BMW Brilliance Plant Dadong is the start of BMW’s domestic production，it has witnessed the complete and successful development process of BMW Brilliance in China. The most successful and the best-selling BMW model in China, the BMW 5 Li is made at Plant Dadong.
Plant Dadong has been under expanded construction with the expanding of the market, and the construction of a new plant in the northeast began in 2014, which boasts complete four technologies, and it’s officially opened in May 2017, focusing on the production of new BMW 5 Li. In November 2020, BMW iX3 made in Plant Dadong was exported to the world market, which proofed that BMW Brilliance Automotive is delivering its “In China, for China and for the world” promise.
As plant business gradually grew, in April 2022, BMW Brilliance Plant Dadong Extension Project, with a space at 910,000 square meters (Equivalent to the size of 125 football fields) was successfully completed, which reformed and extended four technologies, including press shop, body shop, paint shop, and single roof assembly & logistics shop with 2 independent assembly lines. Also, we built new infrastructures such as the largest dedicated railway for finished vehicle among BMW production network, long test track, distributed solar photovoltaic system, and combined heating and power project, etc., laying a solid foundation for the development of Plant Dadong towards BWM iFACTORY, which represents BMW Group's production strategic vision of "Lean, Green, Digital".
With the completion of Extension Project, Plant Dadong provides fully flexible production of internal combustion engine vehicles (All New BMW X5, New BMW X3 and New BMW 5 Li), plug-in hybrid vehicles (New BMW 5 PHEV), battery electric vehicles (New BMW iX3), and responds promptly to future market trends and variable customer demands.
The new plant utilizes industry leading 6-stage servo press line with total pressing force of 10,300 tons, and it can press metal materials such as high-strength steel and aluminum. The third generation Schuler press line enables high efficiency, and the press speed is 18 strokes per minute, with high level of precision up to 0.02mm. The pressing of aluminum is more difficult than that of steels, and computers are used to calculate the spring back parameter of aluminum accurately for precise process. With combination between production line and production system, and it could monitor and analyze real-time production data, so as to improve production efficiency and guarantee quality. Moreover, scrap aluminum and steel are separated and recycled in press shop, making a significant contribution to further CO2 emission deduction.
With approximately 1,600 robots and a variety of connecting technologies serving the production line with an automation rate up to 95% in body shop, we are dedicating body-in-white production of All New BMW X5 and New BMW 5 (Li and PHEV). We have largest TITAN robot from KUKA with a load capacity up to 1.3 tons, grabbing under body deftly, which ensures stability of body accuracy of 0.1 mm action repeatability. Also we use man-machine collaboration technology and big data to create an advanced quality control system, and achieve 100% inline automatic measurement of body-in-white, as well as measurement data link and parts traceability, to ensure the consistency between body-in-white and retail cars, to provide customers with high-quality car body appearance, excellent performance and driving experience.
The paint shop comes with Integrated Paint Process (IPP) technology, and compact technology area size is for building’s energy saving. The highly automated paint process not only secures production efficiency and quality, but also saves energy. Innovative bottom painting removes the middle painting step and heating process for great efficiency. Advanced 3-phase-oven can precisely control the temperature needed for painting of mixed body materials that expands differently in nature, so as to secure accurate body size. The RoDip process revolves the body 360° on its own axis during the dipping process, takes less space, consumes less chemicals and decreases pollution. The newly added PVC weld bead gluing technology further improves tightness, acoustic optimization, imputrescibility and flexibility. The offerings of 15 colors and 2 systematic colors can fully satisfy customers’ special demands and obviously decrease cost and save time. Big data system is integrated into the entire manufacturing process, and tailor-made Online Process Control system (OPC) has effectively avoided potential problems.
International Production System – Identification (IPS-I) went live in 2021 in Plant Dadong assembly shop, replacing the paper job card with the i-tag. When activating i-tag, the system knows real-time location (Positioning accuracy at 30 cm) and specification and of cars in production line, and through Bauteil und Varianten Information Systems (BVIS), part installation and quality tips are carried out for assembly line operators. We regard product quality as our responsibility, high-precision electronic torque control system is used in all key processes, and bolt tightening data up to 280,000 times a day is for deep machine learning through big data system. Basing on ensuring data qualified, any potential abnormal fluctuations can still be found for engineers to predict and eliminate potential risks before problems occur. The shared finish line can provide water-spray test and short track test, etc. for All new BMW X5 and New BMW 5 Li simultaneously to assure product quality. Our assembly lines are equipped with highly ergonomic design, such as height adjustable interior skillet lines and tilting conveyor lines, which can lift or tilt cars to different positions to create a comfortable and healthy working environment for line operators; The Automated Guided Vehicles (AGV) are used for component transportation to lines, as a result that logistics forklifts only works in logistics supply area and this provides safety to technology operators.
