MINI Clubman: In Depth

Press Release

History

Plant Oxford

The origins of the Oxford plant go back to the beginning of the last century when William Morris started to build cars in 1913. In 1994 the BMW Group acquired the plant, then completely modernised the facilities in 2000 and 2001, preparing for production of the new MINI.

In Paintshop and Assembly the MINI Clubman is built together, with the other variants of the MINI on the same, highly flexible production lines. Separate facilities for the new model are required only in some parts of the Bodyshop due to the car’s different dimensions.

Approximately 350 body components are fitted together by means of high-precision welding and handling robots. More than 500 of these computerised robots are working throughout the Bodyshop, and about 80 have been added specifically for the production of the MINI Clubman.

Applying more than 4,100 individual welding spots, the robots put together each individual body to ensure a high standard of stability and torsional stiffness. In some cases, eight robots work on one body at the same time on three different levels.

Quality assurance in the Bodyshop is ensured by integrated Perceptron laser measuring stations and inline measuring robots working to an accuracy of 0.05 millimetres to guarantee absolute precise measurements on each individual body.

The MINI Clubman goes through the Paintshop process together with the various other versions of the MINI in any random order, thus benefiting from all the advantages of the innovative Integrated Paint Process (IPP) introduced at Plant Oxford in 2006. Compared with conventional processes in applying the paint, IPP technology leaves out the individual stage of applying and burning in the filler coat, with the filler function instead being integrated on to one of two newly developed layers of basecoat.

In so-called wet-in-wet application of the two layers, the first layer takes on all functions and properties of the filler primer, while the second layer of basecoat provides the necessary optical qualities such as colour, effect and depth.

As in the past, the basecoat is finally covered by clear paint. The IPP process meets the same demanding requirements as a conventional paint application process in terms of its looks and the functional protection provided by the paint. Yet, in addition, IPP technology makes a positive contribution to the plant’s environmental objectives by omitting the filler stage (which often contains solvent) and thereby significantly reduces the consumption of materials and energy in the Paintshop.

Like other models in the range, the MINI Clubman is available in unique contrasting roof colours exclusive to MINI. So, depending on the customer’s request, the roof is painted in a contrasting colour by robots in a separate paint application process.

In the Assembly Hall the MINI Clubman is built on the same line as the other MINI models. Associates assemble up to 2,000 components on each individual MINI, depending on the customer’s request and the specific equipment chosen.

In the case of the MINI Clubman, 18 main modules are delivered to the assembly line just-in-sequence at exactly the right time and in the right order for assembly. These modules include the engines, the complete front module together with the headlights, bumper and cooling system, the integrated door modules, the seats and the cockpit.

Numerous quality checks are integrated in the assembly process. To carry out these tests, highly qualified associates use wireless and portable hand-held computers to identify the car by means of the chassis number scanned in advance as well as specific, pre-determined test requirements.

A comprehensive sequence of tests is also conducted after assembly, including a driving test on a rolling road and a wide range of electronic tests.

Plant Swindon: supreme precision in steel pressing.

Plant Swindon has been making body panels since 1954. Today the workforce of 1,100 associates makes 90 per cent of the pressings and 80 per cent of the pre-assembly body components such as the lids and doors for MINI assembly at Plant Oxford. Since 2005, the BMW Group has invested £60 million in the production of MINI at Plant Swindon.

The Pressings Production Area is made up of 19 pressing lines with a total of 50 individual presses. All presses have been thoroughly revised, automated and equipped with the latest electronic control systems, with press forces ranging from 400 to 5,000 tonnes.

The appropriate press is used in each case according to the size and complexity of the pressing involved. The front and rear lids on the MINI, for example, are pressed into shape on the longest pressing line with a total of six pressing stages, proceeding from a flat piece of steel plate all the way to the fully pressed, moulded and shaped outer skin. Particularly large body components on the MINI Clubman such as the doors, the roof with its two Dune Lines, and the side panels go through two four-stage large-area presses with a pressing force of 5,000 tonnes.

In all, more than 130 welding and handling robots are used in the highly automated production of complete body components such as the doors and lids. It takes 20 of these robots to build the Clubdoor and the split-door for the MINI Clubman.

Plant Hams Hall: high-tech engine technology for the MINI.

Built near Birmingham in 2001, Hams Hall is the BMW Group’s Competence Centre for the exclusive production of four-cylinder petrol engines for all BMW and MINI models.

The BMW Group has invested £30 million in the Plant since 2005 on the production of petrol engines for the MINI. Approximately 1,000 associates build engines in Hams Hall with the most advanced technology highlights. Hams Hall delivers up to 800 MINI engines a day to Oxford – just-in-time and just-in-sequence for maximum efficiency in final assembly.

Heritage

The new MINI Clubman has its roots in the 1960s when the Morris Mini Traveller and Austin Mini Countryman first came on the market, and later the Mini Clubman Estate in 1969. The characteristic features of these legendary models – unmistakable design, agile driving dynamics, generous interior and the rear split-door – have been re-interpreted for the 21st century and brought bang up to date with the appropriate materials, functions and quality desired today.

Morris Mini Traveller and Austin Mini Countryman

Just one year after the launch of the Morris Mini Minor and the Austin Seven, a new body variant was launched by the British Motor Corporation. Entering the market in 1960 under the motto “revolutionary in concept, smart in appearance”, the technically identical Morris Mini Traveller and Austin Seven Countryman hit the streets. Based on the commercial Mini Van, this new model had glass windows all round and a folding rear seat bench, as well as the now familiar rear split-doors for easy access. In addition, and perhaps as a nod to its trade background, both models featured wooden planks at the side and rear resulting in the nickname ‘Woody’.

The Traveller and Countryman were largely identical to the Mini saloon in terms of technical specifications. An 848-cc four cylinder engine produced a maximum output of 34hp and a top speed of 69mph.

Between 1960 and 1969, BMC sold 207,000 units.

Mini Clubman

Through the merger of BMC and Leyland in 1968, British Leyland was established and the separation of Austin and Morris models was lifted and Mini remained. The new Mini Clubman Estate was launched in 1969 and replaced the Traveller and Countryman.

While the classic Mini remained in production virtually without any changes, the Clubman received a new ‘boxy’ front end and upgraded equipment, including wind-down windows instead of sliding windows on the doors. The engine was the same at first, but in 1975 engine capacity was increased to 1,098cc with a power output of 45hp and top speed of 81mph.

The Mini Clubman Estate reached the end of its lifecycle in 1982 having sold 197,606 units.

MINI’s more recent heritage