The BMW Group is taking its Virtual Factory initiative to the next level, with production planners leveraging digital twins of more than 30 production facilities to streamline global production planning. This advancement allows for processes that previously took weeks for adjustments and testing to be accurately simulated within the Virtual Factory framework.
With plans to integrate over 40 new or updated models into its global production network by 2027, the BMW Group is starting the process with virtual simulations to ensure stability at manufacturing sites. The implementation of the Virtual Factory is expected to result in a significant reduction in production planning costs by up to 30%.
Virtual planning plays a crucial role in the BMW Group’s iFACTORY strategy, utilizing tools that integrate building, equipment, logistics, and vehicle data with 3D process simulations. This integration creates digital twins for all BMW Group plants worldwide.
Using an industrial 3D metaverse application developed on Nvidia Omniverse, real-time simulations enable the virtual optimization of layouts, robotics, and logistics systems within the Virtual Factory. The company continues to evolve the Virtual Factory, incorporating generative and agentic AI capabilities.
One key aspect of the Virtual Factory is the automated verification process for new product launches to ensure compatibility with the production line and prevent collisions. This process, which previously required manual guidance of physical vehicle bodies through production lines, has been automated within the Virtual Factory, reducing the time needed for collision checks from weeks to just three days.
The Virtual Factory also includes features such as automated collision checks, human simulations to optimize manual tasks, and automated mapping of surroundings from existing 3D scans to enhance smart transport systems. Additionally, the BMW Group is exploring all-solid-state battery (ASSB) technology by incorporating large-format ASSB cells from Solid Power into its test vehicle, the BMW i7.
As the BMW Group continues to enhance its Virtual Factory capabilities, the company remains at the forefront of innovation in production planning and efficiency. The integration of digital twins, real-time simulations, and AI technologies is revolutionizing the way vehicles are manufactured, leading to more cost-effective and streamlined production processes.