Logistics is responsible for delivering right parts to the right place at the right time through different methods, also adhere to “Win-Win” to collaborate with suppliers sincerely. With the rapid development of the digital technics, the concept of smart Logistics is gradually implemented in different areas in Logistics Plant Dadong. Automated Guided Vehicle (AGV), Pick by Light, AI Recognition and other technics are utilized to manage operation process and deliver material to all technologies. We commit to reach “Zero Defect” and “Zero Waste”, also take “Sustainability” as an important concept. Digital technics are used to improve efficiency and in a meanwhile we build “Green Logistics”. We connected to deliver excellent service.
With the core concept of sustainable development of BMW Group, Dadong Plant derives green development and fully supports China's goals of carbon peaking in 2030 and carbon neutrality in 2060. As the first batch of factories selected as "National Green Factory", it has won this honor for five consecutive years. We have passed ISO14001 and ISO50001 certificate. Meanwhile, integrate the environmental policies of BMW Group into daily management. Responding to unprecedented challenges under global climate change, we forge ahead. Every year, environmental targets achieve effectively promoted through cross-departmental collaboration. In 2019, the BMW Brilliance Shenyang production base has been fully powered by renewable energy and is committed to promoting the use of 100% renewable energy by major suppliers. We establish reclaimed water reuse system to continuously maximize the comprehensive utilization of wastewater and reduce the water consumption of a single unit year by year, currently in Plant Dadong extension paint shop, we fully achieved zero process water and technology energy efficiency will also be further improved. Assort state-of-the-art VOC treatment facilities to significantly regulate emissions, and promote waste reduction via optimizing waste classification and manage processes.
New Plant Dadong owns high quality staff with high technical background and rich experience. Relying on the professional talent training system, our products can be guaranteed with strict quality standards of BMW Group. Both high quality staff team and advanced equipment and process are the pride of New Plant Dadong.
BMW Brilliance Plant Tiexi is one of the advanced and sustainable plants in the Chinese automotive industry. The construction work started in June 2010 and only 18 months later the first car was rolling off the production line. Celebrating the official opening on 24th May, 2012, the fully-fledged plant includes all workshops needed for the car production occupying an area of more than two square kilometers. At present, the product line-up in Tiexi includes the BMW 3 Series (long wheelbase and standard wheelbase), BMW X1, BMW X2 and BMW 1 Series Sedan. Early 2017, following an assessment by the Liaoning Tourist Attraction Rating Commission, the Plant Tiexi was approved as a National AAAA Tourist Attraction. It is the first production plant attaining such an honor within the Chinese automobile industry, which is also a foremost example of Industrial Tourism in China.
Press Shop has the world’s leading 6 station servo high-speed Press machine (maximum stroke of up to 17/min, maximum pressure up to 2500 tons), Coil line (maximum stroke of up to 60/min, maximum pressure up to 1250 tons), Triple Scan III (measuring accuracy up to 28 microns), Milling machine (milling accuracy up to 10 microns) and other advanced facilities, with high efficiency, high precision low energy consumption and low noise. Through the process of blanking, drawing, trimming, flanging, shaping, punching and other processes, according to demand we provide sufficient quality steel / aluminum products to Body Shop on time. Press Shop as the first step of vehicle manufacturing process, adhering to the vision of driving excellent manufacturing, realizing zero defect quality, supervising of the supplier and responsible for customer, providing quality, perfect, zero defect products and services all the time.
Body Shop use BMW advanced automotive technology, to provide customers a safe, high quality car body with efficient, intelligent modern production line. Body Shop has the best materials, joining technologies, automated production and quality inspection systems in the world. The main features are as follow. Up to 16 joining technologies are used for car body, including advanced laser welding, ball welding, and riveting etc. To guarantee the weld strength at the same time make the welding seams more beautiful that different joining techniques are applied for different functional requirements. Create art-grade car body for customers.
