Munich/Wackersdorf. The BMW Group is relocating its Recycling and Dismantling Centre (RDC) from Unterschleißheim to the company’s Wackersdorf site, with a significant expansion. At the new location, a technologically state-of-the-art competence centre for circularity is being built, advancing vehicle dismantling and recycling expertise for the future. Commissioning is scheduled for early 2029.

“The circular economy is a key element of the BMW Group’s corporate strategy,” says Jörg Lederbauer, Vice-President Circular Economy, Spare Parts Supply High Voltage Battery and Electric Powertrain at the BMW Group. “Our new competence centre in Wackersdorf will be a core component of our circular value chain and will help make the mobility of the future more resource efficient. We want to find the best way to keep materials in the cycle, ensuring that resources retain their value for further use in the long term. This will also reduce our dependence on primary raw materials. At the same time, the use of high-quality secondary materials will continue to significantly lower our vehicles’ carbon footprint.”

For more than 30 years, at its current location in Unterschleißheim, near Munich, the BMW Group Recycling and Dismantling Centre (RDC) has developed methods aimed at achieving significant advances in the recycling of parts and the recovery of materials, and has tested them in practice. The insights gained by the RDC into the recyclability of components and materials, in line with Design for Circularity principles, are already incorporated into product development at the BMW Group. These insights also feed into the cooperation with PreZero, which the BMW Group recently entered into in order to leverage the strategic and economic potential of the circular economy in end‑of‑life vehicle recycling. 

The recycling industry’s global network also benefits from the work of the RDC. Around 3,000 businesses in 32 countries rely on a shared recycling database for information on how recyclable components can be disassembled cost-effectively and valuable materials efficiently recovered.

At the future site, process, material and technology development will be even more closely integrated with vehicle recycling operations. The new scope of activities at the Competence Centre Circularity includes the recycling of hydrogen vehicles, automation of dismantling processes and development of expertise in innovative shredding and sorting technologies.

The BMW Group sees Wackersdorf as the ideal new location for the Competence Centre Circularity, with BMW Group Plant Wackersdorf having embodied flexibility for decades: Housing cockpit production, the Rolls-Royce door and flap production centre, parts supply for overseas plants and the battery testing centre, the site has wide-ranging expertise and is firmly established within the BMW Group network.

“In recent years, the company has set a decisive course for the future of the Wackersdorf location. Throughout this process, the entire plant team has consistently demonstrated flexibility. Building the competence centre for circularity here provides our site with a broader foundation. In this way, we are tapping into an attractive, future-oriented area of activity,” says Stefan Betz, head of BMW Group Plant Wackersdorf.

“The company is systematically continuing its successful transformation. Establishing the new Competence Centre Circularity here represents an important strategic decision by the company in favour of the Wackersdorf location – and, above all, its employees. As employee representatives, we also supported this,” says André Mandl, Works Council Chairman for BMW Group Plants Regensburg and Wackersdorf.

“In Wackersdorf, BMW has been a strong partner by our side for many decades. We are delighted that the BMW Group is reaffirming its commitment to the location with this move. It sends a clear signal for our site and for sustainable future technologies,” says Thomas Falter, Mayor of Wackersdorf.

“The cutting-edge Competence Centre Circularity will make a major contribution to regional value creation and further development of the circular economy,” adds Thomas Ebeling, District Administrator of Schwandorf District. “In combination with the trechnology transfer centre planned for Wackersdorf by the Regensburg University of Applied Sciences and the University of Applied Sciences Amberg Weiden, close integration of business and academia on the circular economy will now also be possible. In this way, we are strengthening the region.”

Following the location decision, the detailed planning phase for the Competence Centre Circularity at the new site can now begin. The existing RDC in Unterschleißheim will remain fully operational until the relocation. The BMW Group will provide further information on the next steps in due course.

+++ From regional development powerhouse to the BMW Group's highest-volume vehicle plant in Europe – Record production in 2025: Plant hits 40-year high with 356,901 vehicles +++

+++ 8.7 million vehicles since start of production in 1986 +++
+++ Plant Director Armin Ebner: “Continuous efforts to increase competitiveness are the key to our success” +++

Regensburg. Plant Regensburg achieved a new production record of 356,901 vehicles in 2025, making it the BMW Group’s highest-volume car plant in Europe. Since the plant opened in 1986, 8.7 million vehicles have rolled off its production line. “With this record production, we not only reached a new all-time high in the plant’s 40-year history but also – as in the previous year – helped the BMW Group’s German plants build more than one million vehicles again in 2025,” says Plant Director Armin Ebner. “For 40 years, the plant has been a central development powerhouse for the eastern Bavarian region.”

