Munich / Paris. The BMW Group and Mistral AI are partnering to advance the use of AI in crash simulation. The aim is to improve quality, accuracy and speed in complex engineering tasks. The collaboration marks a first step towards scaling domain-specific AI across further areas of vehicle development and the BMW Group value chain.

Munich. BMW Group Plant Munich is approaching the biggest milestone in the transformation process: series production of the BMW i3, the second model in the Neue Klasse range, gets underway here in August. This marks the start of the rollout of the Neue Klasse within the BMW Group’s global production network.

“We have been making rigorous preparations. With the BMW iFACTORY we have devised a consistent, strategic framework for our production,” explains Milan Nedeljković, Member of the Board of Management of BMW AG, Production. “We have paved the way for the upcoming start-ups in all our plants and have invested heavily in technologies, digitalisation and AI.”

BMW Group Plant Munich has undergone extensive modernisation in recent years. The result is a plant that now works even more efficiently, flexibly and digitally, and is optimally positioned for the requirements of electric mobility and the Neue Klasse.

But that’s not all: as of 2027, the Munich plant will exclusively produce all‑electric vehicles and thereby achieve a further boost in efficiency. This is assisted by proactive planning, close collaboration with development teams and suppliers, as well as modern production technology in the new structures. “We have considerably reduced production costs over recent years. With the start of production of the BMW i3, we will reduce overall production costs at the Munich plant by a further 10 per cent, bringing them below the level of the current vehicle generation,” says Peter Weber, Head of BMW Group Plant Munich. In addition to optimised production processes and targeted automation and digitalisation, the new vehicle architecture of the Neue Klasse also ensures efficiency.

Plant Munich is investing around 650 million euros in its transformation into a fully electric production site.

Highly efficient production at historic site

Plant Munich has been consistently reinventing itself for more than 100 years – from a location outside the city to today’s site surrounded by it. The facility has undergone a fundamental process of redevelopment for the Neue Klasse – with production of up to 1,000 vehicles a day continuing during this period. A new body shop and state-of-the-art vehicle assembly including new logistics areas were set up on an area spanning around a third of the plant’s footprint. Extensive updates have also been made to existing technologies.

Plant manager Peter Weber highlights what the workforce has achieved: “The people at the factory played an essential role in making this transformation a success. With their high level of expertise, enthusiasm and tremendous dedication, our employees have shown that world-class industrial production is possible even under the toughest conditions. The BMW i3 is just the beginning – several Neue Klasse models will be manufactured in Munich in the future, including the BMW i3 Touring.”

A vision for all technologies: the BMW iFACTORY

The BMW iFACTORY focuses on the areas of efficiency, sustainability and digitalisation. Within this framework, the company’s plants around the world are implementing site-specific solutions and, in so doing, strengthening the company’s resilience as well as its ability to deliver reliably at any time and worldwide. This vision has now also been consistently implemented across all technologies at BMW Group Plant Munich.

“We have rethought the entire value stream from supplier to finished customer vehicle. We have looked at every single process in detail and made optimisations. Now our plant is even more efficient, more flexible and even more digitised than ever before. We are thereby safeguarding the future viability of the plant,” adds Peter Weber.

In the press shop, steel and aluminium boards are turned into tens of thousands of components on highly automated press lines daily. Uniform press and tool standards across the global production network result in efficiencies on many levels: installation and integration of the systems are standardised, tools for the presses can be swapped within the network, and employees can work at various locations and help each other. An AI-assisted camera system supports quality control before an underground transport system moves the parts to the body shop. Output has increased significantly compared with previous structures. Cuts of steel and aluminium are collected, sorted and then used to manufacture new steel or aluminium coils.

Plant Munich has set up a new body shop for the Neue Klasse featuring systems planned and realised using a virtual twin. A total of 800 new industrial robots take care of the joining processes here; decreasing the number of joining processes to five reduces process complexity. With an automation rate of around 98 per cent, robots perform the majority of standardised processes. Automated surface inspection (ASI) assists with quality assurance.

In the paint shop at Plant Munich, digital and AI-assisted systems control central quality processes. Automated surface inspection (ASI) uses cameras and artificial intelligence to detect even the most minor deviations on the surface and documents them digitally. Automated surface processing (ASP) works on the variations detected directly during the running process. To purify the exhaust air, the paint shop uses the energy-efficient, electrically powered eRTO process. This is complemented by heat and energy recovery as well as water-saving cycles.

What once was the home of engine manufacturing at BMW Group Plant Munich has become a new assembly area for the Neue Klasse. The assembly area is set up for end-to-end digital processes: vehicles, systems and tools are interconnected and digital live tracking and automated inline quality checks support employees in the assembly line process. During assembly already, the BMW i3 digitally transmits the status of up to 20,000 features to the production system. Ergonomic workstations, height-adjustable systems and simplified processes lighten the load for employees, while targeted training supports new digital fields.

Aspart of the transformation, logistics at BMW Group Plant Munich has focused squarely on efficiency and direct integration of production. The logistics department at the Munich plant moves around 2.5 million parts every day; in future around 70 per cent of these parts will be delivered directly to the assembly workstations. This will reduce internal transport distances, save space and accelerate supply to the production lines. This is made possible by a multi-storey building structure developed specially for the plant’s city location. Delivery is at ground level and then conveyor technology transports the parts to the right levels, where they are distributed directly to the assembly workstations. This enables the principle of direct delivery to be applied systematically even in a multi-storey plant. At the same time, the level of automation in logistics has been significantly increased. Automated supply systems, smart transport robots and driverless transport systems will handle around 60 per cent of supply tasks in the future. A digital logistics control station manages all processes centrally, ensuring transparency and data-driven optimisation.