The paint shop is a major lever in resource conservation at Plant Tiexi. Thanks to state-of-the-art technologies and processes, water consumption, VOC emission and waste water in the paint shop are reduced to 1/3 of the industry average level 10 years ago. Applying a new technology, the car body can now dip into the tank vertically by rotating over an axis. This results in smaller dipping tanks and reduces the amount of chemicals and energy required. In addition, the Integrated Paint Process (IPP) completely compensates the primer function by an innovative base coat.
Due to the advanced and highly ergonomic work stations in the assembly shop, the staff can work comfortably with higher efficiency and better quality. The lines have been designed to move forward automatically, enabling the worker to concerntrate the assembly process without having to walk along with the car. In addition, the ergonomic swiveling units can rotate at the maximum of 90 degree angles so that the assembly staff can work in a very comfortable environment. In terms of sustainability the assembly has also to offer many highlights. Having integrated an energy recuperation system at the rolling road test station, recuperated energy is transferred to the plant grid. In addition, 90 percent of the water used in the rain test and car washing can be recycled.
A scientific logistic system plays an important role in modern car manufacturing nowadays. Materials must be sent on time with the right order to the correct location as it requires a highly efficient and flexible logistic system; At the same time, the concept of digitalization and innovation is more and more mature in Plant Tiexi Logistics, such as the technics application of Automated Guided Vehicle (AGV), Flexible inhouse bin, Logistics Data Warehouse etc. We sincerely collaborate with suppliers with “Win-Win” consideration. What is more important with pride, a railway was installed as planned to connect directly to the plant, which is more scientific and enhance the transportation efficiency for materials and completed vehicles. And in a meanwhile Logistics adhere to “Sustainability development”, take “ Zero Carbon” as target, to build “Green Logistics”.
The Powertrain Plant is the newest one of the BMW Group. It is located in the economic and technological development zone in northeast China's Shenyang City. The plant occupies an area of 0.9 square kilometers. In August 2013, the construction works of the new plant started. In January, 2016, the new plant officially has opened. The Powertrain Plant hosts all the three functional areas of powertrain production, which includes foundry, machining, assembly and HVB center. The plant also has a quality performance test center as well as an inbound and outbound logistics center. It is one of the advanced and sustainable powertrain plants worldwide and locates in close proximity to both BMW Brilliance vehicle plants. This leads to an optimized lean value stream.
Aiming for sustainable development, the plant has an optimal layout and adopts numerous of environment-friendly and energy-saving technologies. The media tunnel built during the initial period of plant construction reserves sufficient space for the supply of electric power, water-pipes, heat supply and ventilation pipelines. World-leading Building Automation System (BAS) integrates energy consumption monitoring, analysis and adjustment. The system has thousands of detectors installed all over the plant working on a 24/7 basis. Lighting in the plant leverages natural lights and intelligent lighting system. Compared with the traditional BMW heating concept, the new plant can reduce external energy input for heating by 80% due to a heat recovery technology.
The foundry is the starting point of the engine plant’s value stream. For the production of the crankcase the foundry boasts world's advanced smelter, which can reduce the energy consumption. Further highlights are:
Direct connection of melting and casting by underground conveyer system with no losses of temperature and increased safety.
Innovative casting feeding system to reduce return material demand.
Contemporary casting of two crankcases for higher efficiency and enhanced energy usage.
World-leading low pressure die casting technology brings high yield, excellent control of operative parameters, good metallurgical and technological quality.
Each casted part receives an integrated data matrix code that includes all relevant process parameters.
Industry 4.0 technology: self-learning x-ray quality inspection is self-adjusting the areas of interest to ensure the supply of zero defect products to the customer.
Totally inorganic binder process in sand core making is cutting-edge technology worldwide, the binder is based on water-soluble alkali silicates quartz sand dissolved in water, and brings almost zero emission in the binding process, which is highly environment friendly. The foundry is almost neutral in scent and provides highly advanced and healthy workplaces for the associates.
Most of the used sand can be recycled for the sand core process (highly environmentally friendly).
