Digital Factory Prepares Electric Vehicle Series Production

BMW Group Plant Munich has entered a new industrial phase as pre-series units of the fully electric BMW i3 roll off the production line for the first time. The transition combines digital factory planning, phased plant conversion during ongoing operations, and functional validation of manufacturing systems to prepare for series production scheduled for the second half of 2026. The project illustrates how digitally connected production environments support scalable electric vehicle manufacturing.

Digital Planning and Functional Validation of Production Systems
The transformation toward Neue Klasse production began with the installation of new manufacturing infrastructure, including a redesigned body shop and assembly areas equipped with updated automation technology. Before physical vehicle assembly, the plant carried out industry-standard “common function tests,” in which production equipment runs through complete process cycles without actual components.

These simulations validate equipment interactions, workflows, and interface integration under realistic operating conditions. By reproducing production sequences digitally and physically, engineers verify cycle stability, system synchronisation, and operational reliability prior to pre-series manufacturing.

The approach reduces ramp-up risks by identifying potential process deviations early and ensuring that individual manufacturing stages operate as an integrated system.

Pre-Series Production as a Step Toward Industrial Readiness
Following successful system validation, the facility began producing complete pre-series BMW i3 vehicles in early 2026. This phase allows manufacturing, logistics, and quality teams to operate under real-world conditions across all production stages, including press shop operations, automated body construction, paint processes, and final assembly.

Pre-series manufacturing provides measurable feedback on material flows, process timing, and automation performance. Data collected during this stage supports iterative optimisation of digital interfaces and production workflows ahead of full-scale manufacturing.

Automation and Digitally Connected Manufacturing
The upgraded body shop incorporates highly automated robotic systems that assemble and weld vehicle structures. In parallel, the modernised press shop forms sheet-metal components under digitally monitored process conditions, enabling engineers to supervise and adjust operations via centralised control systems.

These connected production technologies form part of an integrated automotive data ecosystem designed to synchronise equipment, planning tools, and operational analytics across the plant.

iFACTORY Principles: Virtual First, Physical Implementation Second
Plant Munich applies BMW’s iFACTORY methodology, in which production areas are planned and simulated in virtual environments before construction begins. Digital twins of assembly lines and production workflows enable early functional testing, layout optimisation, and scenario analysis.

Virtual simulations allow alternative process configurations to be evaluated without physical modification, reducing commissioning time and supporting a smoother production ramp-up. Employee training also benefits from this approach: operators learn workflows in augmented reality environments before interacting with real machinery.

Plant Transformation During Ongoing Production
The facility’s reconfiguration was completed within approximately 18 months while maintaining ongoing production of existing models, including the BMW 3 Series and 4 Series. Roughly one-third of the plant footprint was reorganised, including construction of a new body shop, updated logistics areas, and a redesigned assembly line.

Maintaining production continuity during large-scale conversion required synchronised planning across logistics, equipment installation, and workforce training, demonstrating the role of digital planning tools in managing complex industrial transitions.

Toward Series Production of the Neue Klasse
With functional testing complete and pre-series vehicles already assembled, Plant Munich is entering the final preparation phase before full series production begins in the second half of 2026. Lessons learned from pre-series operations will continue to refine processes, digital interfaces, and automation performance.

The project highlights how digitally planned manufacturing systems, virtual validation, and integrated automation can accelerate the transition to electric vehicle production while maintaining operational stability in existing facilities.

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