BMW Seria 5 F10 – toate datele despre noul BMW Seria 5

Supreme Quality through Efficiency and
Precision.

• New BMW 5 Series Sedan built together with the BMW 7 Series
and the BMW 5 Series Gran Turismo at BMW Plant Dingolfing.
• Use of shared components among several models guarantees
efficient production and the same high standard of quality as in
the luxury class.
• Innovative production technology going straight into large-scale
production volume.

The sixth generation of the BMW 5 Series Sedan is based on the
same newly developed vehicle architecture also featured in the BMW
7 Series Luxury Sedan. Joint production of the BMW 5 Series Sedan,
the BMW 5 Series Gran Turismo and the BMW 7 Series at BMW Plant
Dingolfing, together with the joint use of components, ensures a
highly efficient production process and a supreme level of quality
meeting the most demanding standards.

The BMW Dingolfing Plant in Lower Bavaria has been part of BMW’s
global production network since 1967 – a network now embracing no
less than 24 production plants in 13 countries. In 1973 the
production of car components in Dingolfing was joined by the
production of complete BMW cars at BMW’s new Plant 2.4. Numerous
prizes and awards confirm the supreme standard of the largest
BMW Plant the world over. In all, more than 7 million BMWs have
been built in Dingolfing so far, clear proof of a more than 40-year
story of success.

Today the Plant employs almost 19,000 BMW associates, more than
12,000 thereof working in automobile production at Plant 2.4. The
model history of the BMW 5 Series is also closely connected
with
BMW Plant Dingolfing. Shortly after the start of production of the
first model generation in 1972, the BMW 5 Series was moved from
BMW’s original plant in Munich to the new plant in Dingolfing – and
since then all generations of the BMW 5 Series have been built in
Lower Bavaria.

Apart from all versions of the BMW 7 Series, the BMW 6 Series as
well as the BMW 5 Series Gran Turismo are currently built in
Dingolfing – and now the new BMW 5 Series Sedan is also being
integrated into the local production process. Representing the
largest production volume at the Plant, the BMW 5 Series accounts
for up to two-thirds of the total production capacity.

Flexible use of the production facilities allows continuous,
ongoing adjustment of the individual model series within overall
production at the Plant, thus ensuring both consistent use of
production capacity and rapid delivery of new cars to the customer.
A further advantage is the many options provided in this way to
increase the efficiency of the production process.

Greater efficiency and quality through common
vehicle architecture and modular components.

The BMW 7 Series, the BMW 5 Series Gran Turismo and the new BMW
5 Series Sedan share many features and joint processes in both
development and production. Indeed, the joint architecture of these
vehicles developed in a common process sets the foundation for
integrated production allowing a flexible response to customer
demands. The modular system of vehicle components provides further
synergy effects.

These components share the same basic concept and are used in
modelspecific and modified variants also for the new BMW 5 Series
Sedan. In their function and quality, these components follow the
same supreme standards already applied to the luxury sedan in the
BMW 7 Series. One example is the development of the axle subframes
as an overriding construction on both model series, with
appropriate fastening and attachment openings for the track of each
model.

Another example is the seats of the new BMW 5 Series Sedan, the
BMW 5 Series Gran Turismo and the BMW 7 Series, which again share
the same structure but differ from one another through their
stitching and leather upholstery.

The technology required for the air conditioning, to mention yet
another example, comes in various modules beneath the surface, then
being fitted in accordance with the customer’s wishes both in the
BMW 5 Series Sedan, the BMW 5 Series Gran Turismo, and the BMW 7
Series.

Permanent progress in production.

The latest know-how gained in the development of modern
production processes is applied at BMW Plant Dingolfing in the
production of cars. An important example of such new processes is
the modular process concept: Proceeding from the use of shared
vehicle components on the BMW 7 Series, the BMW 5 Series Gran
Turismo, and BMW 5 Series Sedan, the production specialists apply
standardised production processes combining supreme quality in the
production of various models on one line with standardised
production planning bringing all models together.

Examples of such modular processes are the installation of the
car’s seats, the process of fitting the chassis supports, and the
actual process of body production in the Bodyshop. Further progress
in production is ensured in the creation of value along the
production line and in logistics. BMW’s objective in all cases is
to ensure a clear-cut flow of individual parts – the one-piece flow
process – all the way from the supplier to the actual completion of
the car itself.

Innovative production processes in the
Bodyshop.

