 2023 Production of the MINI Countryman begins
• 2024 Production of three models begins: the MINI Countryman Electric, fourth-generation BMW 1 Series and second-generation BMW 2 Series Gran Coupé. Night shifts are introduced in assembly

Leipzig. Electrification continues at BMW Group Plant Leipzig: Four months after launching production of the combustion-engined MINI Countryman, the all-electric version is now rolling off the lines at Leipzig as well. After phasing out production of the BMW i3, the birthplace of electric mobility at the BMW Group has welcomed another fully electric car to its range. It now manufactures four models with three drive types by two brands, all on a single production line: the BMW 1 Series, the BMW 2 Series Active Tourer (including the plug-in hybrid version), the BMW 2 Series Gran Coupe and the MINI Countryman in both its fully electric and combustion-powered versions.

The MINI Countryman Electric represents a major step in the MINI brand’s transition to full electrification by 2030 and combines an electrified go-kart feel with zero local emissions mobility. It comes in two fully electric variants: the Countryman E (150 kW, 204 hp | electricity consumption 17.4 – 15.7 kWh/100 km | CO2 emissions 0 g/km) and the more powerful all-wheel Countryman SE ALL4 (230 kW, 313 hp | electricity consumption 18.5 – 16.8 kWh/100 km | CO2 emissions 0 g/km).  

Consistent plant upgrades and flexible production system

To enable production of up to 350,000 units a year – 100,000 more than previously – Plant Leipzig has been continuously upgraded since 2018, with extensive additions and upgrades to the bodyshop, paintshop, assembly and logistics. “Our cars and components are very much in demand. In recent years the BMW Group has invested around 1.6 billion euros in the Leipzig site to produce additional vehicles and electric components, and now we’re increasing vehicle volumes too – which is great news for our plant,” said Petra Peterhänsel, Plant Director.

The main driver behind the volume increase is the MINI Countryman. During the course of 2024, output will rise to almost 500 units a day – on top of the 800 or so BMW vehicles the plant is producing. What’s more, thanks to its flexible production system, Plant Leipzig is in a position to respond quickly to customer demand, for example by increasing the share of fully electric vehicles.

Flexible assembly structures also meant the MINI Countryman Electric could be integrated seamlessly into production. The situation is similar with the different drive units, which are all produced on one and the same line in aggregate assembly and prepared for what’s known as “marriage” with the body. The e-drives, transmissions and control electronics (collectively known as the highly integrated electric drive topology, or HEAT) for the two all-electric models are connected directly in the plant. A new production line was required only for the control electronics.

More staff and nightshifts for increased production volume

Higher production volume means secure employment and up to 900 additional employees in vehicle production alone. By the end of 2024, Plant Leipzig will employ around 7,000 BMW staff. Working hours will need to be adjusted in all technologies, with nightshifts in assembly starting for the first time in September of this year and cars being produced round the clock in three shifts.

“Plant Leipzig first went on stream in 2005 with about 2,600 employees in production. 19 years later there are over 7,000. Over the years, the plant has grown steadily and considerably. The start of nightshifts in assembly represents another important milestone in the success story of our plant and is a clear show of confidence by our company in our site here in Leipzig,” emphasised Works Council Chairman Jens Köhler.

Made at Plant Leipzig: high-voltage batteries for the MINI Countryman Electric

With the production launch of the MINI Countryman Electric, all three stages of the Gen 5 high-voltage battery production process are now represented at BMW Group Plant Leipzig: cell coating, module production and battery assembly. Operations in all three are currently ramping up, with five cell-coating, three module-production and two high-voltage battery-production lines now in place.

“We are in the middle of the transformation to e-mobility,” said Markus Fallböhmer, Head of Battery Production at the BMW Group. “Starting this year, Plant Leipzig will carry out every stage of our in-house high-voltage battery production process. It’s our next great step forwards.”