Unique to Plant Munich is the in-house seat manufacturing facility. It is a “plant inside a plant” and takes on a central role for quality assurance and expert evaluation within the production network. The seats for all versions of the models produced in Munich are manufactured here and delivered to vehicle assembly directly and “just in sequence”. The in‑house seat manufacturing facility is regarded as the benchmark for quality assurance across the BMW Group. Modern, largely automated processes ensure seamless quality control. This is complemented by fully automated end-of-line checks, including for safety-relevant components. The seat manufacturing facility also systematically strengthens the BMW Group’s in-house expertise. It serves as a competence centre and innovation hub, tests new materials, technologies and manufacturing concepts, and supports the evaluation of costs, quality and production processes – making an impact far beyond the Munich location.

Global network, regional value creation: high-voltage batteries and e-drive

With the new assembly plant for high-voltage batteries in Irlbach‑Straßkirchen (Lower Bavaria, Germany) around 90 minutes away, the BMW Group is significantly boosting value creation in the Bavaria region. In keeping with the “local for local” approach, Irlbach-Straßkirchen will deliver high-voltage Gen6 batteries to the Munich plant as well as other German locations. Here, the batteries will be installed in the BMW i3. Manufacture of the high-voltage batteries combines a rigorous zero-defect approach with the latest production technologies, which were developed at Bavarian pilot plants. With seamless inline quality controls, digital twins and the systematic use of artificial intelligence, the BMW Group is setting new standards in battery production.

The Gen6 e-motor for the BMW i3 is produced at BMW Group Plant Steyr in Austria – a location that has been manufacturing drivetrains for over 40 years. With the first e-motor in the portfolio, the plant is developing its role as a prime example of technology openness. All core components of the highly integrated e-drive – from the rotor and stator to the inverter and transmission – are produced on-site. New production lines and state‑of‑the‑art clean room environments have been set up for this. The aluminium foundry at BMW Group Plant Landshut supplies the e-motor housing for Plant Steyr.

Debrecen. The BMW Group has entered the final phase before the first Neue Klasse model rolls off the assembly line. Series production of the new BMW iX3 will get underway in late October at the BMW Group plant in Debrecen, Hungary, as the newest, most innovative manufacturing facility in the company’s global production network officially begins work.

“The start of series production for the BMW iX3 signals a new era of automotive manufacturing. Our new plant in Debrecen has been designed and built fully in line with our strategic vision of the iFACTORY. Digital from the very beginning, the plant will offer a new dimension in efficient production without fossil fuels,” says Milan Nedeljković, member of the Board of Management of BMW AG responsible for Production.

The BMW iFACTORY represents a strategic vision of production, built on streamlined, efficient structures, responsible resource management, economical use of cutting-edge digital innovations and a strong focus on employees. The BMW Group has also registered new patents for a large number of innovative systems and processes at Plant Debrecen.

“We have taken on the challenge of building a completely new vehicle as the first job at an entirely new plant – and doing so in the leanest, most efficient way possible. We have simplified processes, reduced complexity, digitally validated each individual operation and systematically leveraged expertise across our global network. The result is this plant, with its efficient production, innovative processes and the flexibility to integrate additional models,” says Hans-Peter Kemser, head of BMW Group Plant Debrecen.

As with any new model, capacity for the new BMW iX3 will be gradually ramped up in stages after the start of production. Spearheading the arrival of the Neue Klasse, the iX3 showcases the latest design and technology innovations that will define the brand's entire model range in the future. Between now and 2027, the technologies in the Neue Klasse will be integrated into 40 new models and model updates.

From virtual factory to reality

The guiding principles of the BMW iFACTORY have been fully implemented in the technologies employed at the new BMW Group plant in Debrecen. For example, Plant Debrecen was planned and built digitally from the outset, and celebrated its virtual start of production back in March 2023 in the BMW Group’s Virtual Factory. This approach allowed every operation to be tested virtually in advance, enabling production lines to be installed in the buildings exactly as in the digital twin.

Optimal processes for all plant technologies

With an optimised value stream and efficient systems, the press shop guarantees a high level of productivity. The BMW Group continues to follow its proven strategy of using the same tools and presses throughout its global network. This optimises capacity utilisation within the network by allowing press tools to be deployed at multiple locations and enabling staff to be trained in-network.

The body shop, in particular, benefits from prior digital planning and validation. Every process detail was digitally simulated in advance to determine the ideal value stream and ensure that each of the nearly 1,000 robots was optimally positioned. From the outset, close collaboration between development and production teams led to high production efficiency and maximum customer benefit. For example, the number of joining methods was significantly reduced, lowering overall complexity. Design features integrated early in development are also evident in the details of the Neue Klasse, such as the invisible door seal. This creates a visual connection between the window and the door, resulting in a unique look. In addition, maximising the space available for the battery in the body structure – and thus the size and performance of the battery – directly benefits the customer.

