BMW Group Plants Landshut und Wackersdorf, Production Cockpit

Thanks to the impressive combination of lean philosophy, digitalization, and innovative strength, the production cockpit at the BMW Group plants in Landshut and Wackersdorf has been honored with an Automotive Lean Production Award 2025. In addition to the virtually waste-free production of series parts at the two locations mentioned above, the component plants make an active contribution to global supplier empowerment, thus ensuring robust industrialization for all partners. In addition, the production cockpit plays an important role in the early Ito design phase, advising suppliers on everything from product design to tool and equipment selection, and is intensively involved in the development of innovations.

Excellent processes

Overall, the implementation of the PULL principle is impressive. The workstations where the sequence formation begins are consistently supplied via self-regulating control loops.

The introduction of digital Kanban systems and automated photo documentation not only ensures quality but also enables transparent traceability—a decisive advantage in the supply chain.

An existing line was optimized in a consistent CIP process. Among other things, the creation of car sets directly next to the assembly line led to lower downtimes and a reduction in logistics costs. The switch to sequence production in an earlier work step resulted in a 50% space saving and 100% process stability for the workstation in question.

Where automation is used, it is possible to achieve a high OEE with new technological advances, such as fully automatic clamping and screwing, for example on the BMW 1 Series production line.

Quality at the highest level

The production cockpit relies on automated EOL tests with photo documentation and IT numbers, which enable sources of error to be identified and eliminated at an early stage. The integration of AI-supported camera systems for anomaly detection has significantly reduced the error rate for surface defects in the corresponding product. In the indirect area, too, the 8D Assistant ensures preventive error avoidance and accelerated problem solving.

Exemplary support for shop floor employees

The value-added production system (WPS) is exemplified in the production cockpit. Particularly noteworthy is the optimization of workstations. Digital support such as screen displays with step-by-step instructions and pick-to-light systems have improved ergonomics and reduced the likelihood of errors.

Regular foreman meetings, shift handovers, and structured communication routines ensure a high level of transparency and quick problem solving on the shop floor.

Digitalization as an enabler

The integration of AI in production and quality management enables continuous improvement and data-driven decisions.

The digital transformation of employee roles, such as the mobile plant operator, shows how people and technology work hand in hand. The central role, which requires a high level of qualification and responsibility, has led to the rapid and sustainable introduction of AGVs in series production.

Platforms provided by the BMW Group are adapted to specific plant requirements for the digitalization of manual processes, transparency creation, and data analysis, and are used in series production.

The production cockpit at both production sites also relies on individually developed digitalization solutions, such as an e-paper solution that is already being used across plant boundaries, or a digital Kanban card system.

A benchmark for the entire industry

The production cockpit at the BMW Group plants in Landshut and Wackersdorf impressively demonstrates how lean manufacturing, digitalization, and automation can be successfully combined throughout the entire value chain, especially when suppliers are involved. This results in extremely good KPIs.

The production cockpit at the BMW Group plants in Landshut and Wackersdorf impresses with its innovative strength, quality standards, and efficiency.

Congratulations on winning the Automotive Lean Production Award 2025 in the category Supplier!

The BMW Group

With its brands BMW, MINI, Rolls-Royce, and BMW Motorrad, the BMW Group is the world's leading premium manufacturer of automobiles and motorcycles and a provider of premium financial services. The BMW Group production network comprises more than 30 production sites worldwide; the company has a global sales network with representatives in over 140 countries.

In 2024, the BMW Group achieved global sales of 2.45 million automobiles and over 210.000 motorcycles. Earnings before taxes in the 2024 financial year amounted to €11.0 billion, with revenue of €142.4 billion. As of December 31, 2024, the company employed 159.104 people worldwide.

The production cockpit at the BMW Group plants in Landshut and Wackersdorf.

In the cockpit production facility at the BMW Group plant in Landshut, employees manufacture instrument panel tops, instrument panel bottoms, and glove compartments for the BMW 5 Series, BMW 7 Series, and BMW iX with the utmost precision. Every day, several thousand interior components leave the BMW Group's largest component plant.

In the cockpit production facility at the BMW Group plant in Wackersdorf, employees manufacture instrument panels for the BMW 1 Series, BMW 2 Series, BMW 3 Series, and BMW 4 Series with the utmost precision. Several thousand instrument panels leave the BMW Group plant in Wackersdorf every day.