At BMW Group Plant Regensburg, the future of automotive manufacturing is taking shape through virtual planning and advanced technology. With production of BMW’s next-generation model, the NEUE KLASSE, set to ramp up in the second half of the decade, the plant is already mapping out its future operations in digital form.
Armin Ebner, Plant Director at Regensburg, highlighted the company’s goals with the NEUE KLASSE: “Our aim is to set new standards for digitalisation, electrification, and circularity. Today, virtual planning of the new production lines is well underway, even as we continue to build the current BMW X1 and BMW X2 models.”
Innovative 3D Human Simulation for Future Production
A key component of this virtual planning is the innovative “3D human simulation” being implemented in vehicle assembly. This pilot project, the first of its kind company-wide, allows BMW to virtually map future manufacturing structures and simulate the employees who will work on these assembly lines. Sebastian Moser, an innovation and digitalisation specialist, explained, “This means future workflows and individual operations can be tested long before the series launch of new models.”
The use of 3D human simulation covers a complete line section with 41 operating cycles, encompassing over 1,000 square meters of assembly space. This technology enables realistic simulations of operations, allowing for effective cycle specifications and ergonomic analyses to be developed well in advance.
Towards a Digital BMW iFACTORY
Ebner emphasized the importance of this technology in BMW’s strategy: “Virtualisation, artificial intelligence, and data science are accelerating and refining our planning. Digital factory planning enables us to reduce planning effort and realize more efficient, stable vehicle launches in the future.” The BMW Group relies on NVIDIA Omniverse Enterprise for creating and operating 3D industrial metaverse applications, running simulations with digital twins to validate and optimize complex manufacturing systems.
Training with Virtual Reality
The 3D human simulation also serves as a training tool. Dominik Wottke, a production and quality expert, noted, “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.” Employees can wear VR goggles to explore the future assembly line, practice specific operating cycles, and enhance their skills, shortening the learning phase on the actual assembly line.
A Legacy of Innovation and Excellence
BMW Group Plant Regensburg, operational since 1986, is a benchmark for production technology and operational excellence. The plant produces up to 1,400 vehicles of the BMW X1 and BMW X2 models daily, with high-voltage batteries for electric models assembled locally. The site employs around 9,250 employees, including over 300 apprentices, and continues to innovate with projects like the 3D human simulation, ensuring it remains at the forefront of automotive manufacturing.