By use of a unique wire arc spraying technology (LDS) patented by the BMW Group, an innovative coating technology for the production of cast-aluminum crankcases has been introduced: The cylinder faces of all crankcases are coated with a wafer-thin layer of iron particles applied in liquid form. This results in a lower internal friction in the engine and less fuel consumption with reduced engine weight.
Efficient smelters with heat recovery system; heat recovered is used for pre-heating of aluminum ingots and supports indoor heating.
Direct link between foundry and machining, casting parts are transported via conveyer system to the machining workshop directly, which helps to reduce the through put time.
The foundry in the Powertrain Plant is the second one within the BMW Group global production network. Shenyang has implemented all the competence and knowledge from the BMW Group plant Landshut.
In the machining workshop two core engine components cylinder and cylinder heads are machined. The raw cylinder material is provided by our own workshop. The raw cylinder heads material is provided by supplier. From a raw to product ,it will passed a series of incising, drilling, grinding ,milling and robot assembling operations. Production processes are highly automated and self-correcting machinery ensures each component being machined to an exact specification. Highly skilled and experienced associates ensure the high quality of the products and productivity of the operations.
Highlights in machining shop include:
1.Usage of the latest machining technology similar to the other plants in Europe, thus resulting in the same excellent quality and accuracy.
2.Each machining operation utilizes the latest gauging technology to check the features machined for diameter and depth. In order to meeting BMW technology requirements.
3.Latest high-pressure washing machines are used to clean the components to ensure absolute technical cleanness. And during the high-pressure washing, the burr in the hole will be clear away.
4. We are manufacturing to extreme tolerances eg. Valve/guide bore 6 microns ? of human hair.
In the assembly workshop, the production lines are highly flexible and able to produce 3-cylinder and 4-cylinder engines at the same time, whether they need to be installed longitudinally or transversely. Producing zero defect engines for our customers at all times is what the assembly facility is designed to do. A 'no fault forward' philosophy is applied, in-process quality checks are implemented at critical stages and every engine undergoes a mechanical and electrical test during the assembly build. Highlights in assembly shop include:
Assembly processes have been implemented from the European production system.
Highly ergonomic production line is provided to production associates to take care of their health in the long run (in regards to the global BMW philosophy “today for tomorrow”).e.g. latest conveyor system with high flexibility, associates can adjust the height to the most comfortable position.
To ensure zero defect production, all engines are 100% cold tested (test with oil, but without fuel).
Furthermore, the engines are 100% leak tested for oil and water (coolant liquid) . Highly sensitive Helium gas is used in the leak tests for the fuel system.
On top, a statistical amount of engines is also tested with fuel in the performance test center (fired engine).
All technological and test parameters are recorded and long-term storage for each engine. Every engine can be traced back to its birth moment –the casting in the foundry. All process data are utilized in data deep mining and contribute to a permanent improvement of manufacturing processes.
Quality Performance Test Centre——Strong backing to supreme quality
State-of-the-art electric dynamometers used for the test cells, which are capable of testing engines with performance up to 370 kW and over 700Nm.
World-leading test systems of internal combustion engines are used. The system is capable of remote running.
Expert team from BMW's engine plants in Europe work on site to provide technical assistance, monitor the whole process and train local associates. The teams help realise the maximum exploitation of all the advanced equipment and instruments.
A statistical amount of engines undergoes a rigorous dynamic test up to 50 hours after which they are inspected and analysed to ensure the BMW quality standard has been met. This aims to ensure the customers can always get the high quality engines possible.
The logistics team ensures that the right engine derivatives are produced at the right time. Every engine has an order and is produced in the exact sequence as required from the vehicle plants. Logistics schedule, receive, store and move both components machined at the engine plant along with many bought-in parts to ensure a consistent flow of engines is built.
Tow trucks replace forklifts to transport parts to the production lines, in an aim to reduce potential accident and ensure efficient production.
At the sequencing center, finished engines are stored and distributed in sequence to the vehicle plants. For Plant Tiexi, it will take only 82 minutes from the order of an engine until the delivery to the plant. An engine will be send to the vehicle plants in 90 minutes.
October 24th 2017, BMW Brilliance Automotive (BBA) today opened its “High Voltage Battery Center” located at its Tiexi Powertrain Plant in Shenyang, BMW Brilliance is building a complete NEV ecosystem that covers the entire industry value chain from R&D capabilities, battery solutions and technology leadership, to brand and product, charging and infrastructure and e-mobility services.
