[Author Prev][Author Next][Thread Prev][Thread Next][Author Index][Thread Index]
Germany trip, the final episode (BMW factory)
Here is the info from the BMW Tour on Thurs. afternoon.
BMW AG - Factory Tour
BMW 3 Series, 4 door and 2 door compact
Petuelring 130
80788 Munich
Tel: 089 382-23639
BMW factory tour information
April - Mid-October: Every Day
Mid-October - April: Monday, Thursday, Friday
Starting time: 1:15 pm 2 1/2 hours long
Tour info.U.S.A
Goetz Gerlach
1-800-932-0831
Fax 201-307-4003
1993 Production was 533,000
950 3 Series cars produced each day
900 engines built each day , 6 cylinder, 8 cylinder, 12 cylinder , M3 and
M5 engines are produced in Munich.
The 4 cylinders and diesel engines (1700 each day) are produced in Styria,
Austria.
The tour began in the metal or body part fabrication area. The steel
arrives in large rolls where it is then cut into individual sheets. Four
to seven pressing operations (with unique dies) are required to make each
body part. Each die that is inserted into the hydraulic press weighs 25
tons and is the size of a king-size bed (3 ft thick) and costs $325,000
each. There is a large overhead crane that is used to transport the dies
into the presses. The Munich factory uses over 500 dies to make all the
required body parts. The hydraulic presses used to stamp out the body
parts are two stories tall and 20 ft wide and weigh 300 tons. There are 6
or 7 presses lined up in a row with automated feaders that pick up the
sheet steel and transfer it to the next pressing operation. Workers are
used to remove and stack the finished parts. The hydraulic presses use 600
- 2000 tons of pressure to stamp out the body parts. They process over 100
tons of steel per day. The next part of the tour included a video showing
the paint process and the body welding process. BMW affixes a microwave
transponder to each body that transmits data on each cars particular needs
and changes. It is also used to track material flow through the entire
system. It takes 7 1/2 hours to weld the entire body. The welding process
is 95% automated using 275 Kuka robots. The paint process is completely
automated with the exception of the 2nd primer coat. It takes 10 hours to
paint the entire car. There are 2 shifts at the plant. They have teams of
4 persons who do the assembly process. It takes 1min and 20 seconds to
install the windshield. The windshield has the rubber adhesive installed
on it, then it is delivered to the workers who lift it and put it in
place. Each assembly station uses around a 1 min and 30 second cycle time.
They currently have use over 500 suppliers. There are over 20 thousand
parts per car. 15% of the cars weight is from plastic parts. It takes
around 2 hours to build the engines. Each engine is tested for 10 minutes.
The engine and transmission are installed as a unit in 1 minute and 25
seconds. They have one person in a room doing the PROM burn for each cars
unique engine, transmission and Brake system controller. The cars utilize
a plastic intake manifold and a plastic gas tank located in front of the
rear axle for safety. The total assembly time for a BMW is around 30
hours. This compares with 18-20 Hrs. for U.S. and Japanese cars. After
being assembled the car is driven off the line and into a room where it is
run on a dyno to check engine, transmission and braking functions. The
operator using a computer monitor to prompt him through the individual
tests. The BMW tour was the longest (2 1/2 hrs) and the most complete. The
only thing missing was the engine assembly. The tour guide mentioned that
special tours (ie. engine assembly) are available upon request.
I had planned on staying in Munich over the weekend and checking out some
of the Museums, but I had to drive back down to Graz, Austria on Friday
(damn work!) I ended up driving a total of 1300 miles over seven days and
spent $225 on gas! The car got between 25 and 30 MPG. The gas averaged
around $4.5 U.S dollars per gallon. They do have 98 RON octane fuel
though. I stopped over in London for one day and saw a couple of Ur
Quattros with right-hand drive while wandering around Westminster Abby.
The trip was a little hectic but very fun. That's all folks!.
Scott M.