South Carolina, USA. BMW Group Plant Spartanburg in South Carolina, USA, is commemorating 30 years of production with the inauguration of its state-of-the-art press shop in preparation for the upcoming launch of the new BMW X3. All exterior body components of the X3, such as body sides, doors, side panels, and tailgate, will be manufactured in-house at the plant’s press shop.
Addressing the audience in Spartanburg, Milan Nedeljković, a Board Member of BMW AG responsible for Production, emphasized the plant’s significance for the company and highlighted future prospects: “After three successful decades of production, we are enhancing our commitment. By late 2026, the production of fully-electric Sports Activity Vehicles will commence here in Spartanburg – a significant stride in fortifying our global presence.”
By the year 2030, a minimum of six fully-electric models will be produced at the US facility. The high-voltage batteries for the future Battery Electric Vehicles (BEVs) from Spartanburg will be sourced from nearby Woodruff, where the BMW Group is establishing an assembly for sixth-generation batteries. The new advanced press shop also plays a role in bolstering the local manufacturing footprint in the US.
“Our cutting-edge production techniques employed in the press shop will guarantee top-notch quality and efficiency of body components for our customers,” affirmed Robert Engelhorn, CEO of BMW Manufacturing. “Having this press shop on-site aligns with our ‘local for local’ strategy, aiming to produce significant parts where they are required.”
- Advertisement -
With an investment exceeding $200 million, the construction of the approximately 20,000-square-meter press shop has been completed. From site preparation to the initiation of stamping the initial parts on the press line, the entire process took less than two years. This investment has also led to over 200 new job openings in various disciplines, including tool and die technicians, as well as electrical and mechanical maintenance for automated machinery. Several associates from Plant Spartanburg were trained at the BMW Group press shops in Swindon, UK, and Leipzig, Germany.
During the event, the fourth-generation BMW X3 was unveiled to the attendees. The BMW X3 stands as one of the company’s best-selling vehicles in the United States and globally. Plant Spartanburg has produced over 1.7 million BMW X3s since its introduction in 2010. The new BMW X3 is set to be launched in the market in the fall of 2024.
State-of-the-art press shop manufactures up to 10,000 components daily
The press shop marks the initiation of the automotive production process. Huge steel or aluminum coils are unloaded from trucks utilizing a 55-ton overhead crane. These coils are initially processed in the coil line, where the sheet is cut into individual “blanks” at a rate of up to 70 strokes per minute. The prepared blanks are then fed into the five-phase press line for the final body component formations.
The line is equipped with advanced servo technology, enabling the BMW Group to produce large volumes with high efficiency. Each station is serviced by an overhead crane that moves the appropriate press tool (die) into position. The blanks move from one station to another using robot-assisted automation technology known as the “crossbar feeder” for further shaping and trimming operations. With a capacity of up to 18 strokes per minute, the line can produce over 10,000 components daily, varying based on size.
- Advertisement -
Upon completion, the parts undergo quality control inspection using specialized lighting simulating natural daylight. The stamped parts are then organized in containers for transport to the body shop for additional processing.
Similar to other BMW Group facilities, Plant Spartanburg has introduced a closed-loop material cycle for scrap metal from the press shop. Beneath both the press and coil lines, designated areas collect the scrap metal post-stamping. Approximately 60 tons of scrap are accumulated each day, transported by a roughly 300-meter-long conveyor to be recycled and reused in the manufacturing of new steel and aluminum coils.
Over seven million BMWs manufactured in three decades at Plant Spartanburg
- Advertisement -
Marking 30 years of production in South Carolina, Plant Spartanburg has assembled more than 6.7 million BMW vehicles. With a workforce exceeding 11,000 individuals, the facility produces various BMW X models and ranks as one of the BMW Group’s largest plants globally, manufacturing over 1,500 vehicles daily. The 750,000-square-meter campus comprises three body shops with over 2,600 robots, two paint shops, and two assembly halls. The plant derives around 20 percent of its power from recycled methane gas sourced from a local landfill and utilizes hydrogen fuel cell technology to power approximately 800 logistics vehicles.
In 2022, the BMW Group disclosed plans to invest $1.7 billion in its US operations, with $1 billion allocated to prepare Plant Spartanburg for the assembly of fully-electric vehicles and $700 million dedicated to developing a new high-voltage battery assembly plant in Woodruff. Once operational in 2026, Plant Woodruff in South Carolina will produce the sixth-generation batteries to equip fully-electric vehicles at BMW Group Plant Spartanburg.