BMW Group’s Munich plant has officially entered a critical new phase in its transformation, as production begins on the first near-series test vehicles of the upcoming BMW i3. This milestone signals that the factory is now deep into final preparations ahead of full series production, which is scheduled to begin in the second half of 2026.
For the Munich facility, this is far more than a routine test run. For the first time, the new BMW i3 has been built entirely on-site, using the plant’s latest generation of manufacturing technology and fully digitised production processes.
A major milestone for Plant Munich
According to Peter Weber, Head of BMW Group Plant Munich, the start of pre-series production marks a decisive moment in the plant’s evolution. With vehicles now close to series maturity, all core production areas are operating under realistic, real-world conditions.
This includes the modernised press shop, the newly built body shop, the state-of-the-art paint shop, and the newly configured assembly area. Alongside these upgrades, BMW has also implemented innovative logistics structures designed to support future electric vehicle production at scale.
Over the coming months, insights gathered during this ramp-up phase will be used to further fine-tune processes, ensuring a smooth and reliable transition into full series production.
From pilot builds to full in-house production
Pre-series vehicles play a crucial role in introducing new models into production. Until recently, early BMW i3 units were assembled by teams working between the Munich plant and BMW’s nearby pilot facility at the Research and Innovation Centre.
Now, with all new production and logistics areas completed, the entire manufacturing process takes place within Plant Munich itself. Vehicles pass through every production stage on site, meaning logistics systems, equipment, and workflows must already function seamlessly.
Even though production volumes remain low at this stage, every component is delivered through its designated material flow and processed directly on the main production line. Each part and every individual production step is closely monitored and evaluated.
Stress-testing the factory of the future
A key focus during this phase is the approval and validation of new production equipment and tools, particularly how well they integrate with BMW’s existing digital systems. Running full system tests using real vehicles allows engineers to identify weak points, inefficiencies, and opportunities for further optimisation.
These early findings will shape process improvements over the coming months, helping BMW refine its manufacturing approach before series production begins.
Training the workforce for next-generation production
Employees are also at the heart of this transition. Training initially took place using virtual tools and augmented reality, allowing workers to familiarise themselves with new processes before physical systems were ready.
Now, hands-on training is underway directly on the new machinery and production lines. Close cooperation between departments ensures that all areas of production—from logistics to assembly—are fully aligned. This integrated approach is designed to support a smooth, stable, and successful launch when series production of the BMW i3 officially begins.