Continuous efforts to increase competitiveness as key success factor 

“Continuous and consistent efforts to increase our competitiveness remain the key to our success. Every single day in Regensburg, we demonstrate that competitive production is possible in Germany,” adds Ebner. By implementing efficiency measures within its production system, BMW Group Plant Regensburg has lowered costs by more than a quarter since 2019.

“Digitalisation is an important lever for this,” says Ebner. Examples include the use of artificial intelligence in automated surface processing in the paint shop and for quality controls during vehicle assembly, or a cloud-based traffic control system for supplying parts. Since early 2025, new vehicles have also been able to navigate autonomously, without a driver, from the assembly line to the loading area.

More than 150,000 electrified models in 2025

More than 150,000 of the vehicles manufactured in Regensburg in 2025 were electrified – that is, either fully-electric vehicles or plug-in hybrids. The BMW X1 was the highest-volume model, with over 266,000 vehicles produced, while the BMW X2 accounted for more than 90,000 vehicles.

Over 55,000 vehicles remained in the company’s domestic market of Germany. More than half of the cars produced in Regensburg in 2025 went to customers in other European countries. More than 100,000 vehicles were shipped overseas.

Ebner is optimistic about the plant’s anniversary year: “With our attractive BMW X1 and BMW X2 models, we are producing exactly what our customers want, while continuing to operate three shifts around the clock.” Every 57 seconds, a new vehicle rolls off the assembly line. This currently adds up to more than 1,400 vehicles per workday, which are then delivered to customers around the world. Different types of drive train are flexibly manufactured on a single production line – from models with internal combustion engines to plug-in hybrids and fully-electric vehicles.

BMW Group Plant Regensburg – powering jobs across the region

As part of the settlement agreement with the City of Regensburg in the 1980s, BMW pledged to produce 400 vehicles per day and create 3,500 jobs. With the ramp-up and expansion of the plant in subsequent years, both employee numbers and production capacity increased: In 1991, the plant exceeded the 100,000-vehicle threshold for the first time, with around 128,000 cars manufactured. By 1999, it was building about 750 vehicles daily and more than 200,000 annually. In 2005, annual production surpassed 300,000 vehicles for the first time – with a daily output of around 1,000 units. Having assembled its one-millionth vehicle back in 1995, Plant Regensburg is set to produce its nine-millionth vehicle this year.

Employee numbers have also continued to climb: In 1988, the plant employed around 3,300 people. By 1991, that number had risen to about 7,300. Today, the BMW Group’s core staff at its Regensburg and Wackersdorf locations in eastern Bavaria comprises around 9,000 employees, including approximately 380 apprentices.

This makes the plant a significant economic factor and employer across the region. Ebner: “Our employees’ commitment, their innovation mindset and their forward-looking decisions have shaped BMW Group Plant Regensburg into what it is today: a driving force and economic engine for the entire region.”

40 years of BMW Group Plant Regensburg – overview of milestones:

1983      Decision, contract signing for establishment of Regensburg site

1984      Groundbreaking with Minister-President Franz-Josef Strauß;
              construction of production halls begins

1985     Topping-out ceremony

1986     Start of production for BMW 3 Series (E30); around 1,300 employees

1987      Paint shop commissioned;
first networked computers in assembly usher in the computer age

1988     Around 3,300 employees

1990      Body shop commissioned

1991      Annual production: around 128,000 vehicles, surpassing the 100,000 mark;
around 7,300 employees

1995      Production milestone: 1,000,000 vehicles manufactured in Regensburg

1997      Press shop completed

1999      Annual production exceeds 200,000 vehicles for the first time;
              more than 8,700 employees

2001      Groundbreaking for plant expansion: paint shop and body shop

2005      Annual production exceeds 300,000 vehicles for the first time

2007      Groundbreaking for press shop expansion

2010      Assembly/finish refurbishment

2013      New press system commissioned

2014      Completion of automated small parts warehouse

2015      EFQM Excellence Award; BMW X1 series launch

2017      West expansion of assembly commissioned

2018     Start of BMW X2 series production

2025      Additional body shop commissioned in Neutraubling

2026      Around 9,000 employees, including approx. 380 apprentices

40 years of BMW Group Plant Regensburg – vehicle models produced:

*Updated: Dec. 2025

BMW Group Corporate Communications
Saskia Graser, head of Communications Regensburg and Wackersdorf +49 151 6060 2014, Email: Saskia.Graser@bmw.de

Media website: https://newsroom.bmwgroup.com/global/en

Email: presse@bmw.de

BMW Group Plants Regensburg and Wackersdorf
BMW Group Plant Regensburg has been in operation for more than four decades. After construction of the production halls was completed in 1984, series production of the BMW 3 Series (E30) began in autumn 1986. As part of the settlement agreement with the City of Regensburg, BMW pledged at that time to produce 400 vehicles per day and create 3,500 jobs.