BBA’s HVB Center in Shenyang is BMW Group’s third comprehensive battery center worldwide, and first outside of Germany. The Center encompasses battery R&D, production and testing in one location. The HVB Center’s innovative and bespoke in-house production process enables BBA to differentiate itself from competitor brands and ensures customers driving its electrified models receive the full BMW driving experience.
The HVB Center is a competence center which brings together battery production, R&D, quality, laboratory, procurement and supply chain management functions. A robust and flexible production process means BBA can achieve faster product launches while delivering a battery product that combines optimal safety, durability and performance.
At BMW Brilliance, HVB packs are produced in two stages. In the first, highly-automated process, standard lithium-ion cells are processed and combined into a larger unit, known as the battery module. In the second stage, battery modules are mounted together with connections, control units and cooling units in an aluminum housing to form a complete HVB pack. This production process has two decisive advantages: first, standardized battery modules mean that properties and quality standards are uniform, forming the basis for a wide variety of electric drive variants. Second, the aluminum housing size and shape, as well as the number of battery modules used, can be perfectly adapted and tailor-made for each vehicle.
At BBA’s HVB Center, innovative production processes have been applied in order to carry out double-module battery production. State-of-the-art robotics ensure maximum accuracy in the highly automated process of forming double modules from lithium-ion cells. The application of advanced and Industry 4.0 technologies means the Center sets new standards for HVB production in China. An integrated process management (IPM) system for quality management leverages big data to trace battery cells and processes through production, including information as detailed as tightening torque. Automatic laser welding gives high accuracy and stable weld quality, adding strength and reliability to the battery frame and electrode connections, thereby enhancing battery function and safety. Optical checking is enabled by 3D cameras that detect abnormal trends in welding and foil application, verify and optimize welding quality, and flag potential quality defects.
The entire production process takes place in an environment with strictly controlled cleanliness, humidity and temperature. Plasma cleaning technologies are used for surface cleaning to achieve increased surface tension force for better application of foil and glue. In the final stage of module assembly, the double-module is completed in an isolated workshop with a controlled constant humidity of under 31% to ensure gluing quality. Another feature of the automated production line is the robotic arms equipped with suction cups that capture and deliver cells, preventing any potential risks involved in manual handling.
|Start of Production||January, 2016|
|Production Technologies||Foundry, machining and assembly|
|Latest generation 3-cylinder and 4-cylinder BMW TwinPower
|Capacity||After a ramp up period, the engine plant will be able to meet the production demand from the two vehicle plants in Dadong and Tiexi|
|Core Components||Cylinder head, crankcase, High-voltage battery|
|Aug. 2012||BMW Brilliance announced to build a Powertrain Plant|
|Aug. 2013||Ground breaking ceremony|
|Nov. 2014||First cast of foundry|
|Jan. 2016||Official opening|
|Oct. 2017||HVB center opening|
|Sep. 2020||HVB center II opening|
BMW Brilliance R&D Center is located at the company’s Plant Tiexi in Shenyang, China. With a wide range of new R&D facilities added by BMW Brilliance, China is the BMW Group's largest R&D Center outside of Germany, and further equips BBA for future growth. Construction of the first phase of BMW Brilliance R&D Center began in 2012 and it opened in 2013. Since its establishment, the Joint Venture has steadily expanded its local R&D activities and competencies and built up its R&D facilities. An engineering workshop and an office building opened in September2016 and early 2017 respectively. Following the upgrade of existing facilities and opening of a second testing center, BMW Brilliance R&D Center Phase II is fully built up. With overall scale increasing to more than 40,000m2, a five-fold increase from the original construction, the company's R&D strength has reached a new high level. Planning to be completed and open around 2022, the R&D Phase II extension project expands the R&D facilities of the test benches, engineering workshop and E/E (electronic/electrical) workshop based on original R&D Center Phase II. The new facility will help to improve the capability of developing and verifying the entire process, including HVB, E/E, mechanical design and other functions, and provide the technical guarantee for the successful launch of BMW Brilliance's increasingly NEV product-line.
