BMW Production Processes of Expanded Body Shop

Inside BMW’s new iFACTORY in Debrecen, Hungary, the heart of production has come to life with the ramp-up of final assembly for the next-generation BMW iX3 — the very first model of the Neue Klasse. This groundbreaking plant sets a new benchmark in electric vehicle manufacturing, integrating cutting-edge production processes inspired by BMW’s most advanced global sites, including Plant Lydia in China and Plant Leipzig in Germany. At the core of this transformation is a highly modular and ergonomic assembly line, boasting simplified wiring harnesses, fewer connecting elements, and a new cockpit pre-assembly system that dramatically improves flexibility and efficiency.

The BMW iX3’s body structure and production logistics reflect a bold leap into the future: an 80% just-in-sequence delivery rate enabled by a revamped “finger structure” layout, virtual-first plant planning, and completely fossil fuel–free operations. Thanks to its lightweight zonal wiring design and innovative quality control methods, the Neue Klasse promises streamlined production at scale, with Debrecen leading the charge ahead of BMW Munich’s adoption in 2026. As the final testing phase gives way to full-scale production later in 2025, this facility isn’t just building the next electric BMW — it’s redefining how all-electric vehicles are made.

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✅ Source: BMW