The Process of Making BMW - Report Example

The Process Of Making BMW The process of making a BMW car is truly an overwhelming one, a fact that emerges strongly when one goes through the detailed and well-thought out manufacturing and quality checks each BMW car goes through. Currently BMW manufactures its various car models in 22 production and assembly plants situated in the countries of South Africa, UK, Germany, Brazil and China. The organization has a worldwide network visible through its 35 sales subsidiaries that are spread out in 12 countries1. Here is an overview of the process in which a BMW car is made. Car manufacturing: From thought An eye for perfection begins right from the point of product conception. Each idea that would become a car goes through a regular product development process (PDP), which is now mandatory for all BMWs. Under this process, the various components and new technologies are integrated to form a complete vehicle. The final product thus realized must meet the stringent real time tests that all BMW cars go through. This process has also been employed in the BMW Hydrogen 7 series that are due to hit the roads in 2007 when a limited edition of these cars would be sold to select users in select countries. This would be the world's first hydrogen powered and luxury performance car. A Process Development Center (PDC) has also been created for the pre-production testing of supplier components. An analysis center allows for functional analysis, testing compliance to standards and testing improvements made to the line. The production plant Once designed, tested and approved, the BMW next goes into the production plant. This plant comprises of three distinct departments: the body shop, the paint shop and the assembly line. The KISS system (Kernfertigungs - integierendes Ste uerungs System) is employed to completely automate communication in the production plant and also to design and store an electronic history for each car. It schedules and sequences the production methodology, making the making of BMW a well-organized process. The body shop The first stop in the body shop is the press shop. Here the various body panels, both outer and inner are pressed in special presses. Once the various panels are shaped out, they are welded together to create the complete body shell. Computerized robotic systems weld the small components together that make the three parts of the underbody of the car shell: the motor compartment, the floor pan and the rear compartment. The next stopover is the underbody marriage station (a BMW patent technology), where each car is attached to a geometric pallet. This allows for easy rotation and lifting of the underbody for associates and machines to easily weld bolts and various other small components into place. Next, the car enters the framing area where pre-assembled sides come to join the underbody. Once the pieces are weld together, robotic laser sensors inspect the unit for any possible errors. The car body is mounted once again on the geometric pallet to further weld and braze the unit for additional strength2 and prevention from water leaks. On completion, the car shell is transferred on the conveyor belt to the final stage of the body shop: fitting and finishing. In this stage the BMW is fitted with the various metallic components like door hinges, trunk and hood hinges. A grinding and sanding booth then smoothens these hinges and car body, making it better receptive to the paint. The hang-on panels including the doors, fenders, the hood, trunk and quarter panels are finally attached. BMW associates then carry out a final inspection whereby the car is checked for pluses (raised areas) and minuses (indentions). Once the smooth finish of a car is ensured, it is ready to go to the paint shop. The car is then lifted overhead and put on specially constructed computerized conveyors that transfer the semi-finished car shell to the paint department. This section of the factory is highly automated and computer controlled. The paint shop In the paint shop, the body of the to-be car is cleaned in a phased manner that includes brush cleaning and degreasing. Next is the phosphate stage, where the car body is coated with a crystalline structure of zinc, nickel and manganese that would protect the car against corrosion. This also allows for the adhesion of the E-coat whereby electrodeposited paint would be put on the car for added protection against corrosion. After being painted, the car shell is sent to large ovens where the paint is dried. A five-lane sealer deck is the next stop for the BMW, where associates spray and lay down bead seams, which would prevent water leaks and cut out noise. From here the car enters the Underbody Sealer Area (UBS) where polyvinyl carbonate is sprayed on the underbody for corrosion proofing, prevention from water leaks and noise, and the body is oven dried once again. In the e-coat finishing and inspection deck, defects and deformities are removed and sound deadener pads are installed for further noise cut-off in the car. The car is finally ready to enter the primer spray booth, a clean room in manufacturing, where the car is coated with primer. The body bakes in the oven once again to enter the sanding and inspection booth, where errors if any in the previous cycles are corrected and the car is sent into the primer room for a basecoat. From here the car is quickly oven dried and sent to the clearcoat booth where the car is finally coated on the inside by robots and on outside using the electrostatic zone. This coat gives the car a good shine and is then oven dried in the largest oven in the unit. Associates also spray cavity wax into the car cavity and spread it evenly for coating the entire