BMW iFACTORY: Tomorrow's production.

Car production: BMW Group bodyshops assemble hundreds of individual steel, aluminium, carbon and fibre composite components to create bodies with absolute precision. Depending on the model, they are joined in a variety of ways, from spot welds to laser welds, soldering, bolting and bonding. The job is done by state-of-the-art, ultra-precise, highly efficient robots. The extensive expertise of the team ensures top quality and repeatability. Qualified employees control, monitor and maintain the systems and substantially support process security.

Motorcycle production: Highly flexible systems with integrated testing technologies are among the key features of BMW Motorrad engine assembly. Here, over 600 different small parts and components are put together to create high-performance two- (boxer), four- and six-cylinder engines, with several automatic stations supporting the team. A boxer engine takes between 90 and 130 minutes to produce. A straight six-cylinder takes about 150.

Car production: Paintwork not only gives a car its characteristic colour but also provides long-term protection from corrosion and environmental influences. In a first step, the body is cleansed and degreased in a dip. Then a coat of zinc phosphate is applied, followed by four more coats of paint and varnish to give the car its brilliant colour and protect it from the elements. Careful quality checks are performed at every stage. Lab specialists use simulations to test the colour consistency and durability of the paints.

Motorcycle production: Motorcycle parts come in up to 160 different shapes and are painted by computer-controlled robots, in a choice of more than 25 water-based paint colours. The paint line is designed to handle various sizes and geometries of component in variable order. But the expertise of experienced specialists remains crucial: a steady hand is essential, especially when it comes to applying the traditional pinstripes and various tape applications to the tanks and side fairings.

Car production: The painted bodies are finally assembled by experienced and well-trained employees – who can even realise customers’ more unconventional visions. Different trim and equipment options, add-ons, country-specific variants and much more besides create an unmistakable customised product. For the BMW 3 Series Sedan and Touring, customers can choose from more than 20,000 interior variants. And because the options are virtually unlimited, two identical vehicles hardly ever off the production line together.

Motorcycle production: Motorcycles are transported to assembly via flexible transport systems. By the time a bike is complete, it will have passed through as many as 150 different workstations. At each one, the transport system automatically adjusts its height to suit the operator. Operatorsr also get all the order, torque and settings data they need fully automatically. Depending on the model, the 2,000 or so parts and components take between 220 and 360 minutes to assemble into a ready-to-ride BMW Motorrad bike.

Car production: Completed cars are first taken to an in-plant logistics area for interim storage. They are then prepared for distribution and delivered to national and international markets by truck, rail and/or ship. Distribution is efficiently managed by an intelligent smart IT-supported logistics system that optimises routes and uses real-time data to seamlessly track locations, arrival times and transport conditions.

Motorcycle production: BMW Motorrad bikes are prepared for their journey to the customer before they even leave the finish area. Those destined for key markets in Europe are put into reusable folding steel crates. Bikes for overseas customers are packed in robust containers made of wood and cardboard. Sustainability and logistical efficiency are the key factor in determining whether trucks, rail or ships will be used for transportation.