At BMW Group Plant Debrecen, the paint shop plays a critical role in significantly reducing the CO₂e footprint of the BMW iX3. Production of the new BMW iX3 will generate a total of about 80 kg CO₂e (scope 1/2 emissions). This figure covers CO₂e emissions from Plant Debrecen, as well as in-house parts production at other BMW Group facilities, including components manufactured in Landshut, for example. This represents a reduction of approx. two-thirds compared to production of existing BMW derivatives. For Plant Debrecen alone, this approach will reduce CO₂e emissions from the manufacture of a vehicle, including its high-voltage battery, by around 90% – to about 34 kg CO₂e (when operating at full capacity, compared with other BMW Group facilities).

Paint shops typically rely on gas to reach the high temperatures (up to 180 degrees Celsius) required. Plant Debrecen will be the BMW Group's first car plant supplied exclusively with electricity from renewable energy sources during normal operation, i.e. without using fossil fuels such as oil or gas. Because of its high energy demands, the paint shop is the most important factor in significantly lowering Plant Debrecen’s CO₂e emissions. In the paint shop alone, using electricity from renewable sources reduces annual CO₂e emissions by up to 12,000 tonnes. About a quarter of the plant's annual power needs will be supplied by the 50‑hectare on-site photovoltaic system. Surplus solar energy, such as that generated on non‑working days, is stored in a 1,800 m³ thermal storage system with a capacity of 130 MWh.

The paint shop also uses an energy recovery system. A heat grid was successfully implemented in the design of the new paint shop, delivering additional energy savings of up to 10%. This innovative concept combines multiple measures for efficient energy recovery from the compressed air supply, drying ovens and cooling systems. The recovered waste heat is then used to preheat the water circuit.

In addition, a thermal storage system – holding 1,800 m³ of water, with a capacity of 130 MWh – stores surplus energy from the photovoltaic system during off-peak periods and supplies it as heat during peak demand.

Full digitalisation of production processes further boosts assembly efficiency. The AIQX (Artificial Intelligence Quality Next) IT platform developed in-house at the BMW Group is a key component of the BMW iFACTORY. AIQX uses sensors and camera systems along the production line to automate quality processes. AI evaluates the data and provides real-time feedback to employees on the line. Looking ahead, vehicles on the line will also become active, connected participants in the industrial IoT (Internet of Things) ecosystem. They will conduct self-analysis, interact with plant employees in real time and automatically share and document relevant messages, using tools such as on-board cameras and IT systems. The equipment, tools, components and every BMW in the assembly halls are already digitally connected to the BMW production system.

The building's “finger structure” – an optimised version of the design employed at BMW Group Plant Leipzig – allows 80% of parts to be delivered directly to the correct point of assembly on the line. All-electric in-house logistics also benefit from autonomous tugger trains, which transport high-voltage batteries directly from production to installation points, as well as Smart Transport Robots that autonomously deliver smaller components to the assembly line. By linking all internal and external databases, the entire logistics process achieves unprecedented digital depth, automating many previously manual, interconnected analysis tasks. Well-structured information is therefore available at any time and can be analysed instantly “at the push of a button”.

The BMW Group has created highly intelligent production processes for its new high-voltage batteries developed in-house. Plant Debrecen will be the first of five plants worldwide to begin series production of Gen6 high-voltage batteries. The production processes were initially developed and tested at pilot plants. Artificial intelligence, data analytics and constant knowledge sharing within the production network also play a key role in the ramp-up of production. Digital twins of production and comprehensive AI databases ensure optimisation of processes and employee training. A consistent zero-defect approach enables seamless in-line quality inspections and 100% end‑of-line monitoring. In line keeping with the “local for local” principle, high‑voltage battery assembly takes place directly on site, allowing the production teams to take advantage of infrastructure efficiencies and short distances.

Best of the best:
Plant Debrecen benefits from expertise at all production sites worldwide

BMW Group Plant Debrecen is the first production site in the company's network not tied to a specific primary plant. Instead, it serves as a network plant, combining best practices from various locations worldwide. A major advantage of this approach is that the plant’s current workforce of more than 2,000 employees can be trained within the network, allowing employee know-how from different locations, such as China, South Africa, Mexico, the US and, of course, Germany, to be shared. At the same time, employees throughout the global network gain the opportunity to share their technology insights in Debrecen and bring expertise in production of the Neue Klasse models back to their own location – creating a win-win situation for all the plants.

A long version with further details on all technologies is available as a PDF file in the downloads section.

Munich. Whenever vehicle production equipment fails at a BMW Group plant, every minute counts. The maintenance team must work quickly to identify and resolve the cause of the fault. Now, employees can ask the new digital AI assistant, “Factory Genius”, for help: It can suggest solutions for the specific system problem within seconds, reducing the time required for error diagnosis to a minimum.

“AI applications have become an integral part of modern production systems and are a key element of the BMW Group’s digital transformation. Factory Genius is an example of how generative AI, in particular, can streamline operations for everyone involved and enhance economic efficiency,” says Michael Ströbel, head of Process Management and Digitalisation, Order to Delivery at the BMW Group. But how exactly does the digital assistant, recently launched in its initial development phase, support maintenance staff?

Knowledge discovery tool

The tool essentially works like a search engine, quickly filtering relevant answers to specific user queries from a vast amount of data and user reports. However, this search function does not draw content and information from the internet, but from equipment manuals, quality data, internal fault reports and planning documents it was previously trained on. To keep the data management system up to date, it is regularly fed with new knowledge – for example, in the form of daily-updated shift-log data.