With the automotive industry undergoing a major transformation and mobility shifting towards electric, autonomous, intelligent and shared, BMW Brilliance R&D has a clear focus on new energy vehicles. The team in Shenyang is driving major breakthroughs in NEV technology development and realizing full-process R&D in China from concept to delivery.
BMW Brilliance R&D Center is equipped with a Powertrain Hi-Flex and E-Machine Test Bench and is at the forefront of premium HV battery development. Supported by BMW Group’s highly advanced power battery design concept, BBA works with local partners to jointly develop world-class and tailored battery solutions in China. BBA has achieved full-process development and validation of its high voltage battery housing, which consists of electronics, mechanical design, system structure and functions, and integration. This in-house work ensures high quality and an excellent powertrain system for its premium NEVs. Furthermore, BBA is helping to strengthen and promote the fast development of China’s NEV battery industry by providing technical support to local suppliers for large-scale industrial production.
BBA is committed to building a comprehensive NEV eco-system in China and aims to remain an e-mobility pioneer. The New R&D Center will take a leading role in the development of the company’s forthcoming and future NEV models.
BMW Brilliance R&D Center features state-of-art facilities and is capable of complete vehicle testing. As well as extensive test benches, laboratories and machinery, such as Climatic Chambers, an Insulation Lab for NVH (Noise, Vibration and Harshness) quality testing and an Emission Dyno Test Bench, BBA assures the quality of its vehicles through extensive track and real-world road testing.
BMW Brilliance R&D team is responsible for system and parts R&D, vehicle testing, quality work and homologation of all China exclusive models. Throughout these processes, the R&D team proactively engages suppliers to develop capabilities and embed premium quality along the value added chain. In addition, the localization of international suppliers has supported the fast growth of BBA and attracted more investment into the city of Shenyang.
Through the upgrade of its local capabilities, the BMW Brilliance R&D center is in an even stronger position to attract international expertise and foster local talent. The R&D center is led by a top-class management team that has created an innovative-thinking and inter-cultural team spirit with many Chinese engineers regularly visiting Germany for training and work assignments. With Chinese engineers and technicians making up more than 75% of the R&D workforce, the BMW Brilliance R&D center is a cradle for nurturing excellent local talent.
BMW Brilliance R&D Center Core Competence Fields
• NEV development, calibration and integration
• China specific module and integration work
• Complete Vehicle Integration and Validation
• Homologation of locally produced cars
2012 BMW Brilliance R&D Center Groundbreaking
2013 BMW Brilliance R&D Center Phase I Opening
2015 BMW Brilliance R&D Center Phase II Groundbreaking
2017 BMW Brilliance R&D Center Phase II Opening
2020 BMW Brilliance R&D Center Phase II Extension Groundbreaking
February 2017, according to the evaluation by Liaoning Quality level of tourist attractions committee, Shenyang BMW Brilliance Plant Tiexi tourist attraction has been announced as National AAAA Tourist Attraction, has become the first and the only car manufacturer which wins this honor in the car manufacturing industry. As the model of industrial tourism project, BBA Plant Tiexi shows a valuable gallery for public visitors.
Guided tours for single visitors or small groups take place at fixed dates several times a week. The tours are conducted with a maximum of 20 participants and take 1.5 hours.
Exclusive guided tours take place from Monday to Friday from 9 am to 5 pm. One of our experts will guide your group (maximum of 20 people) through the production and focus on your interests and favorite topics as far as possible.
*In the following two cases, Children must be between 6 to 14 years old.
1. Children Group for each Friday afternoon
2. Saturday Parent-Child Theme Group on Saturday
Each child must be accompanied by at least one parent. Please inquire with the Reservation Center for specific opening time.
Mon. – Sat. (The specific opening time is subject to the actual production situation of the Plant. Please communicate with the reservation center in advance for confirmation)
Hotline: +86 024-84555656
|Individual visitors (will be added to a group)||60 CNY|
|Individual visitors at a reduced rate*||50 CNY|
|Saturday Parent-Child Theme Tour individual visitors||80 CNY|
|Exclusive group (1 to 20 persons)||860 CNY|
|Exclusive groups at a reduced price*||700 CNY|
*Reduced admission fee with relevant proof: students, senior citizens over 60, or soldiers. Free admission with relevant proof: individual police visitors in public group; or police visitors in exclusive groups valid for 9:00-10:00, every Tuesday.