BMW has completed a major upgrade of its Leipzig production plant ahead of the planned introduction of Neue Klasse vehicles, replacing 240 hydraulic lift tables and installing 160 new robots during a five-and-a-half-week production shutdown.
More than 2,000 contractors worked across the 241-hectare site during the shutdown, according to Leipziger Volkszeitung. Vehicle production was suspended throughout the conversion period. BMW has not yet disclosed which Neue Klasse models will eventually be built at the plant.
BMW Reportedly Developing All-Electric i4 Cabrio on Neue Klasse Platform
Assembly Lines Prepared for Heavier Underbodies
The largest changes were made in the assembly area, where BMW replaced 240 hydraulic lifting tables used to support vehicle underbodies.
The changes are intended to accommodate the underbodies of future Neue Klasse vehicles, which incorporate the high-voltage battery and electric powertrain. BMW also renewed swivel hangers and electric overhead conveyors or reinforced their mounting systems to account for the additional weight.
Around 1,500 tonnes of steel were removed from the production facilities and replaced with new structures as part of the work.
BMW Confirms Neue Klasse i3 and iX3 Production in Mexico From 2027
BMW tested the existing transport systems by loading vehicles with sandbags before moving them through the production equipment. The tests were intended to determine whether the systems could handle the increased loads associated with the new vehicle architecture.
Body Shop Receives 160 New Robots
BMW also carried out extensive work in the body shop, installing and programming 160 new robots.
The machines that were removed from service are currently being stored in a production hall. According to Leipziger Volkszeitung, employees have referred to the collection as the “Terracotta Army.”
The area previously occupied by the old equipment will be used to manufacture new doors and flaps. BMW is also preparing a neighbouring former storage facility for Neue Klasse body production.
The paint shop has undergone modifications as well. BMW expanded parts of the facility to accommodate the heavier steel underbody structure of the upcoming vehicles and replaced older equipment.
Nearly €2 Billion Invested in Leipzig
BMW said the latest conversion represents an investment in the low three-digit million-euro range.
The work forms part of a broader investment programme at the Leipzig plant. According to BMW’s figures, the company has invested nearly €2 billion in the site over the past five years.
The extended shutdown provided an opportunity to carry out the latest work without interrupting normal vehicle production during the conversion period.
BMW Reportedly to End Production of CLAR-Based EVs in China Ahead of Neue Klasse Launch
Neue Klasse Production Model Remains Undisclosed
BMW has not yet announced which Neue Klasse models will be manufactured in Leipzig.
The new BMW i3 began production at BMW’s Munich headquarters earlier this month. Leipzig currently produces the BMW 1 Series, BMW 2 Series Gran Coupé, BMW 2 Series Active Tourer and MINI Countryman, including its electric version.
The introduction of Neue Klasse production would give Leipzig a renewed role in BMW’s battery-electric vehicle manufacturing strategy.
The plant previously produced the first-generation BMW i3 from 2013 to 2022. The model was BMW Group’s first mass-produced battery-electric vehicle.
BMW has now completed the technical modifications required for future Neue Klasse production, although the company has yet to identify the model or models that will use the upgraded facilities.