Plant Leipzig’s e-component production capacity has been increasing since 2021. It will now manufacture not just the high-voltage batteries for the MINI Countryman Electric but also e-components for the BMW iX1, BMW iX2, BMW i4, BMW i5 and BMW iX made at other sites. The e-component production unit at Leipzig currently employs some 1,000 people.

To enable production of high-voltage batteries, spaces previously used for the BMW i3 and BMW i8 have been converted and new buildings added. One of them is a new hall with a footprint of about 61,000 m². This houses two lines capable of producing up to 300,000 high-voltage batteries a year. The BMW Group has invested over 900 million euros in e-component production at Plant Leipzig to date.

Resource-saving painting processes

At launch, the fully electric MINI Countryman comes in three additional body colours: British Racing Green, Chili Red and Blazing Blue – and with MINI’s trademark contrast roof, if desired. This is painted using a new overspray-free method that saves resources and is currently being readied for series operation. The term “overspray” refers to the mist of excess paint particles that forms when bodies are painted the conventional way. With the new technique, this mist no longer occurs. This makes it easier to paint in multiple colours as the laborious process of masking is no longer required. Overspray-free painting also helps save CO₂ emissions, as exhaust from the cabin requires less cleansing. In addition, it requires considerably less conditioned air, i.e. air that is brought to the exact temperature and humidity required for painting. As a result, less energy is needed to temper air and treat exhaust.

The burner technology used to dry the paint on contrast roofs was also converted for the start of MINI Countryman production and now consists of a bivalent system. The fuel-flexible burners can run on hydrogen (H2) as well as gas (methane, CH4) and even switch between the two while in operation. Five such bivalent hydrogen-capable burners are used to produce the contrast roofs for the MINI Countryman.

Further burners in the paintshop will also gradually switch to bivalent operations, with the next six hydrogen-capable burners just installed. This makes Leipzig a pioneer in the automotive industry and takes it ever closer to lower CO₂ emissions. “Our vision at Plant Leipzig is to decarbonise production as far as possible by replacing fossil fuels with green hydrogen,” said Petra Peterhänsel, explaining the long-term focus of the facility. This will require sufficient green hydrogen from a grid. A regional hydrogen grid is currently in planning, with Plant Leipzig set to benefit.

Leipzig. The production launch of the MINI Countryman marks a number of debuts and milestones: as the first MINI model to be made in Germany, the new MINI Countryman will roll off one and the same manufacturing line as the BMW 1 Series and 2 Series. Thanks to its flexible assembly structures, Plant Leipzig is in a position to produce two brands with three different drives – combustion, plug-in-hybrid and fully electric – all on the same production line.

Big Love is the motto of not just the MINI brand but also of the plant: Leipzig loves MINI and MINI loves Leipzig. Celebrating the production launch of the MINI Countryman today at a special event in the assembly hall were the BMW AG Board Member for Production, Milan Nedeljković; the Minister President of the state of Saxony, Michael Kretschmer; the head of the MINI brand, Stefanie Wurst; Mayor and Alderman for Business, Work and Digital Affairs, Clemens Schülke; various guests from politics and the media, and plant employees. To make sure everyone in the plant could experience the live broadcast of the celebration, the production lines stood still for almost 45 minutes.

Production of the largest MINI model to date marks an important step into the future of BMW Group Plant Leipzig. Since 2018 the company has invested some €700 million in the Saxony site to increase capacity and enable production of the MINI Countryman. In addition, this third generation of the vehicle will also be available with a fully electric drive. “Leipzig remains electrified,” said Plant Director Petra Peterhänsel.

“When it comes to the transformation,” Nedeljković emphasised, “skill and flexibility are crucial.” He added that the BMW Group had been quick to introduce and advance change: “Plant Leipzig plays a fundamental role in this regard. It was here that we launched production of the BMW i3 exactly ten years ago. We have since built on that, rolling the latest generation of electric cars out across our network.”