By integrating a Large Language Model, similar to those used in chatbots like ChatGPT and Gemini, Factory Genius is also able to understand language: The software can search data for relevant content within the appropriate linguistic context, providing more accurate results than a conventional search engine. In addition to displaying the top matches with links to sources, the assistant can also summarise the maintenance instructions found through contextual search in just a few sentences, if preferred. The user can then ask questions in a chat.

Collaborative in-house development

A pilot project in the body shop at BMW Group Plant Dingolfing laid the groundwork for this in-house development. Alongside the tool developed in Dingolfing in spring 2024, other BMW Group locations, including the plants in Spartanburg, USA, and Rosslyn, South Africa, were working at the same time on similar solutions through a transparent process. All were pursuing the same goal: improving access to information when faults occur or during scheduled training and maintenance. AI experts at the company’s Munich headquarters consolidated this expertise, integrating the plants’ diverse requirements to create a company-wide “best of” application. This can now be used globally in its initial development phase through an internal platform.

In addition to search and chat functionality, Factory Genius also features a translation function, enabling it to switch languages at any time to overcome language barriers. This functionality has proven extremely useful while building the new plant in Debrecen, Hungary, for example, since manuals are often not available in Hungarian.

Transferable methodology

The technology behind Factory Genius has the potential to be applied to other production use cases as well. The general approach enables integration of a wide range of documents and development of assistants tailored to different user groups. Thanks to its cloud functionality, the tool will also be rapidly available worldwide.

If you have any questions, please contact:

Julian Friedrich, BMW Group Plant Dingolfing, Head of Communications
Telephone: +49 8731 76 22020, Email: Julian.Friedrich@bmw.de

Benedikt Torka, BMW Group, Communications Production Network
Telephone: +49 89 382 32455, Email: Benedikt.Torka@bmwgroup.com

Change at the top of BMW Group Financial Services and BMW Group IT: As of August 1, Alexander Buresch will take over the leadership of the BMW Group’s financial services business. His successor as CIO and Senior Vice President BMW Group IT will be Franz Decker. 

Alexander Buresch began his career with the BMW Group in April 1998 at BMW Bank GmbH in Munich and has been responsible for the Group’s global IT since November 2019. Prior to this, he was responsible for the strategy and business development of the BMW Group in China, including the joint venture BMW Brilliance Automotive Ltd. (BBA). His predecessor, Gerald Holzmann, will retire on July 31 of this year.

The new CIO and Senior Vice President BMW Group IT will be Franz Decker, who has served since April 2022 as President & CEO of BMW Brilliance Automotive Ltd., overseeing the joint venture's sites in Shenyang and Beijing as well as the LingYue IT hub in Nanjing.

Birgit Böhm-Wannenwetsch will assume responsibility for BMW Brilliance Automotive Ltd. from Franz Decker. Before this new role in China, she was in charge of the Americas region for BMW Group Financial Services.

BMW Group Financial Services operates in over 50 countries worldwide through subsidiaries and partnerships with local financial institutions and importers. With nearly 8,500 employees, it is one of the leading financial service providers in the automotive sector. In 2024, the Financial Services segment achieved a pre-tax profit of €2.53 billion. Nearly every second new BMW and MINI vehicle is financed or leased through BMW Group Financial Services.

BMW Group IT drives the digital transformation of the BMW Group worldwide. With a clear focus on stable, secure IT systems and consistent customer orientation, it develops innovative software platforms and applications for all business areas. Through targeted industrialization of new technologies, BMW Group IT lays the foundation for future-proof business models. With six global IT and software hubs and employees from over 60 nations in 30 countries, it actively shapes the digital future of the company.

The joint venture BMW Brilliance Automotive Ltd. has been in existence since May 2003. BBA produces six model series for the Chinese market. In May 2024, the six millionth vehicle was produced at BBA.

Munich. Digitalization is one of the strategic top priorities for the BMW Group‘s Purchasing and Supplier Network. The BMW Group pursues a specific focus on generative artificial intelligence (GenAI) to increase the efficiency and long-term viability of the Purchasing and Supplier Network. That’s why the organization is accelerating its digital transformation, through developing innovative applications and strategic cooperation with the BMW Group’s IT hub in Romania.

“At the BMW Group, we consider AI to be more than just a technological innovation. We see it as a key element of the digital transformation,” emphasized Hendrik Lang, Senior Vice President Strategy, Digitalization and Sustainability, Purchasing and Supplier Network at BMW Group. “Empowering our people to use AI technologies is our top priority,” he added. A group-wide AI platform supports customized applications to optimize processes, increase efficiency and create innovative solutions. In these efforts, AI serves as a tool that completes certain tasks faster or automates subtasks, giving employees more freedom for creative and innovative thinking.

The BMW Group is building strategic AI expertise and developing specific AI applications for the Purchasing and Supplier Network at its IT hub in Romania. By the end of the year, the location will be home to a team of experts working on cutting-edge GenAI applications for internal processes worldwide. Founded in the thriving tech center of Cluj-Napoca in summer 2024 as a joint venture of the BMW Group and NTT DATA Romania, BMW TechWorks Romania is tasked with consistently expanding the BMW Group’s Europe-based software expertise according to long-term demands. BMW TechWorks Romania is closely integrated into the BMW Group’s global development and innovation landscape and benefits from Romania’s robust IT and software industry.

