As it moves closer to developing a completely digital, networked manufacturing hub under the BMW iFACTORY concept, BMW Group’s Plant Regensburg is increasing efficiency by digitizing and automating its logistics. A brand-new BMW car, customized from thousands of parts, comes off the assembly line every 57 seconds. Up to 1,400 BMW X1 and BMW X2 models—which come in combustion, plug-in hybrid, and completely electric variants—are sent to clients worldwide every working day.
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Simplified Logistics for Effective Manufacturing
Because every component must arrive exactly on time (“just in time”) and in the right order (“just in sequence”) for manufacturing to run smoothly, Plant Regensburg’s logistics are carefully planned. The BMW Automated Transport Services (ATS), a sophisticated cloud-based traffic control system, oversees a network of automated and autonomous transport technologies that BMW uses to accomplish this. In order to ensure seamless manufacturing, this technology effectively controls the movement of autonomous cars and guarantees that parts arrive precisely when needed.
Advanced Systems for Autonomous Transportation
A wide variety of autonomous cars are used for various logistics jobs at BMW’s Regensburg facility. While Smart Transport Robots (STR) handle larger objects weighing up to a ton, automated tugger trains move minor parts from storage to the assembly line. Over the past ten years, these robots—which were created by BMW Group in partnership with the Fraunhofer Institute for Material Flow and Logistics—have improved to the point where they can recognize and avoid obstacles on their own thanks to sophisticated AI modules.
Cloud-Based Traffic Control in One Place
At BMW’s Regensburg facility, all driverless transport operations are managed by the ATS cloud-based control system. For example, the ATS receives a signal when assembly line workers start a parts request, causing the necessary materials to be delivered on schedule and along the best possible path. The system keeps logistics flowing smoothly and reduces downtime by prioritizing each transport device, making sure they are parked effectively, and charging them as needed.
At the moment, ATS oversees more than 140 smart transport robots and about 50 automated tugger trains, processing 10,000 part deliveries daily. Devices from many manufacturers are part of the fleet, and they all function flawlessly together under the ATS system. Thomas Dietz, who is in charge of process optimization and quality control for physical logistics at the facility, says, “The precision needed to deliver sequenced parts tailored to each vehicle in the exact order for assembly is what makes our logistics unique.”
Growing the self-driving fleet for increased efficiency in the future
At BMW’s Regensburg facility, the fleet is always changing. To further improve operating efficiency, new routes and vehicle types—such as automated forklifts and lift trucks—are planned. This incremental growth is in line with BMW’s goal of creating an intelligent, networked logistics system that supports the manufacturing process by integrating a number of independent systems.
Another step toward completely automated, large-scale logistics was recently taken with the introduction of an autonomous transport truck with a 55-ton payload capacity to the Regensburg press facility.
