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Modernization of 7 Production Lines for a New Model Launch – Without Stopping Production

Top view of an automated automotive production line with industrial robots assembling vehicles, representing smart manufacturing, robotics, and Industry 4.0.
Category:
SPS/PLC
Industry:
Automotive
City:
Munich, Germany 🇩🇪

Client

BMW, a global manufacturer of premium vehicles, initiated a project to launch a new vehicle model at its Munich plant. Introducing the new model required adapting existing production lines to the latest technological and industry standards.

Challenge

The modernization scope covered 7 main production lines operating in continuous mode. A key project requirement was to complete all work without interrupting ongoing production.

Modernizing active production lines in the automotive environment involves high operational risk. Any unplanned downtime can generate significant costs and impact production schedules.

BMW required the following:

  • reprogramming of existing control systems,
  • integration of the lines with the latest industry and corporate standards,
  • preparation of the infrastructure for production of a new vehicle model,
  • modernization of 7 main production lines,
  • ensuring full operational continuity of the plant,
  • preparation of documentation and user training.

The project required precise planning, phased implementation of changes, and close cooperation with the plant’s operational teams.

Diagram showing challenges of modernizing automated production lines while maintaining continuous operations, PLC updates, and minimizing downtime.

Solution

The team applied a phased and controlled approach to modernizing the control systems.

  1. Phased Implementation of Changes
    The modernization was divided into planned stages executed during defined operational windows, which enabled:
    – gradual updates of PLC program,
    – testing of changes in a controlled environment,
    – elimination of risks to ongoing production.
  2. Integration with the Latest Standards
    We updated the control systems to ensure compliance with current industry standards as well as BMW’s corporate guidelines regarding software architecture, safety, and documentation.
  3. Documentation and Knowledge Transfer
    We prepared comprehensive technical documentation covering changes in control systems and production line structure.
    Additionally, we conducted training sessions for operators and technical personnel, ensuring a smooth handover of the modernized systems to the client’s team.
Diagram illustrating a phased industrial automation modernization strategy with PLC updates, controlled testing, incremental rollout, and technical documentation.

Results

The project was completed with full implementation of changes and without any disruption to ongoing production at the Munich plant.
Achieved outcomes:

  • modernization of 7 main production lines,
  • Launch of a new vehicle model without production downtime,
  • Integration of systems with the latest industry standards,
  • Preservation of full operational continuity at the plant,
  • Comprehensive technical documentation supporting ongoing maintenance,
  • Trained personnel prepared to operate the new system.
Diagram presenting industrial automation modernization results, including seven upgraded production lines, zero downtime, operational continuity, documentation, and staff training.

Design, Development, DevOps or Cloud – which team do you need to speed up work on your projects? Chat with your consultation partners to see if we are a good match.

Jakub Orczyk

Member of the Management Board/ Sales Director VM.PL

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Jakub Orczyk