BMW Group Purchasing is actively driving forward the development and implementation of internal AI applications. The initial GenAI tools – including Knowledge Navigator, Offer Analyst and Tender Assistant – were introduced in Purchasing as early as 2024. These applications serve as central knowledge databases that assist in the analysis and comparison of supplier offers as well as tender creation and management. For example, Offer Analyst can perform repetitive tasks and significantly reduce the time required for each offer.

In late 2024, the BMW Group also introduced a central AI access point for the Purchasing and Supplier Network: the BMW Group’s AIconic agent system. This innovative AI solution transforms how teams search for and utilize information by combining cutting-edge natural language processing with intelligent algorithms. The multi-agent system ensures fast, precise data searches and customized processing results for individual users. Integrating different data sources guarantees comprehensive, targeted information retrieval that significantly outperforms previous search functions. With over 1,800 active users performing 10,000 searches, the AI solution has been exceptionally well-received in a short period of time, highlighting its value. “Our multi-agent system AIconic significantly increases employee efficiency and productivity while setting new standards for AI usage,” emphasized Markus Kronen, Head of GenAI in Purchasing and Supplier Network at the BMW Group.

The AIconic multi-agent system is continuously updated to meet the growing demands of the Purchasing and Supplier Network. A top priority is agentization, meaning AIconic will act not simply as a passive search tool but increasingly as a proactive one. The comprehensive agent system currently includes ten agents covering topics such as quality, purchasing and supplier data and purchasing process support. In the future, the application will perform certain tasks without human supervision, such as monitoring supply chain data, creating reports and identifying optimization potential. The next iteration will transform AIconic into an intelligent internal assistant that not only provides information, but also actively recommends actions and automates processes. To make the best use of AI solutions, the BMW Group provides digital training and special AI innovation spaces for employees at all levels. In doing so, employees acquire digital literacy and share their new skills throughout the organization. Clear governance provides a mandatory framework for training and implementing AI solutions, be it for internal applications or procuring external AI expertise.

AIconic is one of the first multi-agent use cases that the BMW Group has implemented on a central AI platform. It has been successfully established as a standard in the Purchasing division. The multi-agent system is based on the BMW Group AI Assistant, the central AI access point for the entire organization. As such, AIconic demonstrates how intelligent agent systems can be developed and deployed across the organization using the AI platform.

*The images displayed were generated using artificial intelligence.

If you have any questions, please contact:

Merete Wonneberger, Communications Purchasing and Supplier Network

Phone: +49-151-601-71430

Email: Merete.Wonneberger@bmwgroup.com

Florian Moser, Communications Purchasing and Supplier Network

Phone: +49-151-601-62847

Email: Florian.Moser@bmwgroup.com

Internet: https://newsroom.bmwgroup.com/global/en

Email: presse@bmwgroup.com

Munich, Germany and Pune, Bengaluru, Chennai, India. The BMW Group and Tata Technologies, a global product engineering and digital services company, are proud to announce the official launch of their joint venture BMW TechWorks India with offices in strategic talent hubs Pune, Bengaluru and Chennai. With the final signing of the contracts and the approval of the authorities, the joint venture will initially start with 100 employees at these three locations and rapidly scale to four-digit number of employees by the end of 2025, with a strong focus on attracting top-tier Indian talent. The BMW Group and Tata Technologies each hold 50 per cent of the shares in this JV.

BMW TechWorks India complements BMW Group’s global strategy by engineering seamless, scalable software solutions for next-gen vehicles and delivering leading digital experiences. Tata Technologies’ proven capabilities across the entire product value chain, from conceptualization to detailed engineering and turnkey SDV development, will drive key software projects for the BMW Group’s premium mobility solutions and facilitate access to India’s impressive talents.

At the heart of this collaboration is the ethos of “Engineer in India for the World”. India’s exceptional engineering and IT talent will play a pivotal role in developing strategic software solutions for SDVs, automated driving, digital infotainment, and automotive digital services.

In addition to automotive software, the joint venture will provide digital innovations for the BMW Group's Business IT. Consequently, BMW TechWorks India will expedite the digital transformation of the car manufacturer's global production network, along with enhancing its digital customer journey and sales processes. Another key area of focus will be the development of AI applications and platforms, which will increase the speed and efficiency of all core business processes.

The JV offers young Indian professionals an unparalleled opportunity to work on breakthrough technologies that will shape the future of mobility on a global scale. The JV's commitment to nurturing local talent and innovating next-gen automotive innovations reinforces India’s emergence as a global innovation hub in the automotive tech ecosystem. Aspiring talent can apply here to be part of the JV and innovate solutions that deliver a global impact.

Christoph Grote, Senior Vice President of Electronics and Software BMW Group expressed his enthusiasm on the establishment of the JV: “BMW TechWorks India is a significant addition to our global vehicle software development initiatives. India’s software talent will be a great asset for our Software-Defined Vehicles of the future. With agile processes and state-of-the-art tools, engineers at BMW TechWorks India will co-create innovative automotive digital experiences, such as automated driving and next-gen infotainment systems.” 

Alexander Buresch, CIO, and Senior Vice President of BMW Group IT commented: “With BMW TechWorks India, we are steadily advancing our international IT-Hub strategy and broadening our global Business IT presence. The partnership with Tata Technologies represents a strategically important step and provides excellent conditions for developing innovative software solutions along our value chain. We are excited to welcome Indian tech talents to join us in driving the digital transformation of the BMW Group.”

