Day 2 of BMW Duty Days 2025 shifted from strategic displays to the operational actuality behind the corporate’s subsequent part of electrification. The tour took us from Munich to Straßkirchen and Irlbach—two small communities in Decrease Bavaria the place BMW is constructing one in all its most necessary amenities—earlier than persevering with to Landshut to speak about provider readiness, AI integration, and extra.
A Excessive-Voltage Battery Plant in Rural Bavaria
The brand new Irlbach–Straßkirchen plant is located in the midst of flat Gäuboden farmland, straight adjoining to a village of just a few thousand residents. Regardless of the agricultural setting, the size is unmistakably industrial: a 500-meter-long, 300-meter-wide meeting corridor, an power heart, logistics corridors, and a newly constructed fireplace station already geared up with six autos. Altogether, the positioning spans 105 hectares, with devoted inbound and outbound logistics zones, new street connections, and a large-scale parking and loading infrastructure sized for over 1,000 workers and intensive every day truck actions.
By late 2026, the positioning is anticipated to supply 1,000 sixth-generation high-voltage battery packs per day, supplying BMW’s Munich, Dingolfing, and Regensburg crops as Neue Klasse manufacturing ramps up. At full workforce ranges by 2028, the plant will make use of round 1,600 individuals, supported by 540 truck actions per weekday, a 23,000 m² inbound storage facility, and a 32,500 m² provide heart.
The manufacturing course of follows BMW’s six-step Gen6 battery meeting logic—cell inspection, clustering, welding, foaming and sealing, power grasp meeting, and end-of-line testing—supported by digital twins of all main equipment and real-time high quality management.
Development progress displays an unusually compressed timeline for Germany. After a public allowing course of that generated greater than 6,000 pages of documentation, BMW obtained approval in April 2024. Simply 19 months later, the core constructions are standing, equipment is being put in, and greater than 1,000 staff enter the positioning every day.
Whereas BMW executives have referred to this speedy tempo as “Bavarian pace,” the comparability typically made internally is China—the place such industrial tasks can transfer even sooner. For Bavaria, that is as shut because it will get. The corporate now brazenly refers to Straßkirchen as a flagship for its iFACTORY rules: lean, inexperienced, digital, and people-focused.
Native Politics and a Troublesome Referendum
As anticipated with large-scale industrial tasks in Germany, this plant was not pushed via quietly. A citizen group mobilized important native resistance. Issues centered on land consumption, site visitors, noise, and the worry {that a} village recognized for agriculture can be remodeled into an industrial hall.
Their efforts triggered a referendum in 2023. Turnout reached 75 %, and two-thirds of voters in the end authorised the BMW challenge. The marketing campaign left social marks which might be nonetheless seen: some banners stay, and a few residents proceed to oppose the event. However the financial impression is simple.
Straßkirchen’s municipal price range has tripled. Lengthy-requested infrastructure investments—together with a bypass street—are actually transferring ahead. Childcare funding, sewage upgrades, and several other native companies have benefited straight from the plant. The mayor brazenly admits the challenge has “modified the trajectory of the municipality.”
A number of board members acknowledged that BMW needed to conduct an unusually intense appeal offensive: data pavilions, public Q&A periods, and direct conversations in native eating places like “Jedermann,” the place executives answered questions late into the night. The corporate made concessions on site visitors routing, water administration, and environmental compensation zones, together with 500 newly planted timber and greater than 3,000 bushes.
In brief: the manufacturing unit has created winners and dissenters, but it surely has additionally introduced a scale of financial exercise the area has not seen earlier than.
Technical Foundations: BMW’s Sixth-Era Battery Structure
Inside the primary corridor, BMW is putting in manufacturing tools for its sixth-generation battery packs. These will use 46 mm cylindrical cells provided by CATL and EVE from Hungary, reflecting a blended sourcing technique influenced by each price and geopolitical concerns.
The shift from prismatic to cylindrical cells is central to BMW’s subsequent EV structure. The brand new batteries promise:
- 30% extra vary,
- 30% sooner charging, and
- as much as 50% decrease manufacturing prices in contrast with present packs.
