BMW creates production “triangle” in the UK to manufacture the new Mini

Abstract

Purpose

The purpose of this paper is to describe how BMW in the UK has put together a production “triangle” that brings together three of its four manufacturing plants in Britain to produce the latest version of the Mini passenger car.

Design/methodology/approach

Describes the major production line techniques that are used in the manufacture of the body‐in‐white (BIW) structure as well as the functions of painting and final assembly of the vehicle. The BIW techniques include logistics, spot‐welding and adhesives, as well as optical and laser inspection.

Findings

Over the space of the last three or four years, the management of BMW Group has come to realize the importance of integrating three of its four manufacturing units in the UK with purpose of achieving greater utilization of its existing capacity, and improving productivity.

Research limitations/implications

The BMW Group continually assesses all of the functions involved in the manufacture of a motor vehicle, and in this context is working both with its own plants as well as with suppliers of equipment and components to enhance production and quality processes. This includes all of the processes of joining steel and other materials using spot welding and adhesives. There is also much to be gained from the interchange of information between the various plants in the group worldwide with a view to implementing continuous improvement. The benefits achieved from one process in one particular plant are quickly communicated to other facilities, again with the object of improving quality and productivity.

Practical implications

It is likely that arising out of greater plant integration and utilization, the management of BMW Group will be able to further increase the capacity of its Mini production units to be in a position to move to the next stage of expansion, namely to reach a target of 300,000 units a year.

Originality/value

This is the first time in the UK that BMW has integrated three of its production facilities with those of three major component suppliers to produce a finished vehicle. There is a heavy concentration of KUKA robots within the BIW and sub‐assembly manufacturing facilities.

Citation

Mortimer, J. (2007), "BMW creates production “triangle” in the UK to manufacture the new Mini", Industrial Robot, Vol. 34 No. 1, pp. 26-31. https://doi.org/10.1108/01439910710718414