Nedeljković explained that all BMW Group plants are set up to produce different models with different drives – from combustion-powered to plug-in hybrid and fully electric – all on a single production line. But what’s special about Plant Leipzig, he added, is that its flexible production system is now being used for multiple brands for the very first time.

Michael Kretschmer, Minister President of Saxony, emphasised the importance of the BMW Group plant in Leipzig for the region and the federal state: “The BMW site in Leipzig is a success story of modern industrial production. Continued investments in the site and the launch of the MINI Countryman reaffirm the company’s commitment to ‘Autoland’ Saxony – and provide a boost for the entire regional economy, benefiting service providers and suppliers across the area.”

Clemens Schülke, Mayor and Alderman for Business, Work and Digital Affairs of the city of Leipzig was visibly pleased about the ‘new Leipziger’: “In my view, BMW Leipzig is an absolute success story. That’s why I am really looking forward to the next chapter: the first German MINI will be a genuine ‘Leipziger’. This model demonstrates the power and flexibility of our strong automotive cluster.”

Stefanie Wurst, head of MINI, detailed the characteristics of the new MINI Countryman: “The first MINI made in Germany stands for superior environmental credentials, not just as a product but equally in terms of its production. Its versatility and powerful, efficient drives make it the perfect companion for the city – but also for adventures beyond.”

Plant Director Petra Peterhänsel emphasised the importance of the MINI Countryman for the future of Plant Leipzig: “Today is a historical day for our site. As the plant develops and production of the MINI Countryman gets underway, our headcount will increase by over 1,000 by the end of 2024.”

“Today, we can see once again just how important our plant here in Leipzig is for the production network as a whole,” pointed out Works Council Chairman Jens Köhler as he thanked the BMW Group for their trust.

Hosting the event was the radio and television presenter Roman Knoblauch. But in addition to the MINI Countryman in Smokey Green with a contrast roof in Energy Silver, there was a secret star of the show: Spike, MINI’s digital friend. As the Intelligent Personal Assistant, Spike will support drivers of the new MINI model family and make the cars even more fun to use.

Leipzig. The start of MINI Countryman production marks a number of firsts and milestones for BMW Group Plant Leipzig: for the first time, a MINI model is being made in Germany – on the same production line as the BMW 1 Series and 2 Series. It’s all made possible by the plant’s flexible structures and development. Over the last five years the BMW Group has invested €700 million to ready Leipzig for increased vehicle volumes and adapt it for MINI-specific requirements. By the end of 2024 the workforce in production will increase by over 900. In addition, the new MINI Countryman is a catalyst for innovations in sustainable production.

“By launching production of the MINI Countryman here in Leipzig, we are introducing multibrand operations to our flexible production system,” explained Milan Nedeljković, Board Member for Production. “Plant Leipzig also offers a number of highlights in terms of resource conservation in production, providing further evidence of the successful rollout of our long-term masterplan: the BMW iFACTORY.”

Seamless integration through flexible structures 

When it comes to production of the new MINI Countryman, the BMW Group is building on the skills and extreme flexibility of Plant Leipzig to forge new pathways in manufacturing. Seamlessly integrated into the production process, the MINI Countryman now rolls off the same assembly line as the BMW 1 Series, BMW 2 Series Gran Coupé and BMW 2 Series Active Tourer.

Thanks to its flexible assembly structures, Plant Leipzig is in a position to produce two brands with three different drives – combustion, plug-in-hybrid and fully electric – all on the same production line. The third-generation MINI Countryman will be available with a petrol, diesel or fully electric powertrain, with the high-voltage batteries for the MINI Countryman Electric also being made in Leipzig. It will reach dealerships on 17 February 2024.

Investments and recruitment to increase production volume

The BMW Group has invested some €500 million in Leipzig to increase production volume for new models. Since 2018 the bodyshop, paintshop, assembly and logistics have undergone extensive additions and upgrades, taking production capacity up from 250,000 units previously, to as much as 350,000 units a year at present.

