Together with a long-standing customer, we carried out one of the most challenging projects at the world’s largest BMW plant—which is also the largest auto exporter in the U.S. The plant manufactures several hundred vehicles daily from the BMW X5 (BEV and ICE) series, as well as the BMW X6 and X7 (existing platform). For BMW vehicle production, we ensure the precise sequencing of the highly complex front and rear axle modules.

We have already successfully implemented several model changes and projects at this plant in the past. However, the starting point for the new project was particularly challenging: The existing platform had to be converted to the new long-distance JIS process, while preparations for introducing the processes for the new platform were already underway in parallel. This meant that material logistics, supply, pre-sequencing, assembly, and shipping were being managed simultaneously for two platforms. An additional layer of complexity arose from the parallel production of ICE (Internal Combustion Engine) and BEV (Battery Electric Vehicle) variants.

Our task involved implementing an integrated process landscape across the entire shop floor. Our nemetris JIT/JIS portfolio is perfectly suited for this—it enables both platforms to be managed in parallel and allows for flexible responses to changes at any time. The transition took place without interrupting ongoing production and within the agreed-upon time and budget constraints.

Crucial to the project’s success was the high flexibility of our solution, complemented by the in-depth expertise of our employees, who have already supported numerous platform transitions and know exactly what matters in such situations. The close, trusting, and repeated collaboration with the customer also ensured rapid coordination and clear decisions.

The project demonstrates how robust the nemetris system landscape is in highly dynamic production environments. The result is a stable, efficient, and future-proof JIS process landscape within a highly complex environment—one that supports the plant in the long term and prepares it for upcoming model generations.