The BMW Group is preparing to launch series production of its sixth-generation (Gen6) batteries for electric vehicles – starting with high-voltage batteries for the all-electric BMW iX5, which will begin at its Woodruff plant this December. The facility is a cornerstone for the North American market and was built near the Spartanburg vehicle plant, where the iX5 will be manufactured, in line with the ‘Local for Local’ principle. From there, the vehicle will also be exported to Europe.
To achieve this, the carmaker has implemented cutting-edge processes. The new cylindrical cells in the 46120 format from battery cell manufacturer AESC are integrated directly into the battery pack using the ‘Cell-to-Pack’ method. All production steps are monitored seamlessly in real time. Specially developed AI assistants process data alongside more than 300 employees and 250 robots to ensure zero-defect production.
Even during the planning and ramp-up phases, BMW consistently relied on digital tools. Digital twins and virtual reality applications facilitated factory planning, while employees completed a specially developed VR training programme. This allowed them to practice real-world processes and equipment operations in a highly detailed virtual environment.
