BMW Group – Technology Exterior Plastics, Production Leipzig

This year's Automotive Lean Production Award in the ‘Lean Digital Transformation’ category goes to Technologie Exterieur Komponenten (TEK) Leipzig. In recent years, the technology's production system has evolved from a predominantly manufacturer of CarSets (complete outer skin of a vehicle) to a large-scale JIS producer (focussing on bumpers, sills and rear spoilers) for the BMW Group, which supplies several plants.

This transformation required a comprehensive strategy, which was developed in a systematically structured series of workshops in 2023. Key factors for the successful implementation of the strategy were a clear and comprehensible strategic vision TEK 2028, the consistent derivation of measures and active change management during the rollout as well as the target development process.

A look at the four strategic action areas of the TEK 2028 target vision shows that key points have already been realised by mid-2024 or are already well advanced in their implementation. These are just a few examples:

Lean & People elements:

• The cost-efficiency initiative with a revision of processes and internal structures made a significant contribution to cost reduction in 2023 (‘From car set builder to JIS high-volume manufacturer’).

• Active work on the value stream in the work organisation - a cornerstone of the BMW Group - is being taken to a new level through the digitalisation of value streams.

• The onboarding of indirect employees will be expanded through the in-house production practice module.

• The new competence fields of digitalisation and sustainability lay the foundation for new qualification requirements.

• Clearly defined development path and qualification process for foremen.

• By increasing the exchange flexibility between tools and injection moulding systems, the expected volume peak in 2025 can be achieved without additional investment.

• Ergonomics assessment of workstations and digital workplace stress management based on measurement data from force measurement gloves and measuring shirts.

Element Digital & Innovation:

• Building up internal expertise in production for the development of low-code apps that provide quick and cost-effective solutions similar to the CIP workshop, e.g. the injection moulding inspection checklist or Q complaint and special inspection apps.

• Use of virtual reality in the programming of paint robots.

• Automatic surface inspection of painted plastic parts incl. AI evaluation.

• Visual support for employees in assembly, with information projected directly onto the component.

• Digital reporting to increase transparency in the process chain, in particular the Q report, the report with the most monthly sessions.
 
Element of ecological sustainability:

• Use of PP/EPDM recyclate with a high secondary raw material content and high post-consumer feedstock.

• Development of a targeted shrinkage parity of recyclate to replace virgin material in the current series.

• Water-free cleaning of all components before painting.
 
The jury is convinced that Technologie Exterieur Komponenten Leipzig will continue to work on its ambitious roadmaps with undiminished passion in the future. The jury presents the Special Award in the ‘Lean Digital Transformation’ category for what has been achieved so far.

Series production began at BMW Group Plant Leipzig in March 2005. Today, up to 1,300 vehicles roll off the production line here every day, currently the BMW 1 Series, the BMW 2 Series Gran Coupé, the BMW 2 Series Active Tourer and the MINI Countryman. The site is also home to Technology Exterior Components (TEK Leipzig), an organisational unit of the Purchasing and Supplier Network department.