To adapt the production system to MINI-specific requirements, the BMW Group invested around €200 million. Initially approx. 100 MINI Countryman cars a day will roll off the production lines, rising to 500 during the course of next year – in addition to the almost 1,000 BMW cars already coming out of the factory every day. This will not only secure existing jobs but also create up to 900 new ones in vehicle production alone.

Electromobility and MINI production drive development

Another important milestone in the development and extension of Plant Leipzig is its transition to electromobility. “Leipzig remains electric,” says a cheerful Petra Peterhänsel, Plant Director. “With the BMW i3 and i8, we were at the vanguard of e-mobility at the BMW Group, and from 2024, we will be producing our next fully electric car: the MINI Countryman Electric. We will manufacture the high-voltage batteries for it in-house as well.”

Starting next year BMW Group Plant Leipzig will run the entire production process for the current fifth generation of high-voltage batteries. This consists of three stages: cell coating, module production and battery assembly. The five cell coating lines, three module production lines and the first high-voltage battery assembly lines are all in the process of going into operation, with a second high-voltage battery assembly line scheduled for launch in 2024.

Capacity for e-component production has also been increasing, since 2021, making Plant Leipzig an important a supplier across the BMW production network. The parts are used in fully electric vehicles such as the BMW iX1, BMW i4, BMW i5 and BMW iX. E-component production in Leipzig currently employs over 800 people, and there are plans to develop it further, with investments totalling more than €800 million.

Sustainable materials and production 

The MINI Countryman Electric is a major step in the MINI brand’s transition to full electrification by 2030 and combines an electrified go-kart feel with a reduced environmental footprint. In developing the new model, the MINI brand’s responsible attitude was very much in the focus with regard to materials and production: chrome no longer features anywhere in the interior or exterior, and the light-metal alloy wheels are cast from up to 70 percent secondary aluminium. The permanently electrically excited synchronous motors are highly efficient and made entirely without rare earth minerals.

The interior is made purely from innovative, high-quality materials that are easy on the environment. The dashboard, door facias, floor covering and foot mats, for example, are made of recycled textiles. A high-quality alternative to conventional materials such as plastics, recycled textiles reduce CO₂ emissions along the value chain and require less water to manufacture.

Innovative painting method for contrast roof 

One of the striking design features of the MINI exterior is the contrast roof, which can be ordered in a different colour from the rest of the body. In the MINI Countryman it will be painted using a new, resource-friendly method known as overspray-free painting. Currently being readied for series operation, overspray-free painting does away with the excess paint – or overspray – generated by conventional painting methods and makes surfaces with more than one colour easier to produce, as they no longer require the laborious process of masking. Overspray-free painting also helps save CO₂ emissions, as exhaust air from the cabin requires less cleansing. Plus it requires considerably less conditioned air, i.e. air that is brought to a set temperature and humidity. As a result, less energy is needed to temper air and treat exhaust.

Another sustainable innovation operating at Plant Leipzig is the burner technology used to dry the paint on contrast roofs. Last year Leipzig became the first car plant in the world to pilot the new technology, which can run on not only natural gas but also hydrogen. The flexible burners can burn hydrogen (H2), natural gas (methane – CH4) or a mixture of the two and can even switch between them without having to halt operations. After successful tests, Plant Leipzig has now installed five hydrogen-capable bivalent burners for series operations, which are now being used for the contrast roof of the MINI Countryman. Plans are in place to convert further burners in the paintshop to bivalent operations.

Plant Leipzig – Built for sustainability

At Plant Leipzig, the focus has always been very much on efficient processes and a long-term strategy for energy generation and consumption, ever since planning began. “Sustainability is in the DNA of BMW Group Plant Leipzig. There’s one example that everyone can see: our four wind turbines, which generate electricity for the plant,” Petra Peterhänsel explained. They were erected in 2013 and deliver 10 MW (generating approx.  25 GWh/year). The second milestone came in 2017, when the battery storage farm went on stream. Equipped with up to 700 second-life high-voltage batteries from BMW i3 vehicles, it offers interim electricity storage for energy from the wind turbines and elsewhere, helping to optimise local energy management and stabilise the grid.

