BMW's new plant in Hungary begins series production of the iX3 in October

First BMW Group automotive plant to rely entirely on renewable electricity during normal operation; no fossil fuels use piese auto online.

BMW's new plant in Hungary begins series production of the iX3 in October

The BMW Group has entered the final phase before the first Neue Klasse model rolls off the assembly line. Series production of the new BMW iX3 will begin at the end of October at the BMW Group plant in Debrecen, Hungary, when the newest and most innovative production facility in the company’s global production network will officially go into operation.

“The start of series production of the BMW iX3 signals a new era in automotive manufacturing. Our new plant in Debrecen has been designed and built entirely in line with our strategic vision for the iFACTORY. Digital from the start, the plant will offer a new dimension in efficient, fossil-free production,” says Milan Nedeljković, Member of the Board of Management of BMW AG responsible for Production.

The BMW iFACTORY represents a strategic vision for production built on streamlined and efficient structures, responsible resource management, economical use of state-of-the-art digital innovations and a strong focus on employees. The BMW Group has also registered new patents for a large number of innovative systems and processes at the Debrecen plant.

“We took on the challenge of creating a completely new car as the first task in a completely new plant – and in the most economical and efficient way possible. We simplified processes, reduced complexity, digitally validated every single operation and systematically used the expertise of our global network. The result is this plant with efficient production, innovative processes and the flexibility to integrate additional models,” says Hans-Peter Kemser, Head of the BMW Group Plant in Debrecen.

As with every new model, the capacity of the new BMW iX3 will be gradually increased in stages after the start of production. As the first model in the Neue Klasse, the iX3 demonstrates the latest design and technological innovations that will define the brand's entire model range in the future. Between now and 2027, the technologies in the Neue Klasse will be integrated into 40 new models and model updates.

From virtual factory to reality

The guiding principles of the BMW iFACTORY are fully implemented in the technologies used at the new BMW Group plant in Debrecen. For example, it was planned and built digitally from the ground up and celebrated its virtual start of production as early as March 2023 as the BMW Group Virtual Factory. This approach allowed each operation to be tested virtually in advance, after which the production lines could be installed in the buildings exactly as in the digital twin.

Optimal processes for all technologies in the plant

With an optimized value stream and efficient systems, the press shop ensures a high level of productivity. The BMW Group continues to follow its proven strategy of using the same tools and presses throughout its global network. This optimizes the use of network capacity, allowing press tools to be located at multiple locations and training personnel across the network.

The body shop in particular benefits from advance digital planning and validation. Every detail of the process is simulated digitally in advance to determine the ideal value stream and ensure that each of the nearly 1,000 robots is optimally positioned. From the very beginning, close cooperation between the development and production teams results in high production efficiency and maximum customer benefit. For example, the number of joining methods has been significantly reduced, which reduces overall complexity. Design features integrated early in the development process are also visible in the details of the Neue Klasse, such as the invisible door seal. This creates a visual connection between the window and the door, resulting in a unique appearance. Another example is the maximization of the available battery space in the body structure – and thus the size and efficiency of the battery – which also directly benefits the customer.

At the BMW Group plant in Debrecen, the paint shop plays a crucial role in significantly reducing the CO2e footprint of the BMW iX3. Production of the new BMW iX3 will generate a total of around 80 kg CO₂e (Scope 1/2 emissions). This figure includes CO₂e emissions from the Debrecen plant as well as internal parts production at other BMW Group sites, including components produced in Landshut, for example. This represents a reduction of around two-thirds compared to the production of existing BMW models. For the Debrecen plant alone, this approach will reduce CO₂e emissions from the production of a single vehicle, including its high-voltage battery, by around 90% – to around 34 kg CO₂e (when operating at full capacity, compared to other BMW Group sites).

Paint shops typically rely on gas to reach the high temperatures required (up to 180 degrees Celsius). The Debrecen plant will be the first BMW Group automotive plant to be powered exclusively by electricity from renewable energy sources during normal operation, i.e. without the use of fossil fuels such as oil or gas. Due to its high energy requirements, the paint shop is the most important factor in significantly reducing the Debrecen plant’s CO2e emissions. In the paint shop alone, the use of electricity from renewable sources reduces annual CO2e emissions by up to 12,000 tonnes. Around a quarter of the plant’s annual electricity needs will be provided by the 50,000-watt photovoltaic system on site. Surplus solar energy, such as that generated on non-working days, is stored in a thermal energy storage system with a volume of 1,800 m³ and a capacity of 130 MWh.

The paint shop also uses an energy recovery system. In the design of the new paint shop, a heat transfer network was successfully implemented, which provides additional energy savings of up to 10%. This innovative concept combines multiple measures for efficient energy recovery from the compressed air supply, drying and cooling systems. The recovered waste heat is used to heat the water circuit.

In addition, a thermal energy storage system – containing 1,800 m³ of water, with a capacity of 130 MWh – stores excess energy from the photovoltaic system during off-peak periods and delivers it as heat during peak demand.

The complete digitalization of production processes further increases assembly efficiency. The AIQX (Artificial Intelligence Quality Next) IT platform, developed in-house at the BMW Group, is a key component of the BMW iFACTORY. AIQX uses sensors and camera systems along the production line to automate quality processes. AI evaluates the data and provides real-time feedback to line employees. In the future, vehicles on the line will also become active, connected participants in the industrial IoT (Internet of Things) ecosystem. They will perform self-analysis, interact with plant employees in real time and automatically share and document relevant messages using tools such as on-board cameras and IT systems. Equipment, tools, components and every BMW in the assembly halls are now digitally connected to the BMW production system.

The building’s so-called “finger structure” – an optimized version of the design used at the BMW Group plant in Leipzig – allows 80 percent of parts to be delivered directly to the correct assembly point on the line. The fully electric intra-company logistics also benefits from autonomous tractor trains that transport high-voltage batteries directly from production to the assembly points, as well as intelligent transport robots that autonomously deliver smaller components to the assembly line. By connecting all internal and external databases, the entire logistics process achieves unprecedented digital depth, automating many manual, previously interconnected analysis tasks. In this way, well-structured information is available at all times and can be analyzed immediately “at the push of a button.”

The BMW Group is implementing highly intelligent production processes for its new high-voltage batteries developed in-house. The Debrecen plant is the first of five plants worldwide to start series production of Gen6 high-voltage batteries. The production processes were initially developed and tested in pilot plants. Artificial intelligence, data analysis and constant knowledge sharing within the production network also play a key role in the roll-out of production. Digital twins of production and comprehensive AI databases ensure process optimization and employee training. The consistent zero-defect approach enables seamless quality checks in the assembly line and 100% monitoring at the end of the assembly line. In line with the “local for local” principle, the assembly of high-voltage batteries takes place directly on site, allowing production teams to benefit from infrastructure efficiency and short distances.

The best of the best:

The Debrecen plant benefits from the experience of all production sites around the world

The BMW Group plant in Debrecen is the first production site in the company’s network that is not tied to a specific main plant. Instead, it serves as a network plant, combining best practices from different locations around the world. The main advantage of this approach is that the plant’s current workforce of over 2,000 employees can be trained within the network, allowing know-how to be shared with employees from different locations, such as China, South Africa, Mexico, the USA and, of course, Germany. At the same time, employees from the entire global network are given the opportunity to share their technological knowledge in Debrecen and bring their experience in producing the Neue Klasse models back to their own location – creating a win-win situation for all plants.

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The BMW Group has entered the final phase before the first Neue Klasse model rolls off the assembly line

“The start of series production of the BMW iX3 signals a new era in automotive manufacturing