Leipzig. Electrification continues at BMW Group Plant
Leipzig: Four months after launching production of the
combustion-engined MINI Countryman, the all-electric version is now
rolling off the lines at Leipzig as well. After phasing out production
of the BMW i3, the birthplace of electric mobility at the BMW Group
has welcomed another fully electric car to its range. It now
manufactures four models with three drive types by two brands, all on
a single production line: the BMW 1 Series, the BMW 2 Series Active
Tourer (including the plug-in hybrid version), the BMW 2 Series Gran
Coupe and the MINI Countryman in both its fully electric and
combustion-powered versions.
The MINI Countryman Electric represents a major step in the MINI
brand’s transition to full electrification by 2030 and combines an
electrified go-kart feel with zero local emissions mobility. It comes
in two fully electric variants: the Countryman E (150 kW, 204 hp |
electricity consumption 17.4 – 15.7 kWh/100 km | CO2 emissions 0 g/km)
and the more powerful all-wheel Countryman SE ALL4 (230 kW, 313 hp |
electricity consumption 18.5 – 16.8 kWh/100 km | CO2 emissions 0
g/km).
Consistent plant upgrades and flexible production system
To enable production of up to 350,000 units a year – 100,000 more
than previously – Plant Leipzig has been continuously upgraded since
2018, with extensive additions and upgrades to the bodyshop,
paintshop, assembly and logistics. “Our cars and components are very
much in demand. In recent years the BMW Group has invested around 1.6
billion euros in the Leipzig site to produce additional vehicles and
electric components, and now we’re increasing vehicle volumes too –
which is great news for our plant,” said Petra Peterhänsel, Plant Director.
The main driver behind the volume increase is the MINI Countryman.
During the course of 2024, output will rise to almost 500 units a day
– on top of the 800 or so BMW vehicles the plant is producing. What’s
more, thanks to its flexible production system, Plant Leipzig is in a
position to respond quickly to customer demand, for example by
increasing the share of fully electric vehicles.
Flexible assembly structures also meant the MINI Countryman Electric
could be integrated seamlessly into production. The situation is
similar with the different drive units, which are all produced on one
and the same line in aggregate assembly and prepared for what’s known
as “marriage” with the body. The e-drives, transmissions and control
electronics (collectively known as the highly integrated electric
drive topology, or HEAT) for the two all-electric models are connected
directly in the plant. A new production line was required only for the
control electronics.
More staff and nightshifts for increased production volume
Higher production volume means secure employment and up to 900
additional employees in vehicle production alone. By the end of 2024,
Plant Leipzig will employ around 7,000 BMW staff. Working hours will
need to be adjusted in all technologies, with nightshifts in assembly
starting for the first time in September of this year and cars being
produced round the clock in three shifts.
“Plant Leipzig first went on stream in 2005 with about 2,600
employees in production. 19 years later there are over 7,000. Over the
years, the plant has grown steadily and considerably. The start of
nightshifts in assembly represents another important milestone in the
success story of our plant and is a clear show of confidence by our
company in our site here in Leipzig,” emphasised Works Council
Chairman Jens Köhler.
Made at Plant Leipzig: high-voltage batteries for the MINI
Countryman Electric
With the production launch of the MINI Countryman Electric, all three
stages of the Gen 5 high-voltage battery production process are now
represented at BMW Group Plant Leipzig: cell coating, module
production and battery assembly. Operations in all three are currently
ramping up, with five cell-coating, three module-production and two
high-voltage battery-production lines now in place.
“We are in the middle of the transformation to e-mobility,” said
Markus Fallböhmer, Head of Battery Production at the BMW Group.
“Starting this year, Plant Leipzig will carry out every stage of our
in-house high-voltage battery production process. It’s our next great
step forwards.”
Plant Leipzig’s e-component production capacity has been increasing
since 2021. It will now manufacture not just the high-voltage
batteries for the MINI Countryman Electric but also e-components for
the BMW iX1, BMW iX2, BMW i4, BMW i5 and BMW iX made at other sites.
The e-component production unit at Leipzig currently employs some
1,000 people.
To enable production of high-voltage batteries, spaces previously
used for the BMW i3 and BMW i8 have been converted and new buildings
added. One of them is a new hall with a footprint of about 61,000
m2. This houses two lines capable of producing up to
300,000 high-voltage batteries a year. The BMW Group has invested over
900 million euros in e-component production at Plant Leipzig to date.
Resource-saving painting processes
At launch, the fully electric MINI Countryman comes in three
additional body colours: British Racing Green, Chili Red and Blazing
Blue – and with MINI’s trademark contrast roof, if desired. This is
painted using a new overspray-free method that saves resources and is
currently being readied for series operation. The term “overspray”
refers to the mist of excess paint particles that forms when bodies
are painted the conventional way. With the new technique, this mist no
longer occurs. This makes it easier to paint in multiple colours as
the laborious process of masking is no longer required. Overspray-free
painting also helps save CO2 emissions, as exhaust from the
cabin requires less cleansing. In addition, it requires considerably
less conditioned air, i.e. air that is brought to the exact
temperature and humidity required for painting. As a result, less
energy is needed to temper air and treat exhaust.
The burner technology used to dry the paint on contrast roofs was
also converted for the start of MINI Countryman production and now
consists of a bivalent system. The fuel-flexible burners can run on
hydrogen (H2) as well as gas (methane, CH4) and even switch between
the two while in operation. Five such bivalent hydrogen-capable
burners are used to produce the contrast roofs for the MINI Countryman.
Further burners in the paintshop will also gradually switch to
bivalent operations, with the next six hydrogen-capable burners just
installed. This makes Leipzig a pioneer in the automotive industry and
takes it ever closer to lower CO2 emissions. “Our vision at
Plant Leipzig is to decarbonise production as far as possible
by replacing fossil fuels with green hydrogen,” said Petra
Peterhänsel, explaining the long-term focus of the facility. This will
require sufficient green hydrogen from a grid. A regional hydrogen
grid is currently in planning, with Plant Leipzig set to benefit.
MINI
Countryman E
Electricity consumption combined: 17,4 – 15,7 kWh/100 km according to
WLTP
CO2 emissions combined according to WLTP: 0
g/km
CO2 Class: A
Electric range according to
WLTP: 462 – 423 km
MINI Countryman SE ALL4
Electricity consumption combined: 18,5 – 16,8 kWh/100 km according to
WLTP
CO2 emissions combined according to WLTP: 0 g/km
CO2
Class: A
Electric range according to WLTP: 432 – 399 km