“Our vision at Plant Leipzig is to decarbonise production as far as possible by replacing fossil fuels with green hydrogen,” said Petra Peterhänsel, explaining the long-term focus of the facility. This will require sufficient green hydrogen from a grid. A regional hydrogen grid is currently in planning, with Plant Leipzig set to benefit.

Leipzig. The BMW Group continues to invest in e-component production at Plant Leipzig and in the future of the site. A leasehold contract has now been signed for an area of land outside the plant premises, on the northern industrial estate – which is also home to the existing facility. The new plot for use by BMW consists of 12 hectares in total, eight of which will be built on in the first stage of construction. This will produce a logistics hall for the current fifth-generation high-voltage batteries and an office building, both of which are due to reach completion in mid-2024.

To mark the start of construction of the Supply Centre North, Petra Peterhänsel, Plant Director, Jens Köhler, Works Council Chairman, Frank Hager, Head of Production for High-Voltage Batteries, Clemens Schülke, Mayor and Alderman for Business, Labour and Digital in the City of Leipzig and Anja Hähle-Posselt, Director of the Office for Economic Development of the City of Leipzig, were joined by Karsten Dickerboom, representing the construction company Max Bögl Stiftung & Co KG, to perform the symbolic turning of the first sod.

Building the future

“These days car production is just as much a part of Leipzig’s economic DNA as the trade fair. We’re delighted that an already strong cluster is now growing further. What’s more, the focus will be on an eco-friendly footprint throughout. With this extension, BMW is sending out a clear signal around Leipzig as a base and electromobility. We are happy to partner the company and support the positive development of these areas,” said Mayor Clemens Schülke.

Plant Director Petra Peterhänsel also sees the transition to electromobility as an important building block in the plant’s development: “Leipzig continues to power ahead. Making the BMW i3, we were the BMW Group’s pioneer in electromobility. Now, with the development of e-component production and the upcoming launch of the MINI Countryman, the future is already taking shape.”

Investment in the transition to electromobility

In the first stage of construction, a warehouse, a two-storey office building and a loading tunnel with a combined gross area of 38,000 m² will be erected. There are also plans for a second construction stage, which will take the total investment to as much as 100 million euros. When all the construction work is complete, the new buildings at the Supply Centre North will provide workplaces for approx. 500 employees.

By 2026 the BMW Group aims for at least one in three new cars sold to be fully electric, so the need for high-voltage batteries will increase. Plant Leipzig is already a cornerstone in supplying e-components for the production network and provides one in three battery modules for the BMW Group’s fully electric vehicles. These include the BMW iX1, the BMW i5 and the BMW iX. With the new hall as a logistics centre for high-voltage batteries, Plant Leipzig is embracing this role even further, with a building that meets all the structural requirements for handling high-voltage components.

Beyond compliance: Stringent environmental standards

Planning the logistics hall, the team applied stringent environmental standards that go above and beyond legal requirements. The buildings will be powered not by fossil fuels, for example. Photovoltaic systems on the roof of the hall will generate approx. 3,000 kW in peak operations. In addition the hall will be heated by a heat pump. The office building will have a green roof, and trees at strategic points along the façade will keep indoor temperatures cool when the weather outside is hot.

The outside space will be landscaped with over 5,700 new shrubs and trees. This will continue the City of Leipzig and the BMW Group’s efforts to add to the green ring around the plant on the Northern Industrial Estate. Outdoor areas will be illuminated by insect-friendly lights, and parking spaces will be equipped with electric charging points for cars and trucks so that electric heavy goods vehicles can operate between the plant and warehouse.

