First units of BMW NEUE KLASSE completed

The birth of a new car model is a lengthy process and encompasses many different phases. While developing the design is a crucial part, just as important is the preparation to manufacture the new model. It is not merely passing over the drawings to the suppliers and factories and starting up production.

Before mass production of vehicles that will be delivered to customers can start, there is a lengthy process of preparing the production lines, installing new equipment and a thousand other processes to validate and integrate.

If the plant is a new one, then there may be even more or less work to prepare for the new model. A brand new plant means that existing equipment need not be replaced for producing the new model and new equipment can be easily and quickly installed. There will also be no disruption of current production as the new model will be the new factory’s first product.

But a brand new factory on a new site in a new location also means that logistics have to be established. Suppliers must find optimal routes to deliver parts and the factory has also to coordinate with the companies, some of which may be on another continent.

The BMW Group’s facility in Hungary, close to the town of Debrecen, is a brand new iFACTORY in its production network. It has been built with an investment of approximately 1 billion euros to make a new generation of vehicles at a rate of up to 150,000 units a year.

BMW Group Plant Debrecen has now moved into first gear as its first vehicles have been completed. While these are models of what will leave the lines in future, they are not intended for any customers. They are test vehicles of the first fully-electric X models – known as the NEUE KLASSE – and mark the beginning of the final preparation phase for the start of volume production in late 2025.

All the operations are just as complex as in actual mass production. Despite the limited number of parts involved, they must still be made available in the appropriate logistics processes. Materials and vehicle parts are delivered daily to Plant Debrecen, with test vehicles coming off the production line on a continuous basis. Every part and every production step is closely scrutinised. Special attention is paid to validation of cutting-edge production systems and tools, including their digital connectivity.

During this phase, new staff will also undergo intensive training on the installations and machinery. Close cooperation across all areas of production will ensure operations are seamlessly integrated for a smooth and successful series launch.

“The production of the first test vehicles in Debrecen is an important milestone in commissioning the new plant,” said Milan Nedeljkovic, member of the Board of Management of BMW AG responsible for Production. “With vehicles now approaching production volume maturity, all logistics and production processes at the plant are being tested and constantly optimised under real conditions to ensure a smooth start of mass production.”

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