Warren Harris, CEO and MD of Tata Technologies, said: “Our joint venture with the BMW Group, BMW TechWorks India, underscores our deep expertise in Software-Defined Vehicles (SDV) and reflects our commitment to driving innovation in both automotive software and business IT. By leveraging Tata Technologies' strong brand presence in India, this JV will attract top talent and provide a platform to develop forward-thinking solutions that redefine the future of mobility. We are excited to partner with the BMW Group in engineering premium, software-driven vehicles, enhancing digital experiences, and accelerating their digital transformation journey.”

Nachiket Paranjpe, President of Automotive Sales at Tata Technologies, commented: "The rapid evolution of automotive technology is transforming the way vehicles are developed, with Software-Defined Vehicles at the forefront of this shift. At Tata Technologies, our deep automotive expertise and end-to-end solutions across the value chain – from concept and detailed engineering to manufacturing engineering and turnkey SDV development – position us perfectly to support the BMW Group in shaping the future of mobility. Through this joint venture, we will push the boundaries of automotive technology, creating vehicles that are not only cutting-edge but also deliver exceptional driving experiences to consumers worldwide."

Aditya Khera, CEO of BMW TechWorks India: “With the launch of BMW TechWorks India, we are establishing a world-class software hub that will play a critical role in the BMW Group's automotive software and business IT strategy. By combining the BMW Group's and Tata Technologies' leadership in software-defined vehicles and product engineering excellence, we are poised for innovation and growth, offering India's top talent the opportunity to shape the future of the BMW Group's mobility solutions“.

The management team of BMW TechWorks India is comprised of seasoned executives from both partner companies. Representing Tata Technologies are Aditya Khera as CEO and Sweta Girinatham as CFO of this JV. From the BMW Group, Oliver Scheickl holds the position of COO of Automotive Software in this new JV and Stefan Flader serves as COO of Business IT.

-------------------------End of joint press release --------------------

Global network for Software & IT-Hubs

For several years now, the BMW Group has been pooling its digital expertise at international locations, thereby securing its IT and software know-how for the long term. In total, more than 15,000 employees worldwide work in software development and Business IT for the BMW Group and its joint ventures. The locations span the entire globe: USA, Portugal, Germany, Romania, South Africa, India and China.

With the new joint venture BMW TechWorks India, the BMW Group sets another milestone in its growth strategy and strengthens its position as a leading company in the field of automotive software and business IT.

BMW Group in India

The BMW Group has been active in India since 2007 and employs around 650 people. BMW India’s headquarter is located close to New Delhi in Gurugram, which is also home to a training centre. Further activities include a production plant in Chennai, a spare parts warehouse in Pune and a dealer network in the country's major metropolises. In 2023, BMW Group India recorded the best annual result in its history with BMW and MINI selling 14,172 units (+18%) and BMW Motorrad selling 8,768 units (+20%). 

Munich/Spartanburg, USA. The BMW Group is exploring the use of humanoid robots in production for the first time. During a trial run lasting several weeks at BMW Group Plant Spartanburg, the latest humanoid robot Figure 02 from California company Figure successfully inserted sheet metal parts into specific fixtures, which were then assembled as part of the chassis. The robot must be particularly dexterous to complete this production step.

At the same time, using a robot can save employees from having to perform ergonomically awkward and tiring tasks. Together with Figure, the BMW Group is currently testing and evaluating how humanoid robots can be used safely in automobile production. This video shows the trial run in the body shop at BMW Group Plant Spartanburg: https://b.mw/Figure_02

“The developments in the field of robotics are very promising. With an early test operation, we are now determining possible applications for humanoid robots in production. We want to accompany this technology from development to industrialization,” says Milan Nedeljković, Member of the Board of Management for Production at BMW AG.

With the BMW iFACTORY, the vision for the production of the future, the BMW Group is always on the lookout for new technologies. Efficiency, digitalisation and sustainability are central to this vision to realisation. During the trial run, the BMW Group gained valuable knowledge of what requirements must be met in order to be able to integrate so-called multi-purpose robots in an existing production system. This includes how humanoid robots communicate with the system under real conditions. After the first use in automobile production, the experts at the BMW Group and Figure are collaborating to prepare Figure for future applications in production and continuing to develop the robots, based on the findings.

Figure 02 embodies the latest technological advances in robotics 

“We are excited to unveil Figure 02, our second-generation humanoid robot, which recently completed successful testing at the BMW Group Plant Spartanburg. Figure 02 has significant technical advancements, which enable the robot to perform a wide range of complex tasks fully autonomously,” says Brett Adcock, Founder and CEO of Figure.

According to the California company, Figure 02 is the world’s most advanced humanoid robot currently available on the market. The combination of two-legged mobility and advanced dexterity means that the Figure 02 is ideally suited for use in areas with physically demanding, unsafe, or repetitive processes, thereby improving ergonomics and safety for associates. Figure 02 boasts three times the processing power of its predecessor, improved voice communication, better cameras, microphones, and sensors, a high-performance battery, and fourth-generation human-scale hands with 16 degrees of freedom per hand and human-equivalent strength.

The robot is capable of fully autonomous execution of human-like and two-handed tasks requiring varied and dynamic manipulation, complex grasping, and coordination of both hands in unison. It is able place various complex parts with accuracy measured in millimetres and can walk dynamically leveraging efficienties of the robot’s design.

