BMW 2015 Annual Report Download - page 33

33 COMBINED MANAGEMENT REPORT
convert and expand the plant throughout 2015. The BMW
Group is investing in a new single-line production system
at this site as the basis for ensuring the brand’s innova-
tive product strategy in the long term. The new tech-
nology and logistics centre in Bognor Regis near Good-
wood was opened as planned. Moreover, Rolls-Royce
Motor Cars recruited 100 new employees during the
period under report.
In Rosslyn (South Africa) the one-millionth BMW 3 Series
vehicle rolled off the production line in February 2015.
In 1973, the plant was opened as the BMW Group’s first
international manufacturing facility and is now an im-
portant part of the network. Within the next few years,
the plant will discontinue production of the BMW 3
Se-
ries and begin making the successor to the current
BMW X3.
In Shenyang (China), BMW Brilliance Automotive Ltd.
(BBA) produced its one-millionth vehicle during the
period under report. BBA is a joint venture of the BMW
Group and its partner Brilliance China Automotive
Holdings Ltd. Its two plants in Dadong and Tiexi manu-
facture the BMW 3 Series long-wheelbase version, the
BMW 3 Series Sedan, the BMW 5 Series long-wheelbase
version, the BMW 5 Series Plug-in Hybrid and the
BMW
X1 for the Chinese market.
The manufacturing sites in Chennai (India) and Rayong
(Thailand) complete the BMW Group’s production net-
work. Last year, the plant in Thailand celebrated its 15th
anniversary and expansion work was continued at the
plant at the same time. It is the only production facility
within the network that produces not only BMW and
MINI vehicles, but also BMW motorcycles.
At the Group’s partner plants, which mostly serve
their
regional markets, a total of 27,216 vehicles were
produced during the period under report. These part-
ner
plants include those in Kaliningrad (Russia), Cairo
(Egypt), Jakarta (Indonesia) and Kulim (Malaysia).
Introduction of modular engine concept practically
completed
In January 2016, the new engine manufacturing plant,
which includes a foundry, was commissioned in Shen-
yang (China) and now supplies engines for vehicle pro-
duction for the Chinese market. With Munich, Hams
Hall (United Kingdom) and Steyr (Austria), the BMW
Group now manufactures engines at a total of four lo-
cations. Moreover, since 2014 the new modular engine
has been introduced in the engine plants step by step,
expanding options for a flexible production system with
uniform production and process standards.
Production of modular engines at the Steyr plant was
increased in 2015. At the same time, the development
centre for diesel engines, which is connected with the
plant, is currently being expanded. The Hams Hall en-
gine plant makes 3- and 4-cylinder petrol engines for
BMW and MINI and is also the exclusive manufacturer
of 3-cylinder petrol engines for the BMW i 8.
Strong production base in Germany
Apart from the expansion of the international production
network, the German plants are an important focus of
ongoing development. For the fifth time in succession,
the BMW Group produced a total of over one million
vehicles at its plants in Munich, Dingolfing, Regensburg
and Leipzig.
Thanks to their innovative strength, the plants in Ger-
many play a leading role within the international pro-
duction network and are often the inspiring source
of
impetus for the global network as a whole. Digitalisa-
tion,
modular concepts and intelligent composite manu-
facture are examples that demonstrate the outstanding
expertise of the production network.
Digitalisation in particular will contribute towards help-
ing
the network produce even more flexibly and effi-
ciently. The use of IT-supported technologies in produc-
tion and logistics makes it possible to design even highly
complex workflows, such as through the use of flexible
robot systems, intelligent tools for staff, simulation, and
automated data collection and analysis.
With the production start-up of the new BMW 7 Series,
employees at the Dingolfing plant have proved that
innovation can be combined with complex production
processes. The intelligent composite manufacture is
particularly obvious in the new BMW 7 Series, where
carbon-fibre reinforced polymer (
CFRP) is exclusively
used in the passenger compartment.
The body struc-
ture, known as Carbon Core, is based on a technology
transfer from the BMW i models. The utilisation of ultra-
lightweight CFRP material and a comprehensive light-
weight design concept make the new
7 Series models
up to 130 kg lighter than their predecessors.
Despite the BMW 7 Series model change, with a total
of around 360,000 units manufactured in 2015, the
Dingolfing plant registered the second-highest annual
production figure in its history. At the same time,