BMW M5 In Depth - Part 2

Press Release

Production of the BMW M5: Exclusivity off the Line

The BMW M5 is built at the Dingolfing Plant, the largest production plant within the BMW Group’s production network comprising no less than 23 production facilities worldwide. Highly flexible in all its operations, the Dingolfing Plant employs a workforce of approximately 23,000 BMW associates – thereof more than 80 per cent skilled workers – and builds some 1,300 BMW 5, 6, and 7 Series every day.

A sophisticated logistics system – BMW’s Customer-Oriented Sales and Production Process (COSP) – ensures that each car is built exactly on time to its specific national specifications and, of course, in line with the customer’s personal order and requests.

Quality management systems consistently optimised and upgraded, together with numerous function and reliability tests in all areas of production, guarantee optimum fulfilment of BMW’s strict quality requirements.

Production of the body-in-white together with other models in the 5 Series.

The body-in-white of the new M5 is built by highly flexible robots on the same lines and facilities which also produce the bodyshells of the BMW 5 Series Saloon and the BMW 5 Series Touring in the regular production process. This course of production takes place in any random order and combination in accordance with instructions from production management. Naturally, the bodyshell of the M5 also benefits from all the innovative bonding and joining technologies used in series production of the BMW 5 Series. This also applies to the application of stamp rivet technology on the lightweight aluminium front end of the car.

Production of specific parts and components exclusive to the M5 is integrated in the production processes and production areas as such. The floorpan, for example, fitted at the rear of the car is modified to provide space for the double-chamber exhaust system. Reinforcements around the rear axle subframe, in turn, serve to accommodate the extra power and performance of the M5. To provide adequate space for the rear wheels, the side-frames have been modified around the rear wheel arches. And, finally, suitably moulded body panels specially made in the press shop are fitted on the side walls.

The joining technologies used in production of the lightweight aluminium front end are bonding, riveting, MIG and laser welding.

In all, BMW uses some 1,000 robots in production of the 5 Series (Saloon, Touring, M5) body-in-white. The bodyshell consists of approximately 500 steel and aluminium parts weighing approximately 350 kg.

Offering the customer a wide range of – sometimes quite unusual – paintwork colours.

In the Paintshop the body-in-white of the M5 goes through all the systematic processes already applied in the regular paintwork process. First there is the RoDip (Rotation and Dipping) pre-treatment process allowing a share of up to 30 per cent aluminium. Then anti-corrosion paint is applied on to the phosphated bodyshells in the cathodic dip bath (CDB) both inside and outside, extending all the way into the smallest nooks and crannies. Following application of the filler by means of all-new robot paint-application technologies, the body of the car is finished in BMW’s new, exclusive M colours on a special paint application line. This ensures a perfect finish in the four M colours as well as a wide range of some 250 individual colours all naturally applied in top quality to fulfil all of the customer’s requests very flexibly and efficiently. The powder-based clear paint applied as the final layer gives the surface an appropriate gloss and protects it from both ultra-violet radiation as well as other elements in the environment.

A particular challenge in the Paintshop is to ensure perfect balance and harmony of colours between the body and individual components such as the bumpers, sills and rear-view mirrors. This efficient process of perfect colour-matching is ensured by new, automatic online measurement of each and every colour shade.

Human performance – the No 1 factor on the assembly line.

Contrary to job requirements and working conditions in the Press Shop, Bodyshop or Paintshop, where processes are largely automated, human performance is the fundamental factor in Assembly. The reason, quite simply, is that the human being is able to work in almost 30 different modes and levels with his hands, while even the most sophisticated and advanced industrial robot is not able to operate on more than 7 levels or planes.

High qualification and motivation of all associates ensure perfect production of customised cars of the highest quality. After all, each and every M5 is tailored to its proud owner – from the drivetrain through the suspension and paintwork all the way to the seats and interior equipment.

Wherever possible the workers on the line are assisted by handling devices picking up and transporting heavy components and thus avoiding heavy physical labour. As a result, the workers are able to concentrate entirely on the process of fitting the parts and components smoothly and with ultimate precision. In this process they are supported by a special Information System for Associates presenting the parts and components to be fitted in each case on a screen. And considering the large number of different models built in Dingolfing, together with their wide range of specifications, this is indeed essential.

Special components exclusive to the M5 – the power unit, seats, steering wheel, rear axle, etc – are also delivered to the assembly line in sequence, just like all other components of the BMW 5 Series in general. A wide range of tests and inspections as well as a comprehensive test drive on the dynamometer come as the final point in production of every M5 before the car goes to the customer.