BMW 5 - Manual (Page 65)

BMW
Media
Information
11/2009
Page 65
integrates several steps in production and is able to turn out up to 160
components in 40 strokes per minute. Up to 21 work processes are
conducted at the same time, from the first stamping process through
various elongation processes all the way to the final insertion of stamped
components.
In ProgDie production the individual strips of material come straight off the
steel plate cylinder and are consistently moved through the die in each step.
This ensures particularly efficient use of material and a reduction in the
consumption of energy. Compared with conventional pressing processes,
this saves approximately 5 million kilowatt hours of electricity each year.
Supreme quality right from the outset.
To fulfil BMW’s strict quality standards right from the start when launching
a new model such as the BMW 5 Series, BMW not only conducts many tests
and examinations with pre-series cars, but also applies the so-called cubing
method: More than a year before the start of production, the quality and
accuracy of more than 800 parts and modules are tested at the plant on
a completely accurate body model. Weighing approximately three tonnes,
this model is milled according to the car’s development data out of massive,
shrinkage-free special aluminium down to an accuracy of 0.1 millimetres.
In several iterations on this model, first the prototypes and then the first
components are fitted in position together with the various suppliers to
check the precise dimensions and perfect fit of components with one
another and on the body as a whole prior to the start of series production.
Modular strategy serving to promote customer-oriented production.
A highly sophisticated system referred to as the Customer-Oriented
Sales and Production Process (COSP) ensures that each car ordered by
the customer is completed exactly on time and fully in accordance with the
customer’s specific wishes and requests.
COSP is also ensured by highly flexible production based not only highly
developed logistics but also on the most efficient processes. Particularly
the processes conducted on the assembly line benefit from the use of
pre-assembled modules delivered as a whole straight to the production line.
The complete front-end, for example, is one single module delivered just-in-
sequence to the line, where subsequently only a few final steps are required.
The bodies-in-white for the various models are built in any random order
and combination according to the data provided by production management.
In conjunction with modular supply, this allows highly flexible and very lean