Today, Plant Regensburg is one of more than 30 BMW Group production locations worldwide. More than 1,400 BMW X1 and BMW X2 model vehicles roll off the assembly line each day, destined for customers around the globe. Different types of drive train are flexibly manufactured on a single production line – from models with internal combustion engines to plug-in hybrids and fully-electric vehicles.

Within the framework of the BMW iFACTORY, the BMW Group is also setting standards at its Regensburg location in the fields of digitalisation, circularity and competitiveness – as confirmed by recent awards. For example, in 2025, the plant was named “FACTORY OF THE YEAR” in the category “Excellent Large-Series Assembly”. In addition, the BMW X1 from Regensburg was once again voted Best in Class in “Best Cars 2025”. It is already possible to experience, in virtual form, what the factory will look like in the coming years. Production of the “Neue Klasse” – BMW’s next model generation – is set to ramp up in Regensburg in the second half of this decade.

BMW Group Plant Wackersdorf is home to cockpit production and parts supply for overseas plants, and also serves as the door and flap production centre for Rolls-Royce. With its battery testing centre, the site also makes a significant contribution to electromobility.

The BMW Group's core staff at its Regensburg and Wackersdorf locations in eastern Bavaria comprises around 9,000 employees, including approximately 380 apprentices.

www.bmwgroup-werke.com/regensburg/de.html

+++ Award in the category "Supplier" for outstanding interaction of lean management, digitalization, and innovative power +++ Martin Frensch, Senior Vice President of Body, Exterior Trim and Interior in the purchasing and supplier network at BMW Group: "Lean before Digital is our guiding principle for efficient and forwardlooking production." +++

Landshut/Wackersdorf. The cockpit production at the BMW Group plants in Landshut and Wackersdorf will be awarded with the  Automotive Lean Production Award in the category "Supplier". The  jury was impressed by the outstanding ensemble of lean management, digitalization, and innovation in the interior components production at the BMW Group. The award will be presented at the 19th Automotive Lean Production Congress on November 25 and 26, 2025, in Poznań, Poland.

Smart production of cockpits: increased flexibility and efficiency in the production and supply chain.
With highest precision, employees at the BMW Group plants in Landshut and Wackersdorf manufacture interior components for the BMW 1 Series, 2 Series, 3 Series, 4 Series, 5 Series, and 7 Series, as well as the BMW iX. Every day, several thousand instrument panels and glove boxes leave the two component plants. "Technological know-how, highly automated production processes, AI-supported quality controls as well as lean value streams form the foundation for efficient work in this field of production," explains Wolf Duwenkamp, Vice President Purchasing, Quality, Production Cockpit and Door Panels at the BMW Group plants in Landshut and Wackersdorf.

Excellent processes, digital transformation and highest quality standards.
The production process at the cockpit production of the BMW Group plants Landshut and Wackersdorf is based on the PULL principle. The workstations where sequencing begins are optimally supplied through self-regulating control loops, ensuring a smooth material flow. The digital transformation of employee roles, such as the mobile operator, demonstrates the close collaboration between humans and machines and brings out additional benefits. Automated end-of-line inspections using AI-supported camera systems, allow an early detection and elimination of potential sources of error.

“Lean before Digital is our guiding principle for an efficient and forward-looking production in the component manufacturing. The combination of excellent processes, digital transformation, and the highest quality standards forms the foundation of our success. By sharing our knowledge, we actively contribute to the global supplier qualification, ensuring robust industrialization of all partners,” explains Martin Frensch, Senior Vice President of Body, Exterior Trim and Interior in the purchasing and supplier network at BMW Group. “To remain competitive, we must continuously question and develope ourselves. The Automotive Lean Production Award shows that we are benchmark, which is something to be proud of,” Frensch adds.

