BMW Plant in Leipzig: A Pioneer in the Digitalization of Production Processes
BMW is consistently driving forward the digitalization of its production processes. At the Exterior Components Technology (TEK) unit in Leipzig, a terahertz-based measurement system is being used for the first time to non-destructively determine the thickness of paint coatings on plastic components.
The newly industrialized technology enables automated, precise, and repeatable quality inspection directly within the production process. “With terahertz measurement technology, we are replacing a time-consuming, manual inspection process with a fully automated solution and taking quality assurance to a new level,” says Christoph Theiselmann, Head of Exterior Components Technology in Leipzig.
With the industrialization of terahertz measurement technology, TEK Leipzig is taking on a dual pioneering role: within the BMW Group, the in-house production facility is the first site to integrate this technology into the production system. At the same time, TEK Leipzig is also setting new standards in the plastics sector, as terahertz measurement technology is being used for the first time to inspect paint layer thicknesses on plastic components.
Following the successful pilot and ramp-up phase, all skid types — that is, the various component carrier systems—have been qualified for measurement. Currently, all paint colors are being qualified in stages. The technology offers great potential for use in other plants, particularly in the area of painted body-in-white as well as within the supplier network.
The Exterior Components division is an organizational unit within the Purchasing and Supplier Network department based at the Leipzig site. With its 450 employees, it specializes in the production of plastic exterior skin parts using injection molding, such as bumpers, sills, and spoilers. In addition to Leipzig, the BMW Group plants in Dingolfing and Regensburg are also supplied with these components.
About the Technology
Until now, the inspection of paint layer thicknesses on plastic components at TEK Leipzig was performed manually and destructively using scalpel cuts and a microscope. The inspected parts generated scrap, and deviations could often only be detected after a delay.
Terahertz measurement technology fundamentally changes this process: The sensors are integrated into two robots in the existing end-of-line measurement cell and are positioned automatically and with high precision on the component. The thickness of the individual paint layers is calculated from the transit time of the reflected terahertz waves. The measurement is performed within a few seconds with micrometer precision.
The new technology enables objective and reproducible measurement results as well as the early detection of process deviations. Non-destructive testing reduces scrap and material consumption while increasing process and cost efficiency. At the same time, digital measurement data increases transparency in the production process and lays the foundation for data-driven process control.