E-component production as the powerhouse for the future of Leipzig

One of the drivers behind the extensive additions that are currently being made to Plant Leipzig – both on the premises and off – is e-component production. Measures will safeguard existing jobs and increase the number of new ones. At the moment more than 800 employees work in e-component production in Leipzig, rising to over 1,000 by 2024. Further jobs will be created with service providers.

From next year BMW Plant Leipzig will run all three stages of the high-voltage battery production process: cell coating, module production and high-voltage battery assembly. E-component production capacity has been steadily increasing since 2021, and at present battery cells are coated and assembled into modules there. One in three battery modules for fully electric vehicles by the BMW Group already comes from Leipzig today, and a battery assembly system is currently under construction, expected to go on stream early next year. The BMW Group is investing up to 1 billion euros in extending e-component production at Leipzig.

With BMW i3 production now phased out, 2024 will see Plant Leipzig launch its next fully electric model: the new MINI Countryman. The crossover will come with a choice of combustion engines or a fully electric drive, the high-voltage batteries for the latter being made directly in Plant Leipzig’s workshops.

Leipzig. An era is coming to an end at the BMW Group plant in Leipzig. The serial production of the BMW i3 is now to come to an end, some eight and a half years after it was launched. A source of inspiration, a driver of innovation, a pioneer of locally emission-free driving pleasure: The list of attributes that have accompanied the BMW Group's first large-series production automobile with fully electric drive since its debut in 2013 is long. The BMW i3 (combined power consumption: 16.3 - 15.3 kWh/100 km according to WLTP, 13.1 - 14.0 kWh/100 km according to NEDC, CO₂ emissions: 0 g/ km) started out as an exotic specimen on the still barely tapped market for electric vehicles, developed into a classic with unmistakable charisma already in the course of its production period and goes down in the company's history as a pioneer of sustainable mobility.

For the BMW Group Plant Leipzig, the farewell to the BMW i3 is linked to the start of a new chapter in electric mobility. In a seamless transition, further e-drive components will be manufactured there with immediate effect in addition to producing high-voltage battery modules, which is already being done since May 2021. And already next year, the next generation of the MINI Countryman will be manufactured at the same location - with a fully electric drive, among other things. In this way, the electric mobility expertise of the workforce, which has been built up over the past years, will be used and advanced further. At the same time, the BMW Group Plant Leipzig becomes the first location in the company's global production network where BMW and MINI models are manufactured together.

The final anniversary: 250 , 000 units of electric driving pleasure made in Leipzig.

The BMW i3 ends its production run with an impressive homerun. Just a few days ago, the 250,000 unit of the compact e-vehicle was produced in Leipzig. This makes the BMW i3 the world's most successful electric vehicle in the premium compact segment. And contrary to what might be expected for a model that is being phased out, its popularity did not wane as it matured.

The BMW i3 has been sold in more than 74 countries around the world. In many markets, it achieved a significantly higher market share in the electric vehicle segment than the BMW brand in the area of conventionally powered cars. It also succeeded in inspiring additional target groups in the premium mobility offers from BMW. In the early years, more than 80 per cent of all BMW i3 buyers were new customers for the BMW Group.

The enduring appeal of the BMW i3, which is manufactured exclusively at the Leipzig site for the entire global market, is also due to its especially individualistic character. Its independent vehicle architecture consists of a drive module as an aluminium chassis, which carries the e-drive, the suspension and the high-voltage battery as well as a passenger cell made of carbon fibre-reinforced plastic (CFRP) called the life module. This design, developed from the outset for pure e-mobility, made possible a particularly generous amount of space in the interior and a cockpit and centre console design which is both high-quality and very advanced. The same applies to the exterior design, which is still groundbreaking in its ninth year of production, and which is dedicated less to fashion or status than to technological avant-gardism.

Visionary technology standard-bearer with great symbolic power.