About Automotive Lean Production – Award & Study.
The goal of the joint project by AUTOMOBIL PRODUKTION and Agamus Consult is to demonstrate how the European automotive industry leverages the potentials of lean and digitalization. For 19 years, companies – both OEMs and suppliers – have been participating in a benchmark study, facing international competition for the prestigious Automotive Lean Production Awards with the guiding  principle “Learning from the best!”.

In the event of enquiries please contact:

BMW Group, Corporate Communications

Carolin Seidel, Press Spokesperson BMW Group Plant Landshut
Email: Carolin.Seidel@bmwgroup.com, Phone: +49 151 601 90340

Stefanie Schindler, Communications BMW Group Plant Landshut
Email: Stefanie.Schindler@bmw.de, Phone: +49 151 601 41977

Saskia Graser, Head of Communications Regensburg and Wackersdorf Email: Saskia.Graser@bmw.de, Phone: +49 151 6060 2014

Dr. Annika Biss, Communications BMW Group Plant Wackersdorf
Email: Annika.Biss@bmwgroup.com, Phone: +49-151-601-52588

Media website: https://newsroom.bmwgroup.com/global/en
Email: presse@bmw.de

BMW Group Plant Landshut

At BMW Group Plant Landshut, around 3,800 employees produce light metal cast engine, suspension and body structure components, electrical and electronic components, plastic components for the vehicle exterior, carbon body components, cockpit and equipment features, engines and propeller shafts. Plant Landshut is the BMW Group’s largest component plant and supplies components to all BMW Group vehicle and engine plants worldwide – and therefore for virtually every BMW, MINI and Rolls-Royce vehicle, as well as for BMW Motorrad. Component production at BMW Group Plant  Landshut is characterised by digitalisation, a focus on sustainability and a commitment to responsible use of resources. With its forward-looking technologies, BMW Group Plant Landshut assumes the role of innovation driver in the technological transformation of the automotive sector and its supplier industry. At the Technology Centre adjacent to the plant, specialists from a wide range of disciplines are brought into development processes for new vehicles in the early stages and help to actively drive sustainable development of future vehicle models. BMW Group Plant Landshut is a socially responsible, innovative and attractive employer for the region of Landshut and Lower Bavaria.

https://www.bmwgroup-werke.com/landshut/en.html

BMW Group Plants Regensburg und Wackersdorf

The BMW Group vehicle plant in Regensburg has been in operation since 1986 and is one of more than 30 BMW Group production locations worldwide. Every workday, around 1,400 vehicles of the BMW X1 and BMW X2 models roll off the production line at Plant Regensburg, destined for customers around the globe. Different types of drive trains are flexibly manufactured on a single production line – ranging from vehicles with internal combustion engines to plug-in hybrids and fully-electric models.

BMW Group Plant Regensburg was recognised as “FACTORY OF THE YEAR” 2024 in the category “excellent large-series assembly” of the prestigious industrial competition. As it implements the BMW iFACTORY, the BMW Group is focused on digitalisation of the Regensburg plant site to create a digital and intelligently connected factory. It is already possible to experience in virtual form what the factory will look like a few years from now. Production of models for the NEUE KLASSE, BMW’s next generation of vehicles, will ramp up in Regensburg in the second half of the decade.

The BMW Group plant in Wackersdorf is home to cockpit production and parts supply for overseas plants. With the opening of a new battery testing centre and commissioning of the first phase in autumn 2024, the location has also become a key facilitator for electromobility. An entirely new area of expertise for the site is the door and flap production centre for Rolls-Royce.

The BMW Group core staff at the Regensburg and Wackersdorf locations in eastern Bavaria consists of around 9,250 employees, including around 350 apprentices.

www.bmwgroup-werke.com/regensburg/en.html


The BMW Group

With its four brands BMW, MINI, Rolls-Royce and BMW Motorrad, the BMW Group is the world’s leading premium manufacturer of automobiles and motorcycles and also provides premium financial services. The BMW Group production network comprises over 30 production sites worldwide; the company has a global sales network in more than 140 countries.

In 2024, the BMW Group sold over 2.45 million passenger vehicles and more than 210,000 motorcycles worldwide. The profit before tax in the financial year 2024 was € 11.0 billion on revenues amounting to € 142.4 billion. As of 31 December 2024, the BMW Group had a workforce of 159,104 employees.