Currently, there are no Figure AI robots at BMW Group Plant Spartanburg, and there is no definite timetable established for bringing Figure robots to the plant. BMW Group will continue to work with Figure for data capturing and training capabilities for the Figure02 robots.

Munich / Cluj-Napoca. The BMW Group is expanding its global network of IT and software hubs with the opening of a new location in Cluj-Napoca, Romania. In cooperation with NTT DATA, BMW TechWorks Romania will become the hub for European IT and software projects and will accelerate the company's digital transformation.

"With BMW TechWorks Romania, we are strengthening our footprint in the EU and contributing significantly to the digital experience of our customers" explains Alexander Buresch, CIO and Senior Vice President of BMW Group IT and emphasizes: "Our global IT hubs secure our Business IT and software expertise in the long term and accelerate the implementation of our IT strategy based on latest technologies such as cloud innovations and AI.”

Partnership with NTT DATA

NTT DATA is a long-standing partner of the BMW Group and brings its extensive experience in agile software development and its outstanding network in the Romanian IT landscape to the joint venture.

“Our collaboration with the BMW Group is a testament to our mutual respect and shared vision for the future of the automotive industry. By combining our strengths, we are poised to deliver innovative and transformative solutions that will benefit our customers worldwide", says Chieri Kimura, EVP of NTT DATA, Inc., CEO EMEAL.

"BMW TechWorks Romania is driven by two strong partners, with the objective of becoming a reference for the digital transformation of the BMW Group’s industrial ecosystem. It is a mission of honour which NTT DATA received in the wake of a 30 plus years old valued partnership between our two companies”, underlines Maria Metz, CEO of NTT DATA Romania.

Ideal conditions for dynamic growth

The joint venture will more than double its workforce to 250 developers by the end of the year. In the long term, the aim is to reach a four-digit number of employees in order to consistently expand the BMW Group's global software expertise. The dynamic growth path is also reflected in ambitious business goals: the aim is to achieve double-digit million turnover by the end of the year.

Ralf Waltram, Vice President and Head of Global DevOps Hubs explains: “BMW TechWorks Romania joins a global network of IT hubs that already includes locations in Germany, South Africa, the USA, Portugal and China” and adds: “Cluj-Napoca, known for its innovation-friendly ecosystem, entrepreneurship, start-ups and high density of IT talent, offers ideal conditions for the joint venture”.

Focus on IT projects in the EU

The new IT hub develops central building blocks for IT projects with a focus on Europe:

• Connected Procurement: Highly complex supply chains and control systems require networked IT systems
• Digital Shopfloor: Modern production IT as the backbone of the BMW iFactory
• Direct Sales Model: Development of central IT components for the implementation of the BMW and MINI direct sales model in Europe

Innovation hub Cluj-Napoca

Marian Haus, COO BMW TechWorks Romania: "We want to attract qualified IT talent for our rapid growth in the coming years and are therefore particularly pleased about the excellent technical education at the universities in Cluj-Napoca and the city's lively tech scene.” Emil Petru, CEO BMW Techworks Romania adds: “"We are proud to be part of the BMW Group as of today and to play a decisive role in shaping the digital transformation of the company here in Romania."

In total, more than 9,400 employees worldwide already work in IT and software development for the BMW Group and its joint ventures.

Job opportunitites at BMW TechWorks Romania can be found here: https://www.bmwtechworks.ro/careers

Munich. BMW Group Plant Munich is making increasing use of applications with artificial intelligence (AI). AI is fast, reliable and easy to integrate into the various production processes and, coupled with smart data analytics and cutting-edge measurement technologies, it opens up new opportunities for more efficient vehicle production.

Robert Engelhorn, Director of BMW Group Plant Munich, is working to advance the application of these technologies: “At Plant Munich, it takes about 30 hours to manufacture a vehicle. During that time, each car we make generates massive amounts of data. With the help of artificial intelligence and smart data analytics, we can use this data to manage and analyse our production intelligently. AI is helping us to streamline our manufacturing even further and ensure premium quality for every customer. It also saves our employees from having to do monotonous, repetitive tasks.” As with any innovation, the key factor is effectiveness: “Our team in production are highly experienced specialists, so they are the best judges of whether an AI application can boost quality and efficiency at any given stage of production,” says Robert Engelhorn.

The options for using AI and smart data analytics are currently being tested in various areas of BMW Group Plant Munich. In some areas, the technologies are already in use in series production, such as the press shop and function validation.

Smart Data and AI in the press shop

The press shop at the BMW Group’s home plant in Munich turns more than 30,000 blanks a day into vehicle body parts. Since 2019 each blank has been given a laser code at the start of production so the body part can be clearly identified throughout. This code is picked up by the iQ Press system, which records material and process parameters – such as the thickness of the metal and oil layer, and the temperature and speed of the presses. The parameters are then related to the quality of the parts produced.

Uploaded to the cloud in real time, the data is immediately available in its entirety for the production team to gain a clearer picture of the manufacturing process. iQ Press data is an important tool for them, as it eliminates the need for each body part to be checked in minute detail, in quality control for example, and picks out only irregularities that require action.

Artificial intelligence also offers potential to identify recurring patterns in a process, based on the data collected, to support continuous optimisation. So, as well as improving the efficiency of production systems, iQ Press helps to further increase hourly output from the press shop.

Predictive maintenance in the body shop

Body shop robots are fitted with a combined total of over 600 welding tongs. If the tongs ever need replacing unexpectedly, it costs significant time and money. Moreover, many of the robots are difficult to access, so dismantling and replacing their tongs can take hours.

