Leipzig

2013

The BMW Plant Leipzig..

Secret of our success: balance of customer, strateg
and participation.

Title
BMW
Plant Leipzig

Munich
September 2009

Leipzig
2013

The BMW Plant Leipzig.

Content.
1.

About the BMW Group.

2.

BMW plant Leipzig: What makes us unique?

3.

Our strategy to excellence.

4.

The cascading strategy process and target management process

5.

Processes and methods to achieve unique customer value:

VPS, Kata and our understanding of the role of management.

6.

Some examples for business performance.

7.

Distinctive initiatives for our success.

8.

Summary: Why are we Germanys best factory 2013?

Leipzig
2013

The BMW Plant Leipzig.

About the BMW Group: the production network.

Leipzig
2013

The BMW Plant Leipzig.

Our products at Plant Leipzig.

Range of products:
BMW 1 Series 5-door.
BMW 1 Series Convertible.
BMW 1 Series Coup.
BMW X1.

Jobs on site: currently approx. 6.000 (including exte

service providers and suppliers) 3.200 at BMW.
Plant size: 229 ha.
Start of serial-production: March 2005.

Capacity of production:
up to 740 units per day.

Leipzig
2013

The BMW Plant Leipzig.

What makes us unique?

Vehicles made by the BMW Group set the highest standards with regard to aesthetics,
efficiency, dynamic performance, technology and quality and thus underline the compan
status as a technology and innovation leader.
leader

On 18th September 2013 we have started the production of the BMW i3.
The BMW i3 is an emission-free
free urban vehicle with electric drive and a carbon (CFRP) bo
Furthermore, we will manufacture the BMW i8,
i8 a plug-in hybrid sports car with electric d
and combustion engine from 2014. The BMW i8 also comes with a carbon (CFRP) body.

Leipzig
2013

The BMW Plant Leipzig.

Our strategy to excellence: Customer orientation
Market flexibility

Structure flexibility
Excellence in:

Quality
Participation and subsidiarity

Time

Costs

Sustainabilty

Process orientation (VPS)

Leipzig
2013

The BMW Plant Leipzig.

Our strategy to excellence: flexibility and adaptability are
key competitive factors.
working hours
(hours per year)

Volume planning within

defined ranges

volume
(entities per year

8000
7000

range of
business
operating time

6000
5000
4000
3000
2000
1000

production follows sales

Leipzig
2013

The BMW Plant Leipzig.

Our strategy to excellence: structural flexibility. Ideal plant
structure according to the flow principle.

press shop
body
b
shop
paint shop
CFK

new vehicles

Carbon fiber reinforced plastic

assembly
VZ

TEK

Technology exterior components

assembly

body shop

VZ

Material
Just
in Time
/
Material Just
in Time
/
Just ininSequence
Just
Sequence

The BMW Plant Leipzig.

The cascading process: business planning at the Leipzig plan
Number ONE

standard processes

Leipzig
2013

production
division strategy

plant business
plan

Vision
The BMW Group is the leading
provider of premium products
and premium services for
individual mobility.
Mission statement production division
We are a Number ONE production
network. We manufacture premium cars
and engines, in a customercustomer and valueoriented way, using excellent processes

Target vision plant Leipzig

We have the most competitive
production system.

Initiatives o
BMW Group le

Initiatives/ena
on productio
division leve

Initiatives/ena
on plant lev

Leipzig

The BMW Plant Leipzig.

Participation in the business planning process.

Business planning
Strategic analysis

Strategy development

Business plan

Monitoring: achievement
of objectives

Target management
3-level
level-model*

Target proposals
bottom up

Target management

* Three management hierarchy levels are involved in each target agreement meeting.

Leipzig

The BMW Plant Leipzig.

Holistic organisational approach in the business planning
process

Development
environment

Improvement by continuous
reflection.
Business plan
Strategy

System:
Leipzig plant

OD*
Identity
values
Capability
behaviour

Practice
Processes
*OD: organisational development

Leipzig
2013

The BMW Plant Leipzig.

Business planning process as the basis for our daily busines
constant pursuit of perfection

Enthusiastic employees within an open mind

culture.

Plant business plan process.

Transparency and consistent
indicator system.

human

Standards / CIP
problem-solving competence.

value

value
stream

flow

pull

Leipzig
2013

The BMW Plant Leipzig.

Participation of associates in the CIP

Poka Yoke
team of experts
management
on site

qualification
training centre

VPS
workshops
VPS
waves

today for tomorrow

ergonomics

The philosophy of our value added oriented production system (VPS) has reached the employee.
Training and support modules encourage initiative and creativity of each individual.

Leipzig
2013

The BMW Plant Leipzig.

Daily routines in the CIP
Where we are and what
we know

where we want to be and

what we have to study
unforeseeable
learning path

Target state

Comfort zone

or learning task

Challenging
Unsolved
Solvable
Solution is known

Actual state
(also key competencies
and capabilities)
unsolved problems
and barriers

current
knowledge
frontier

Leipzig
2013

The BMW Plant Leipzig.

Business performance: hours per vehicle and costs per vehicle

Costs per vehicle

improvement per year: -7,2%

2009

2010

2011

external view

2012

improvement per year: -7,0%

2009

2010

2011

internal view

2012

Leipzig
2013

The BMW Plant Leipzig.

Sustainability in the production processes.
Sustainable mobility has started before the vehicle first touches the road.

50 % less energy (fully sourced from renewable sources), 70 % less water consumption.

On-site installation of four windmills.

Leipzig

The BMW Plant Leipzig: its hard not to participate.

Leipzig
2013

The BMW Werk Leipzig.

Summary: key success factors as Best German factory.

People.
Transparency.
Standards.
Consequent cascading of strategy.
Subsidiarity and participation.
Last but not least: happy customers.

Leipzig
2013

The BMW Werk Leipzig.

Fascination of Production. Welcome to a plant tour tomorrow.
Thank you for your attention.