These characteristics have not only made the BMW i3 into a trailblazer for the transformation to CO₂-free mobility, but are also proof of how innovative the BMW Group is in a wide range of areas. "The BMW i3 has great symbolic power," says Oliver Zipse, Chairman of the Board of Management of BMW AG. He describes the development of the BMW i3 as a prime example of the "BMW way". This is characterised in particular by the courage to "pioneer topics, to do something different and not just follow the mainstream". This mindset continues to endure, according to Zipse, because "even the BMW iX, which is quite surprising in its capabilities, has its origins in this corporate culture".

The employees involved in manufacturing the BMW i3 at the BMW Group Plant Leipzig know all too well what this culture means in practice. After all, the BMW i3 was a visionary technology standard-bearer from day one, and not just because of its electric drive. With its Life-Drive architecture, it also set new standards in the field of intelligent lightweight construction. In Leipzig, innovative processes unique in the automotive industry have been established for moulding large-format car body parts from the particularly lightweight high-tech material CFRP. Today, the BMW Group has unique expertise in the industrial use of carbon fibre in body construction and aluminium in designing chassis components.

"The BMW i3 is a true pioneer and the epitome of pioneering spirit," says Milan Nedeljković, Member of the Board of Management for Production at BMW AG. "Thanks to the BMW i3, the Leipzig plant became the birthplace of e-mobility at BMW." With the expansion of the production of e-drive components, the Leipzig plant will remain "electric" in the future, says Nedeljković. "It will become the hub for electric mobility and supply our production network worldwide with components."

Innovation driver for e-mobility and multiple award winner.

Thanks to its model-specific technology developments, the BMW i3 has also become an innovation driver for the BMW and MINI brands in numerous other areas. The 135 kW/184 hp electric motor of the BMW i3s (power consumption combined: 16.6 - 16.3 kWh/100 km according to WLTP, 14.6 - 14.0 kWh/100 km according to NEDC, CO₂ emissions: 0 g/km) has been delivering urban driving fun and locally emission-free go-kart feeling in MINI style since 2020. The purely electric MINI Cooper SE (power consumption combined: 17.6 - 15.2 kWh/100 km according to WLTP, 16.9 - 14.9 kWh/100 km according to NEDC, CO₂ emissions: 0 g/km) has since become the most popular model variant of the British brand.

Originally developed for the BMW i3, the fifth generation of BMW eDrive technology is now being produced. It is used in numerous purely electric and plug-in hybrid models from BMW and MINI. The ramp-up of electric mobility will continue in the coming years. By 2030, every second BMW Group vehicle sold worldwide is to be fully electric.

The BMW i3 has received numerous awards during its production period. In Germany, it was awarded the "Green Steering Wheel” already in 2013, followed three years later by the "Golden Steering Wheel", also awarded by "Auto Bild" and "Bild am Sonntag". The design, vehicle concept, interior, sustainability, value retention and connectivity technology of the BMW i3 received further national and international awards and public survey successes. These include class victories in the competitions of the magazines "Auto Zeitung" and "auto, motor und sport", awards as "UK Car of the Year", "Green Car of the Year", "Classic of the Future" and "Swiss Car of the Year" as well as the "World Car Design Award", the "iF gold product design award" and the French "Trophée de l'argus".

Rethinking mobility: The holistic approach of the BMW i brand.

In addition to the all-electric drive, the BMW i3's outstanding eco-balance also stems from the choice of materials, which is fully geared towards sustainability and resource-conserving production. It was the first BMW Group model to receive an ISO certificate issued by independent auditors at the time of its market launch, confirming its optimised environmental performance throughout its entire life cycle.

Partly recycled raw materials are used for its outer skin made of thermoplastics. The plastic used in the interior is made op of 25 percent recycled material. The textiles used for the seat surfaces are made entirely from recycled fibres. The door panels of the BMW i3 are made of kenaf fibres. Eucalyptus wood from certified cultivation in Europe serves as the raw material for parts of the instrument panel.