area. BMW has shown its concern towards the environment by adopting water-based colour paints to be used along with powder based colour lacquer. Besides its various technologies, the paint shop offers the Mini-Mix and Micro-Mix paint systems, which allows for fast colour changes between individual body shells. This system comprises of eight stages and eliminates the requirement for 'batch painting' various cars before switching colors. Approximately ten hours are required to paint and dry a car, a process from where it goes into the assembly line where the various components are integrated one by one. BMW Assembly After the body shop and the paint shop, the BMW unit is all ready and waiting at the entrance line, a point from where assembly begins. The first step is the sunroof seal where heated rubber seal is applied to the car flange. After this a tilt conveyor is used for placing the unit on an Automated Assembly Build Vehicle (AABV). Fuel system components and brake system components are now installed with ease and efficiency. The door handles, airbags, electrical harnesses and other features are now installed on each door. Wiring is heated for pliability and fitted through the areas of the cabin, trunk and engine. Shocks, battery and additional electrical modules are also installed. With all this done, the car enters the trim cover, all ready for installing the first interior components. The seatbelts, headliner, CD player and AC unit are set in place and the wiring harness is completely covered. A separate station assembles the cockpit for better quality control reasons and places it into the car shell as a single unit. The separated doors are now attached, further trim features like the spoiler are added and the car enters the Trim 2 stage. High end technologies and environment friendly concepts BMW is a highly quality conscious organization, a fact that comes through with the innumerable quality checks that take place at each stage. All components that are manufactured go through stringent quality audits, both during production and while assembly. BMW utilizes FDM technology for direct production of components during manufacturing and testing. This testing and production tool helps with enhancement in ergonomics, producing complex shapes of components, reduction in warehousing and reduction in costs and production expenditures. Besides these the FDM can be utilized for function tests, tests for package space, display and cubing models. The various components also go through life cycle assessment tests and designs for recycling, aspects that more often than not lead to innovative concepts. Technologically advanced components The BMW six cylinder engine, which is renowned all over the world, offers a smooth performance while driving. In the BMW 3 series, these engines have been further improved for a further empowered performance. Double VANOS (double variable camshaft control) makes all BMW petrol engines highly efficient, as these constantly adjust the timings of intake and exhaust valves. This controls the amount of fuel/air mixture to match requirements leading to optimum performance and less burning of residual gases. A unique four-valve technology with a centrally located spark plug is utilized. This helps to optimize a better cylinder charge for petrol engines. The four-valve design also leads to a highly efficient combustion chamber, which leads to lesser fuel consumption. A constant ignition is present and the spark plug in each cylinder has its own ignition coil causing a strong spark that again enhances the efficiency of combustion and reduces fuel consumption. The vital engine functions of ignition, fuel injection, lambada control etc. are overseen by the DME (Digital Motor Electronics) module. User-friendly features Innovative technologies are employed at each stage, making the BMW an extremely attractive and advanced car in all ways. This comes through the wide range of features that the BMW comes equipped with. For example, the bluetooth technologies, park distance control mechanisms, voice recognition software and wireless application protocols keep BMW travellers well connected to the world. Cruising through heavy traffic is effortless with technologies like the active cruise control, iDrive, navigation systems and the active comfort seats. The car comes complete with features like anti-locking braking system and electronic brake management. Brake force display, cornering brake control and dynamic brake control are other features that make driving a BMW a safer experience. The cornering brake control is a system unique to BMW, which makes braking during bends smoother and more controlled. As an environment conscious organization, BMW thoughtfully employs its CleanEnergy strategy to its cars. This means that right from the point of production to the point of recycling, fuels and materials are used keeping the environment and high-end driving performance in mind. All new BMW cars come equipped with high-end progressive drive technologies that are not just luxurious and smooth to drive but also fuel-efficient. The ready car arrives at the BMW Ltd. Vehicle Distribution Centre, where it goes through a quality check and a complete pre-delivery inspection before it is delivered to the customer. References used http://www.bmwusfactory.com/build/ http://www.bmweducation.co.uk/coFacts/default.asptopicID=12 http://www.bmwusa.com/About/development.htm http://www.bmw.co.uk/apm/3_Series_Techguide.pdf http://www.bmw.co.uk/apm/owner/info/owner_info_index/0,3348,,00.html http://www.autobloggreen.com/2006/09/12/bmw-officially-announces-the-bmw-hydrogen-7/ http://www.bmwworld.com/models/newclass/2002.htm http://www.designbuild-network.com/projects/bmw/ Read More