The economic success of the BMW Group has always been based on long-term thinking and responsible action. Sustainability is a key element of the BMW Group’s corporate strategy and covers all products from the supply chain and production to the end of their useful life.

www.bmwgroup.com
LinkedIn: http://www.linkedin.com/company/bmw-group/
YouTube: https://www.youtube.com/bmwgroup
Instagram: https://www.instagram.com/bmwgroup
Facebook: https://www.facebook.com/bmwgroup
X: https://www.x.com/bmwgroup

+++ Faster, more efficient transition from gas to alternative energy sources possible +++ Pilot project will save around 480 tons of CO2e per year +++

Regensburg. As it transitions from natural gas to renewable energy, the BMW Group is gradually electrifying its paint shops as part of its efforts to decarbonise vehicle production. A recently concluded pilot project at Plant Regensburg demonstrates how this transition can be simplified and accelerated. The key lies in the installation of a thermal oil system. Using thermal oil as a heat transfer medium enables heat generation to be decoupled from the rest of the system’s components. This allows the energy supply to the coating lines to be adapted flexibly at any time.

“One advantage of switching to thermal oil is the flexibility to choose the energy source for heat generation in our paint shops. For example, thermal oil can be heated using electricity, geothermal energy, solar thermal energy – or even a hydrogen-powered heating system. The ability to change fuels quickly at any time makes our paint shops more resilient. If an energy source becomes scarce or unavailable, we can respond at short notice,” explains Samuel Flieger, project manager for technical planning in the Regensburg paint shop.

This means paint shops can already be set up to run on renewable energy – even if gas-free heating is not yet an option. The power grid is not currently equipped at all locations to handle the high energy demands of a fully electrified paint shop, largely due to its extremely energy-intensive drying processes. A thermal oil-based system can also be operated with gas as an interim solution.

Testing successfully concluded in Regensburg

The Regensburg pilot project team took advantage of the production downtime over the New Year period to install the thermal oil technology. Within just a few days, they replaced the gas-powered drying equipment used for one of the three top coat lines with an electrically heated thermal oil system – complete with an innovative electric-powered eRTO exhaust air unit.

The key innovation lies in using the new electric heating unit to transfer heat to the thermal oil, instead of directly heating the air around the car bodies in the drying chamber after paint application. The heated oil circulates in a closed loop and, in a second step, heats the air in the drying chamber via heat exchangers. The circulating thermal oil reaches temperatures of several hundred degrees Celsius. Unlike water, it remains stable even at these high temperatures.

Retrofitting boosts energy efficiency

Wherever waste heat is generated, it is recovered and reused as process heat. This reduces the temperature of the exhaust air released through the hall's roof. As a result of these retrofitting measures, the drying equipment’s total energy consumption has been reduced by approximately 40 percent. Switching to thermal oil heating, combined with the system's improved energy efficiency, will reduce the carbon footprint of BMW Group Plant Regensburg’s paint shop by approximately 480 tons of CO₂e per year.

If you have any questions, please contact:

Christian Dürrschmidt, Communications Regensburg
Cell phone: +49 151 6060 5194,
Email: Christian.Duerrschmidt@bmw.de
 
Saskia Graser, head of Communications Regensburg and Wackersdorf
Cell phone: +49 151 6060 2014,
Email: Saskia.Graser@bmw.de
 
Media website: https://newsroom.bmwgroup.com/global/en
Email: presse@bmw.de

BMW Group Plants Regensburg and Wackersdorf
 
The BMW Group vehicle plant in Regensburg has been in operation since 1986 and is one of more than 30 BMW Group production locations worldwide. Every workday, around 1,400 vehicles of the BMW X1 and BMW X2 models roll off the production line at Plant Regensburg, destined for customers around the globe. Different types of drive trains are flexibly manufactured on a single production line – ranging from vehicles with internal combustion engines to plug-in hybrids and fully-electric models.

BMW Group Plant Regensburg was recognised as “FACTORY OF THE YEAR” 2024 in the category “excellent large-series assembly” of the prestigious industrial competition. As it implements the so-called BMW iFACTORY, the BMW Group is focused on digitalisation of the Regensburg plant site to create a digital and intelligently connected factory. It is already possible to experience in virtual form what the factory will look like a few years from now. Production of models for the NEUE KLASSE, BMW’s next generation of vehicles, will ramp up in Regensburg in the second half of the decade.

The BMW Group plant in Wackersdorf is home to cockpit production and parts supply for overseas plants. With the opening of a new battery testing centre and commissioning of the first phase in autumn 2024, the location also makes a significant contribution to electromobility. An entirely new area of expertise is the door and flap centre for Rolls-Royce.