Innovative production technologies have been developed for the
production of several models in correspondingly high numbers. One
example is the production of aluminium doors with the support of
the BMW’s Aluminium Competence Centre in Dingolfing. The know-how
gained in the research processes conducted here, as well as the
innovative developments made possible in this way, benefit all of
the BMW Group’s brands.

The large share of aluminium in the body components of the new
BMW 5 Series Sedan enables the experts in Dingolfing to contribute
even more of their outstanding competence in this technology. The
new aluminium processing technology developed at BMW Plant
Dingolfing, for example, sets the foundation for the precise
modelling of sophisticated design features such as the character
line on the side doors. The large load-bearing aluminium plate
shells within the doors, in turn, ensure a high standard of
all-round stiffness. And to join the individual components with one
another, the Plant uses both laser welding and structural
bonding.

BMW Plant Dingolfing also uses innovative processes in the
production of steel panel components. Two new steel panel presses
involving an investment of approximately Euro 50 million will serve
in future to give the body components of the new BMW 5 Series Sedan
a unique standard of quality.

BMW is the world’s first car maker to use hard-pressing
technology at Plant Dingolfing, with hot-galvanised steel plate
first being moulded cold and subsequently heated to a temperature
of 900o C or 1,650o F. Then the components are cooled down in a
pressing tool with integrated water-cooling to approximately 70o C
or 160o F within a few seconds, being hardened in the process with
maximum efficiency. This gives the components involved three to
four times the stiffness of conventional steel plate.

The ProgDie rapid-action press also new in the production
process likewise offers an exceptionally high standard of
efficiency in production and the use of energy. Among the world’s
largest presses of its kind, the ProgDie press integrates several
steps in production and is able to turn out up to 160 components in
40 strokes per minute. Up to 21 work processes are conducted at the
same time, from the first stamping process through various
elongation processes all the way to the final insertion of stamped
components.

In ProgDie production the individual strips of material come
straight off the steel plate cylinder and are consistently moved
through the die in each step. This ensures particularly efficient
use of material and a reduction in the consumption of energy.
Compared with conventional pressing processes, this saves
approximately 5 million kilowatt hours of electricity each
year.

Supreme quality right from the
outset.

To fulfil BMW’s strict quality standards right from the start
when launching a new model such as the BMW 5 Series, BMW not only
conducts many tests and examinations with pre-series cars, but also
applies the so-called cubing method: More than a year before the
start of production, the quality and accuracy of more than 800
parts and modules are tested at the plant on a completely accurate
body model.

Weighing approximately three tonnes, this model is milled
according to the car’s development data out of massive,
shrinkage-free special aluminium down to an accuracy of 0.1
millimetres. In several iterations on this model, first the
prototypes and then the first components are fitted in position
together with the various suppliers to check the precise dimensions
and perfect fit of components with one another and on the body as a
whole prior to the start of series production.

Modular strategy serving to promote
customer-oriented production.

A highly sophisticated system referred to as the
Customer-Oriented Sales and Production Process (COSP) ensures that
each car ordered by the customer is completed exactly on time and
fully in accordance with the customer’s specific wishes and
requests. COSP is also ensured by highly flexible production based
not only highly developed logistics but also on the most efficient
processes. Particularly the processes conducted on the assembly
line benefit from the use of pre-assembled modules delivered as a
whole straight to the production line.

The complete front-end, for example, is one single module
delivered just-insequence to the line, where subsequently only a
few final steps are required. The bodies-in-white for the various
models are built in any random order and combination according to
the data provided by production management. In conjunction with
modular supply, this allows highly flexible and very lean
production taking up minimum storage space and enabling the BMW
Plant to respond quickly to the customer’s wishes and any
subsequent changes.

Emission-free foundry

The new BMW 5 Series Sedan comes with petrol and diesel engines
featuring cylinder heads and crankcases from the world’s first
emission-free foundry in Landshut about 60 km north-east of Munich.
To avoid emissions in the casting process, the light-alloy foundry
at the BMW Plant is converting the production of sand cores in the
die-casting process, replacing conventional organic binding agents
by inorganic binding agents particularly friendly to the
environment. This reduces emissions potentially harmful to the
environment to almost zero.

Introducing this innovative production method, the light-alloy
foundry is reducing emissions from combustion residues in general
by 98 per cent. This ultra-low-emission production process is being
introduced in Landshut initially for the aluminium crankcases and
cylinder heads of BMW’s six-cylinder diesel engines. And currently
the process of inorganic sand core production is being carried over
step-by-step to the entire range of production in the light-alloy
foundry.

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