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BMW Group’s Plant in Regensburg aims to redefine automotive manufacturing with smart, cloud-based logistics to fully automate and digitally connect production for a more efficient future. Every 57 seconds, a uniquely crafted BMW vehicle is completed, meeting specific customer preferences. Nearly 1,400 BMW X1 and X2 models leave the plant daily, representing a mix of classic, hybrid, and electric vehicles shipped to customers worldwide. This rapid production hinges on precisely timed logistics, using intelligent transport systems to deliver thousands of components seamlessly in sequence.
At the heart of this logistical revolution is the Automated Transport Services (ATS) cloud-based control system. This smart system guides a fleet of driverless vehicles, coordinating deliveries “just in time” and “just in sequence” for every car on the line. Different types of autonomous transport devices work together to streamline production. Automated tugger trains handle the load for small parts, while larger components, weighing up to a tonne, are managed by Smart Transport Robots (STR). These robots, powered by advanced AI and developed with Fraunhofer Institute, detect their surroundings and navigate independently, avoiding obstacles on the go.
When assembly line workers need new parts, a simple rotation of the empty container triggers ATS to replenish supplies. The control system optimizes transport routes, prioritizes deliveries, and ensures smooth traffic flow within the plant. It also efficiently parks and charges transport devices as needed. Nearly 50 tugger trains and over 140 Smart Transport Robots are coordinated through ATS, handling around 10,000 part deliveries daily.
The success of this system lies in the precise delivery of each sequenced part, which is essential for keeping production running smoothly. Even a brief disruption in the delivery order could halt operations, highlighting the importance of ATS in maintaining the steady pace of production. Continuous improvements in hardware and software ensure the system stays reliable and resilient.
Plans are underway to expand this driverless fleet to include new types of autonomous vehicles, such as lifting trucks and automated forklifts, gradually fulfilling BMW’s vision of a fully connected, smart logistics network. A recently commissioned 55-tonne autonomous vehicle in the Regensburg press shop is a testament to this future, paving the way for larger, more versatile transport solutions in BMW’s evolving digital factory.