The BMW Group core staff at the Regensburg and Wackersdorf locations in eastern Bavaria consists of around 9,250 employees, including about 350 apprentices.

www.bmwgroup-werke.com/regensburg/de.html

+++ Investment of over € 100 million in BMW Group Plant Wackersdorf – site in Upper Palatinate becomes key enabler for electromobility +++

Wackersdorf. One year ago, the BMW Group announced plans to build a new battery testing centre at the Wackersdorf location. Now, the initial phase has come on-stream as planned. Scheduled for completion in late 2025, the site, which spans over 8,000 square metres, will rigorously test individual battery cells, complete high-voltage batteries and other electric powertrain components for future BMW Group models early in development, well before they go into production.

The investment of around 100 million euros has primarily focused on complex test-bench technology and the upgrades to the building's existing infrastructure required for operation. Hall 80, located on the grounds of the Wackersdorf plant, has been remodelled for this purpose: Originally constructed in the 1980s for a planned reprocessing facility, the building has quite a history.

In recent months, structural work for the new battery testing centre has been in progress, including installation of a new floor slab. A total of 2,200 tonnes of structural steel and 10,000 cubic metres of concrete were used in the expansion.

The commissioning of the initial section means that the so-called “battery testers” will be operating around the clock to test battery cells during the early phase of development. Essentially, the electrical performance of individual battery cells is determined during charging and discharging under different conditions. This allows use cases that will be relevant for customers later to be simulated, long before a vehicle under development drives on the road. 

“Parallel testing of several hundred battery cells will initially be possible. Once the ramp-up is complete, testing capacity will reach several thousand battery cells,” explains Project Manager Dr Felix Schmidt-Stein. In the final phase from 2025 onwards, the testing centre will also be used to validate the BMW Group’s battery-electric vehicles prior to the official launch of series production and ensure the required premium quality. “For example, this includes subjecting the batteries to vibration and shock tests,” adds Schmidt-Stein. “We can also simulate complex driving patterns in endurance tests, including charging and discharging cycles. Tests like these are essential for type approval of electric vehicles.” 

“Commissioning of the first phase of the new battery testing centre means that the BMW Group's Wackersdorf location is poised to become a major facilitator in the transformation towards electromobility,” confirms Site Manager Christoph Peters. “The new battery testing centre gives our site a broader foundation. We are now adding a fourth pillar in Wackersdorf – in addition to supplying our overseas plants, cockpit production and door production for Rolls-Royce models. This represents a strong commitment to the future of the site.” 
BMW Group Corporate Communications

Saskia Graser, head of Communications Regensburg and Wackersdorf
Cell phone: +49 151 6060 2014, Email: Saskia.Graser@bmw.de 

Media website: https://newsroom.bmwgroup.com/global/en 
Email: presse@bmw.de 

BMW Group Plants Regensburg and Wackersdorf

The BMW Group has viewed itself for decades as the benchmark for production technology and operational excellence in vehicle construction – including at its locations in Regensburg and Wackersdorf. 
The BMW Group vehicle plant in Regensburg has been in operation since 1986 and is one of more than 30 BMW Group production locations worldwide. A total of up to 1,400 vehicles of the BMW X1 and BMW X2 models come off the production line at Plant Regensburg every workday – destined for customers all over the world. Different types of drive trains are flexibly manufactured on a single production line – from vehicles with internal combustion engines to plug-in hybrids, to fully-electric models. 

High-voltage batteries for the electric models built in Regensburg are also produced locally, in direct proximity to the vehicle plant. They are assembled at the electric component production facility, which opened in 2021 at the Leibnizstrasse location.

BMW Innovation Park Wackersdorf also belongs to the Regensburg site. The 55-hectare campus built in the 1980s was originally intended as a nuclear reprocessing facility. The BMW Group has located its cockpit production there, as well as its parts supply for overseas plants. In addition to BMW as the largest employer, several other companies are also based at Innovation Park Wackersdorf. A total of around 2,500 employees work there. 
The BMW Group core staff at the Regensburg and Wackersdorf locations in eastern Bavaria is made up of around 9,250 employees, including more than 300 apprentices.

www.bmwgroup-werke.com/regensburg/de.html 

+++ Realistic simulations of future operations already possible in digital factory layout +++ Employees trained on “digital twin” using VR goggles +++

Regensburg. At BMW Group Plant Regensburg, it is already possible to experience in virtual form what the factory will look like a few years from now: Production of the NEUE KLASSE, BMW’s next model generation, will also ramp up in Regensburg in the second half of the decade. Plant Director Armin Ebner: “With the NEUE KLASSE, which is based on an entirely new vehicle architecture, our goal as a company is to set new standards for digitalisation, electrification and circularity. Today, many years before the official launch of series production, virtual planning of the new production lines is already well underway – even as we continue to build the current BMW X1 and BMW X2 models.”

