To streamline and improve its manufacturing process, the BMW Group is embracing artificial intelligence (AI). AI capabilities have recently been added to the company's Spartanburg, South Carolina plant.

BMW's Spartanburg plant covers more than 8 million square feet and produces roughly 60% of all BMW vehicles sold in the United States. This equates to over 1,500 vehicles produced each day. The introduction of AI technologies has significantly enhanced the assembly process.

Robots now weld between 300 and 400 metal studs onto the frame of each SUV in the body shop. This means that machines apply approximately 500,000 studs per day. AI technology is used to ensure that each stud is precisely placed. If a stud is discovered to be out of place, the system instructs the robots to correct it without the need for human intervention. This closed-loop system has proven to be extremely effective. According to BMW Group Manager Curtis Tingle, AI technology has increased efficiency fivefold, exceeding all previous expectations.

Furthermore, the use of AI in the stud correction process has resulted in cost savings. Tingle stated that the technology saves the company more than $1 million per year. BMW was also able to reduce the number of workers on the assembly line by six as a result of improved efficiency.

BMW has integrated AI software into their inspection process, in addition to the new AI capabilities in the body shop. As vehicles move down the assembly line, 26 cameras capture images from all over the floor. AI algorithms analyse these images, identifying any problems and alerting workers to the need for repairs. This ensures that no defective vehicles are sent out.