Until now, the condition of tongs has been monitored by eye, by a member of the production team. But in recent months, the maintenance specialists at Plant Munich have been fitting sensors to all the tongs to measure friction levels three times per shift and report any abnormalities. The data they produce is constantly evaluated by software, allowing potential machine failures to be predicted. Martin Hilt, Innovation and Digitalisation Officer at Plant Munich, explains: “Because we have the sensors and collect their data in a cloud, we can now monitor round-the-clock whether any maintenance work is needed. So, we can plan any replacements better and potentially schedule them for a production break.”

Dust particle analysis in the paint shop

Despite comprehensive cleansing systems, vehicle bodies can pick up dust particles as they make their way to the paint line. Though invisible to the human eye, the particles can affect the quality of the finish. Until now, potential defects have gone undiscovered after the painting process, revealed only by the automatic surface inspection. They then had to be reworked, or the bodies repainted completely.

Now, however, every paint shop system incorporates sensors that measure dust levels and allow the quality of paintwork to be predicted. “We can now tell quickly if the environmental parameters are not quite right at some point, either within the paint shop or in one of the buffer areas. It takes a lot of data to do this, which we collect throughout the process, evaluate historically and analyse in real time,” explains Martin Hilt.

Over the last few months, a further special sensor developed by Plant Munich has been measuring dust levels on body parts at the beginning of the painting process, before and after the emu feather rollers. In the future, when dust levels are too high, car bodies will pass through the paint shop untreated and be sent for further cleansing.

AI-based image recognition in assembly

AI projects in assembly mainly focus on automated image recognition. Here, the technology is used to evaluate images of a component and compare them in milliseconds with hundreds of other images from the same sequence. The system then identifies any deviations from the norm, such as parts that are incorrectly positioned or fitted, or absent.

At Plant Munich, automated image recognition allows the production team to identify whether the hazard warning triangle, wiper caps and door sills have all been correctly fitted to each car. Previously, small bubbles in the foil cover of a door sill were often enough to prevent the conventional camera gates from seeing if the logo on the door sill was correct. But now an associate photographs each part concerned in turn and can even use the mobile equipment to check parts that are more difficult to access. Distance, angle and light hardly have any effect on AI evaluations, which reveal within fractions of a second whether everything is in place or not.

The AI system is trained by associates. They start by photographing the component concerned from various perspectives and marking potential deviations on the images. This allows them to develop an image database that can be used to build up a neural network for evaluating the images. Evaluations are carried out fully automatically, and the machine decides by itself whether or not a part meets all the specifications.

RFID identifies components in the vehicle

Radio Frequency Identification (RFID) allows components to be identified automatically and contactlessly throughout the value chain. “Our goal is to save production workers from having to scan components manually, and simultaneously to streamline manufacturing even further by ensuring the right components are fitted to the right vehicles,” says Martin Hilt. RFID is currently being used in seat production at Plant Munich but will soon be used throughout the vehicle assembly as well.

Smart RFID labels required for the system are applied before the component leaves the supplier. They remain in place throughout production, allowing line-side antennae to pick up every labelled component within each car as it passes.

Function validation with the Comfort Access robot

Comfort Access was first introduced in the current BMW 3 Series. A small team from Electrics/Electronics Validation in Munich has now developed a special robot to validate its integration.

Vehicles with Comfort Access use three exterior antennae to generate a three-dimensional electromagnetic field around the car. When the driver enters the field, the system recognises the car key. At about 3 metres from the car, it switches the Welcome Light on to illuminate the area outside the driver’s door. At about 1.5 m, the doors unlock – and relock automatically if the driver walks away.

Until now, this special feature has been validated manually, with parameterisation in development alone taking two days per vehicle. The Comfort Access zones and the influence of production processes on them are then checked manually again in the plant, before production begins, taking into account the various country-specific requirements and equipment features, such as trailer couplings. All in all, it is a lengthy process and not always entirely accurate, given the multitude of different functions.

To solve the problem, the BMW Group and the University of Applied Sciences (HTW) in Dresden have developed a measurement robot that autonomously circles the vehicle several times in a pre-defined pattern to determine the strength of the magnetic field at various required points. Attached to the robot is a box containing the car key. The box can be set at different heights to reflect the different ways a driver might carry it: in their hand, their sports bag or a breast pocket, perhaps. As soon as the robot detects the vehicle electronics locking or unlocking the doors, its inbuilt Lidar scanner measures the distance between the key and the vehicle, and surveys the vehicle’s surroundings. The data that is generates goes straight to a central computer, where it is portrayed as a graphic.

The advantages of the system are obvious: “This robot is not only much faster, it’s also more precise. The results we obtain are highly detailed and, most importantly, objective. So we can even start validating the function before the car has its first test-drive,” explains Martin Hilt.

Vehicle location in the production system

The specialists responsible for product integration at Plant Munich ensure stable processes to deliver defect-free vehicles throughout. They are also responsible for integrating pre-series vehicles into production to allow a smooth official production launch with series quality right from the start.

“Since the start of this year, our specialists have been using a new app that notifies them as soon as the pre-series vehicle they are tracking reaches a specified point in assembly. It allows them to locate any car they want – so they can check, say, a particular combination of equipment features,” says Martin Hilt.

The new app not only replaces the manual process but also improves validation. In the future, it can also be used on series vehicles.