The holistic concept for sustainability also includes the extensive use of renewable energy in the production of the BMW i3. Four wind turbines on the site of the BMW Group plant in Leipzig supply the electricity needed for its production. At an early stage, they made the Saxon location a pioneer for CO₂-neutral vehicle production, which has been standard in all BMW Group plants around the world since last year.

In addition, the BMW i brand has provided impetus for sustainable driving pleasure and a comprehensive transformation to CO2-neutral mobility in many ways and far beyond the development of electrically powered vehicles. These activities include the urban car-sharing service DriveNow (called SHARE NOW today) which for many users is the ideal opportunity to come into contact with electric mobility for the first time, as well as the services now known as BMW Charging and MINI Charging for convenient charging at home and for easily accessing public charging stations, and the BMW Group's participation in the European fast-charging network Ionity.

The perfect introduction to the world of e-mobility - and a reliable endurance runner.

For many customers, the BMW i3 became a constant companion early on in urban settings, for the daily commute and often far beyond. The frequent drivers among the "early adopters" above all praise the low energy and maintenance costs, but also how reliable the vehicle is and the cycle stability of its high-voltage battery. They report on brake pads that have not had to be replaced even after more than 250,000 kilometres, because a large part of the deceleration power is provided by recuperation when driving the BMW i3, and of the impressive long-term quality of the high-voltage battery, which leads to only a negligible reduction in range even after similarly long running times. The BMW Group took this positive experience as an opportunity to increase the maximum mileage associated with the eight-year warranty period for the battery from 100,000 to 160,000 kilometres at the beginning of 2020.

The BMW i3's high-voltage battery has undergone continuous development since its market launch, doubling its storage capacity while retaining the same installation space. With a cell capacity of 120 ampere hours (Ah) and a gross energy content of 42.2 kilowatt hours (kWh), it now enables ranges of up to 307 kilometres (BMW i3) according to WLTP.

The high-voltage batteries developed and produced by the BMW Group are used in other areas as well. Examples of this are the Streetscooter vans used by the German postal service and the city buses of the Turkish manufacturer Karsan, as well as motorboats with electric drives of the Torqeedo brand, for which they also serve as a source of energy. In addition, BMW i high-voltage batteries are used as stationary energy storage systems for electricity generated from renewable sources such as wind or solar power. The BMW Group plant in Leipzig also has such an energy storage farm. It consists of 700 interconnected BMW i3 high-voltage batteries in which the electricity generated by the four wind turbines on the plant site can be stored.

Locally emission-free, elegant and exclusive: The HomeRun Edition of the BMW i3s.

On its home stretch, the BMW i3 once again showcases the elegant and extravagant side of its character that has already been the subject of several limited special models. The BMW i3s HomeRun Edition, was treated to a Frozen paint finish from BMW Individual for the first time. This premiere is associated with a maximum of exclusivity: Only ten units of the BMW i3s HomeRun Edition have been produced.

An an exclusive for the BMW i3s HomeRun Edition, two new BMW Individual paint finishes have been added to the range: Frozen Dark Grey and Frozen Dark Red II. In addition the HomeRun Edition includes 20-inch light-alloy wheels in a double-spoke design, an electrically operated glass roof, solar control glazing and Adaptive LED headlights. The special models also come with the particularly high-quality Suite interior design, which includes Vernasca Dark Truffle leather upholstery, a leather instrument panel, a leather steering wheel with galvanised trim, a Carum Grey roof lining, Ambient lighting and the welcome light. Other options include heated seats, comfort access, alarm system, Real Time Traffic Information, Concierge Service, Park Distance Control and rear view camera. Also included are the Comfort package and Driving Assistant Plus, the Professional navigation system, telephony with wireless charging, the Harman Kardon hi-fi speaker system and online entertainment with music flat rate.

The production of the ten special models was a final highlight not only for the employees involved in its production at the BMW Group Plant Leipzig. Customers of the special models were able to witness the completion of the vehicles in the assembly hall for themselves.