BMW starts pre-series production of ‘Neue Klasse’

The first (pre-series) cars of the Neue Klasse have rolled off the production line at the new BMW plant in Debrecen, Hungary. These are not production models but test vehicles of the all-electric X SUV model of the Neue Klasse.

As the validation of production processes is “progressing according to plan” with the assembly of the test vehicles, BMW says it is well on track to start series production at the end of 2025 as planned.

With the cars almost ready for series production, the entire logistics and production processes are tested under real conditions at the plant in Debrecen, Hungary. They are continuously optimized to ensure a smooth start to series production. The paint shop started trial operation in September.

Milestone

“The production of the first test vehicles in Debrecen is an important milestone in commissioning the new plant,” says Milan Nedeljković, member of the Board of Management of BMW AG responsible for Production.

The test vehicles will pass through all production steps. That also means that all logistics processes, production facilities, and operations performed by employees must already run smoothly. “These operations are just as complex as in actual series production. Despite the limited number of parts involved, they must still be made available in the appropriate logistics processes,” adds BMW.

iFactory

The new BMW factory in eastern Hungary was first announced in July 2018, and construction was scheduled to begin in mid-2019. In fact, the foundation stone was not laid until June 2022, but it was for a pure EV factory and not a mixed plant with combustion models, as announced in 2018.

The entire vehicle plant, press shop, body shop, paint shop, and assembly capacity is 150,000 vehicles per year. The new factory is also being built in line with BMW’s ‘iFactory’ strategy. The global flagship plant sets the path for all BMW factories worldwide. The ‘iFactory’ sets targets for energy use and sustainability and provides for a high degree of digitalization in production.

On the road to series production

The processes can be planned digitally, but there is no way for BMW to avoid precise testing in practice. “Materials and vehicle parts are delivered daily to Plant Debrecen, with test vehicles continuously coming off the production line. Every part and every production step is closely scrutinized,” writes the German carmaker.

“Special attention is paid to validating cutting-edge production systems and tools, including their digital connectivity. Running system tests for the future vehicle model helps identify further potential for optimization. In the coming months, the focus will be on refining processes based on the insights gained,” the press release continues.

New staff will undergo intensive installation and machinery training during this phase. Close cooperation across all production areas has to ensure operations are seamlessly integrated for a smooth and successful series launch.

BMW has not yet given further details about the model and only shows test vehicles with heavy camouflage. The BMW Vision Neue Klasse X study presented in the spring provided a glimpse of the electric SUV from Hungary.