Virtual image of new production lines years before series launch

As part of a pilot project implemented in vehicle assembly, BMW Group Regensburg is utilising “3D human simulation” for the first time company-wide. “This allows us to not only map future manufacturing structures virtually in a digital twin, but also simulate the employees who will work on our assembly lines in the future,” explains Sebastian Moser, an innovation and digitalisation specialist for the Regensburg production system. In practice, this means future workflows and individual operations on the Regensburg assembly line can be virtually mapped and tested long before the series launch of new models.

“The project is a further step towards the digital and intelligently connected BMW iFACTORY,” confirms Ebner. “Virtualisation, artificial intelligence and data science are accelerating and refining our planning. Digital factory planning enables us to reduce planning effort and realise more efficient, stable vehicle launches in the future.” The BMW Group is adopting a digital-first approach to validate and optimise complex manufacturing systems throughout its production network, relying on NVIDIA Omniverse Enterprise, a platform for creating and operating 3D industrial metaverse applications, to run simulations with digital twins.

Human simulation already very close to future factory reality

To date, the "3D human simulation" at the BMW Group site in Regensburg encompasses a complete line section with 41 operating cycles, covering over 1,000 square metres of assembly space. Realistic simulation of operations in the future factory layout makes it possible to already develop effective cycle specifications and conduct health-friendly ergonomic analyses today.

“The ‘model people’ on our digital assembly line move and behave just like real people,” explains Dominik Wottke, a production and quality expert in vehicle assembly at the Regensburg plant. “For example, if the software detects that a virtual employee needs to bend too low or lift a weight that is too heavy to be able to complete an operation, then that is also the case in the real world. We are therefore able to respond to this in a targeted manner and make improvements in the modelling.”

VR goggles take employees on virtual journey into the future

The “3D human simulation” also serves as a training and information tool. “We can use video sequences from the digital twin to take our associates on a journey into the future and show them what their future workplace will look like,” says Wottke. Project managers have set up a virtual room for this purpose, where employees from vehicle assembly in Regensburg can wear VR goggles to explore the future assembly line virtually and examine details up close, if needed. They can also practice specific operating cycles and enhance their skills, working alongside virtual “colleagues”. The aim is to train these operations so well in advance that the learning phase on the actual assembly line can be shortened.

If you have any questions, please contact:

Christian Dürrschmidt, Communications Regensburg

Cell phone: +49 151 6060 5194,

Email: Christian.Duerrschmidt@bmw.de

Saskia Graser, head of Communications Regensburg and Wackersdorf

Cell phone: +49 151 6060 2014,

Email: Saskia.Graser@bmw.de

Media website: https://newsroom.bmwgroup.com/global/en

Email: presse@bmw.de

BMW Group Plants Regensburg and Wackersdorf

The BMW Group has viewed itself for decades as the benchmark for production technology and operational excellence in vehicle construction – including at its locations in Regensburg and Wackersdorf. 
The BMW Group vehicle plant in Regensburg has been in operation since 1986 and is one of more than 30 BMW Group production locations worldwide. A total of up to 1,400 vehicles of the BMW X1 and BMW X2 models come off the production line at Plant Regensburg every workday – destined for customers all over the world. Different types of drive trains are flexibly manufactured on a single production line – from vehicles with internal combustion engines to plug-in hybrids, to fully-electric models.

High-voltage batteries for the electric models built in Regensburg are also produced locally, in direct proximity to the vehicle plant. They are assembled at the electric component production facility, which opened in 2021 at the Leibnizstrasse location.

BMW Innovation Park Wackersdorf also belongs to the Regensburg site. The 55-hectare campus built in the 1980s was originally intended as a nuclear reprocessing facility. The BMW Group has located its cockpit production there, as well as its parts supply for overseas plants. In addition to BMW as the largest employer, several other companies are also based at Innovation Park Wackersdorf. A total of around 2,500 employees work there.