At cell stage, power density improves by round 20%, whereas pack-level prices fall due to a transfer towards cell-to-pack building, eliminating modules solely. The Gen6 pack additionally helps BMW’s upcoming pack-to-open-body integration, the place the automobile construction turns into an energetic aspect of the battery housing.
Larger nickel content material, decreased cobalt use, and silicon-enriched anodes drive these positive aspects. Half of the uncooked materials enter will come from recycling streams, and the rest can be sourced via suppliers’ international networks. Battery cell manufacturing at companion websites in Hungary operates on 100% renewable power.
Notably, the plant consumes nearly no course of water. Rainwater is collected, and non-production wants—canteens, sanitation—are dealt with by way of a separate water system. A 62,000 m² photovoltaic set up on the roof will assist offset power demand starting in 2026.
A Roundtable on Provide Chain Resilience
Later within the day, BMW hosted a roundtable centered on provide chain stability and the business’s transition towards electrification. BMW Board Member for Buying and Provider Community, Nicolai Martin, emphasised a transparent level: long-term provider well being is tied on to competitiveness.
“We don’t depart suppliers behind,” he stated, “however each firm should guarantee its competitiveness. Innovation, effectivity, and information readiness are decisive components.”
Martin underscored BMW’s operational scale: the corporate processes greater than 36 million elements per day, backed by an annual buying quantity of €90 billion. Electrification magnifies the complexity—battery cells are actually the one largest supply of upstream CO₂ in BMW’s worth chain, making provide chain decarbonization a core strategic lever.
Transformation pace varies enormously by area, and BMW continues to depend on suppliers that efficiently navigate the transition—from combustion-era parts to EV-ready manufacturing. BMW makes use of digital instruments equivalent to Catena-X digital twins to extend transparency from uncooked supplies to meeting, a functionality Martin described as important for each sustainability reporting and long-term resilience.
Localization stays a precedence, however full regional self-sufficiency is just not at all times possible. Martin reiterated BMW’s choice for open markets and decrease commerce boundaries, although present coverage traits level in the wrong way.
Landshut: Provider Growth and AI Deployment
The second half of the day moved to Landshut, the place BMW’s Zero Defect Campus serves as a structured coaching and transformation atmosphere for suppliers. Roughly 70–80 suppliers per yr take part within the two-day workshops, which mix operational idea with on-site store flooring work.
Suppliers assessment BMW’s manufacturing routines, KPIs, transparency instruments, and communication techniques—then determine 5 to seven components they will implement themselves. BMW later follows up straight at provider websites to evaluate progress.
Landshut itself is one in all BMW’s most superior element crops, using 3,800 individuals and producing greater than 5 million parts yearly. These span mild metallic casting, plastics, cockpit modules, cardan shafts, energy-master parts for EVs, and extra. The sunshine metallic foundry makes use of two-thirds secondary aluminum, and BMW goals to realize 50% recycled sand utilization in casting by 2026.
High quality management is more and more automated. Each e-motor housing undergoes a CT scan capturing 2,400 photographs in 42 seconds, enabling structural evaluation that may be inconceivable with guide strategies. Finish-of-line testing is totally digitalized and built-in with plant-wide information techniques.
Subsequent door, the AI Lab highlights BMW’s digitalization push. The corporate has developed an inside multi-agent generative AI interface that connects LLM capabilities with real-time operational instruments equivalent to coaching platforms, high quality databases, and manufacturing monitoring techniques.
One instance is AIQX, BMW’s in-house laptop imaginative and prescient system used for optical inspections. Conventional rule-based picture processing couldn’t deal with reflective surfaces or inconsistent lighting. AIQX trains customized fashions for every use case, bettering detection charges and lowering the necessity for guide rework. Greater than 1,000 AIQX use circumstances are already deployed throughout BMW crops. By an initiative referred to as AI Lab on Tour, BMW is now coaching suppliers to undertake related techniques.
These instruments should not experimental—they’re being built-in into manufacturing environments and utilized by line staff, planners, and high quality engineers.
What turned clear on Day 2 is that BMW sees electrification not solely as a technological shift however as an operational restructuring—one requiring new crops, new workflows, new provider ability units, and new digital instruments.
[Photos: Rainer Haeckl © BMW AG]
