In an extraordinary breakthrough, BMW Group Plant Regensburg has implemented an end-to-end digitalised and automated process for inspection, processing, and marking of painted vehicle surfaces in standard production. This revolutionary development marks the first instance of this technology being used in a car plant worldwide. The AI-controlled robots use a unique and innovative approach that processes each vehicle individually to ensure that objective quality standards are met. This allows for more stable operations, shorter lead times, and a consistently high level of vehicle surface quality. The cloud-based data storage system used also allows for optimal analysis of causalities, taking another step forward in the BMW Group’s goal of achieving a digital and intelligent connected factory, also known as the BMW iFACTORY.
The process begins with Automated Surface Inspection, which identifies and records the features that require processing after the topcoat has been applied. Using deflectometry, the system identifies deviating characteristics by projecting black and white striped patterns onto the vehicle’s surface. The cameras then scan the surface and detect even the slightest variation in the reflective paintwork through the change in the striped pattern. The system then creates a digital 3D image from the data collected and classifies it based on objective criteria. In this way, all vehicle surfaces are inspected for customer quality assurance purposes and treated as needed.
The next step in the process is the Automated Surface Processing. The system uses AI-controlled robots to sand, apply polishing compound, and polish each body surface in a tailored manner. This is done because the tiny specks and bumps that can appear after the topcoat is applied are in different spots on each vehicle. With up to 1,000 vehicles going through the finishing process every working day, this adds up to 1,000 unique processes. The new method offers reliable detection of characteristics and a shorter process lead time. It also processes all deviations recorded in the optimal order and with the appropriate speed, stability, repeatability, and always with the same premium quality.
The final step in the process is Automated Surface Marking, where trained employees add the finishing touches and conduct the final inspection of the body. The previously recorded data with the characteristics supports their work, and a laser projector digitally marks the relevant areas of the body surface to ensure nothing is overlooked. The three-stage automated process is currently being rolled out to other plants.
Using this technology, BMW Group Plant Regensburg has taken the lead in revolutionizing the car production industry. It is the first plant to use this three-stage automated process in standard production. The AI-controlled robots, along with the cloud-based data storage system, have allowed BMW to achieve more stable operations, shorter lead times, and a consistently high level of vehicle surface quality. The future looks promising, as the plant aims to intervene in the process even earlier if there are any inconsistencies, enabling them to prevent faults from occurring in the first place. The equipment used will also be able to automatically record operations performed by employees, reducing complexity and increasing the added value.
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