The BMW Group core staff at the Regensburg and Wackersdorf locations in eastern Bavaria is made up of around 9,250 employees, including more than 300 apprentices.

www.bmwgroup-werke.com/regensburg/de.html

+++ Site Manager Christoph Peters: “BMW Group’s Wackersdorf location set to become a major facilitator for the transformation towards electromobility” +++ Building constructed in the 1980s as reprocessing facility to symbolise Wackersdorf site’s electric future +++ 

Wackersdorf. Signalling its strong commitment to the Wackersdorf location in Upper Palatinate and as part of its continuing e-mobility ramp-up, the BMW Group is investing around 100 million euros between now and 2026 in a new battery testing centre that will be integrated into the site’s existing building structures. The first deliverables for BMW Group development activities in the field of high-voltage batteries will go into regular operation as early as mid-2024. From then on, across a total area spanning 8,442 m², high-voltage batteries and other electric powertrain components for future BMW Group models will be put through their paces very early in development – well before the start of production.

“The BMW Group’s Wackersdorf location is set to become a major facilitator for the transformation towards electromobility,” confirms Site Manager Christoph Peters, adding that the new battery testing centre will broaden the foundation of the BMW Group site in Wackersdorf. “In addition to supplying our overseas plants, cockpit production and, from 2024, door production for Rolls-Royce models, this will become Wackersdorf’s fourth main area of activity. This, in turn, strengthens our location’s future viability.”

The around 100-million-euro investment will mainly be focused on complex test bench technology and the upgrades to the building’s existing infrastructure needed for their operation. Hall 80, located on the plant grounds, is currently being remodelled for this purpose: This building, which was originally constructed in the 1980s for the reprocessing facility planned at the time, has quite a history. “Now, this storied building will become a symbol of our plant’s electric future,” says Peters.

Structural work is already underway, including installation of a new floor slab for the building. In mid-2024, with commissioning of the first section, so-called “battery testers” will be put into service. From the outside, these resemble large, rather insignificant refrigerators – however, on the inside, they make use of cutting-edge high tech. Here, battery cells will be tested round the clock, early in their development. Essentially, the electrical performance of individual battery cells is determined during charging and discharging under different conditions. This allows use cases that will be relevant for customers later to be simulated, long before a vehicle under development drives on the road. Parallel testing of several hundred battery cells will initially be possible. Once the ramp-up is complete, testing capacity will reach several thousand.

In the final phase from 2025 onwards, the testing centre will also be used to validate the BMW Group’s battery-electric vehicles prior to the official launch of series production and ensure the required premium quality. This includes subjecting the batteries to vibration and shock tests, for instance, using so-called “shakers” – highly complex testing devices of which there are currently only a few across Europe. Complex driving patterns, including charging and discharging cycles, can also be simulated in endurance tests. Tests like these are essential for type approval of electric vehicles. In some cases, country-specific tests must also be completed. Capacity for such tests in the free market is currently limited – which is why the BMW Group is creating its own capacity with the new battery testing centre in Wackersdorf.

If you have any questions, please contact:

BMW Group Corporate Communications
Dominik Hämmerl, Communications Wackersdorf
Cell phone: +49 151 6060 3889, Email: Dominik.Haemmerl@bmw.de 

Saskia Graser, acting head of Communications Regensburg and Wackersdorf
Cell phone: +49 151 6040 3232, Email: Saskia.Graser@bmw.de

Media website: https://newsroom.bmwgroup.com/global/en

Email: presse@bmw.de

BMW Group Plants Regensburg and Wackersdorf
The BMW Group has viewed itself for decades as the benchmark for production technology and operational excellence in vehicle construction – including at its locations in Regensburg and Wackersdorf.
The BMW Group vehicle plant in Regensburg has been in operation since 1986 and is one of more than 30 BMW Group production locations worldwide. A total of up to 1,000 vehicles of the BMW 1 Series, BMW X1 and BMW X2 models come off the production line at Plant Regensburg every workday – destined for customers all over the world. Different types of drive trains are flexibly manufactured on a single production line – from vehicles with internal combustion engines to plug-in hybrids, to fully-electric models.
High-voltage batteries for the electric models built in Regensburg are also produced locally, in direct proximity to the vehicle plant. They are assembled at the electric component production facility, which opened in 2021 at the Leibnizstrasse location.
BMW Innovation Park Wackersdorf also belongs to the Regensburg site. The 55-hectare campus built in the 1980s was originally intended as a nuclear reprocessing facility. The BMW Group has located its cockpit production there, as well as its parts supply for overseas plants. In addition to BMW as the largest employer, several other companies are also based at Innovation Park Wackersdorf. A total of around 2,500 employees work there.
The BMW Group core staff at the Regensburg and Wackersdorf locations in eastern Bavaria is made up of around 9,000 employees, including more than 300 apprentices.

bmwgroup-werke.com/regensburg/de.html