Solution: Smart Factory for final vehicle assembly
Sector: Automotive manufacturing
Location: Regensburg, Germany
BMW, renowned for innovation and ultra-efficiency, implemented Ubisense Smart Factory in its Regensburg car manufacturing plant, to automate tool control and eliminate manual barcode scanning, driving widespread efficiency gains.
Every day, more than one thousand cars are manufactured at BMW Regensburg, with multiple models produced on the same assembly line, each to an exact customer specification. Achieving this level of productivity and customization involves 150 workstations and many thousands of complex processes. With so many interactions happening simultaneously, errors, delays and waste were proving impossible to monitor and avoid.
BWM needed to gain better visibility of its operations and eliminate inefficiencies to generate significant cost savings and productivity gains.
Ubisense Smart Factory is specifically engineered to help manufacturers sustain continuous flow, optimize efficiency and reduce errors in manual assembly processes. Its rich capabilities include exceptionally reliable asset identification and automatic tool configuration, anywhere on the production line.
Using its best-in-class real-time location system (RTLS) to track thousands of interactions along the BMW assembly line and instantly adapt tool settings, Ubisense Smart Factory enabled BMW factory workers to seamlessly complete their processes and meet their objectives, without delaying operations.
Ubisense Smart Factory completely eliminated manual barcode scanning at the plant, saving time and helping factory workers avoid costly mistakes. Ubisense Smart Factory’s automatic identification capabilities allowed the BMW team to easily rebalance operations to maintain optimal production flow.
By implementing Ubisense Smart Factory at the Regensburg plant, BMW was able to completely eliminate costs related to manual tool control, minimize line stoppages and significantly reduce cycle time. It has saved hundreds of unproductive hours a day, cut the risk of errors and minimized the amount of rework. Empowered with unprecedented levels of visibility into their manufacturing processes, BMW can now make better informed, data-driven decisions to continually streamline and enhance operations at the plant.
Benefits in Brief
- Eliminated the cost and burden of manual processes
- Increased efficiency and automation
- Reduced risk of errors and rework
- Increased productivity and savings
- Enabled total traceability and compliance
- Assembly line: 1.9km
- Sensors: 470
- Cars per day: 1,100
- Workstations: 150
- Tightening operations: 165,000 per day
About BMW Regensburg
BMW Group is the world’s leading premium manufacturer of automobiles with a global sales network in more than 140 countries. Operational since 1986, the Regensburg plant employs 9,000 staff that deliver 1,100 vehicles per day, including the BMW 1 series, BMW 3, BMW M3, BMW Z4 and 4-wheel-drive models.