BMW invests further in the UK with Hams Hall developing new engines on brand new production lines.

A large investment programme to develop the BMW Hams Hall engine plant near Birmingham is complete. The production of new three and four-cylinder engines is already being ramped up on brand-new production lines, and over one million components will be machined at the plant for the first time this year as supply extends to other plants in the Group.

The investment project, part of £750 million that has been spent across BMW Group’s UK manufacturing sites, has ensured the Hams Hall site remains a state-of-the-art facility, capable of producing the next generation of engines and securing a long-term future for the plant.

Engines, as well as machined components manufactured at BMW Plant Hams Hall contribute to a range of cars across BMW Group’s product portfolio. This includes MINI – the new Clubman model goes on sale in just a few weeks’ time, as well as the new BMW 7 Series, also launched this month.

Plant Director, Markus Fallboehmer says: “The transformation in our plant has been huge. Over the last few years we have completely re-developed our two main production areas and installed over 600 brand-new pieces of equipment and machinery. While a high level of technology and automation ensures our plant remains a state-of-the-art facility, the ergonomics of the workstations where we have more manual input have been carefully thought through and adjusted to suit each individual member of the team.

“A large investment has also been made in our workforce via a number of training programmes and opportunities for people to upskill and take on new job roles. We have changed the make-up of our workforce as well with over 100 people securing BMW contracts, some of whom were previously working for us on a temporary basis. Looking further ahead to the future, we have trebled the number of apprentices training with us to ensure we have a strong, skilled workforce for many years to come.”

Development of the site is another piece of the jigsaw in BMW Group’s global strategy for engine production. The Hams Hall facility is now operating alongside other plants in Germany and Austria, all producing the same new family of next generation engines.

“Our new engine family of highly efficient three, four and six-cylinder engines have a standard design, a high number of similar parts and a uniform process for manufacture,” explains Ilka Horstmeier, who heads up BMW Group’s global production network for engines and electrified powertrain. “This gives us a large amount of flexibility and means we can optimise production between each of our manufacturing locations and respond quickly to changes in customer demand or market developments. The investment in Hams Hall has enabled the plant to grow and play an ever-increasingly important role in the production of these latest engines.”

Production of a small number of new engines was first introduced at Hams Hall last year. Three-cylinder BMW TwinPower Turbo technology 1.5-litre petrol engines are hand-built exclusively at Hams Hall on a special production line for the BMW i8, the first purpose-built, plug-in hybrid sports car. This engine has already contributed to a series of award-wins for the revolutionary vehicle as well as two class and an overall win at the International Engine of the Year awards.

Overall, the new Efficient Dynamics high-tech engine family includes petrol and diesel engines, all employing TwinPower Turbo technology and ranging from 1.5 to 3.0 litres. With different power ratings, the engines can be adapted to a variety of vehicle concepts. Commonality across the engines makes it possible to be extremely flexible in achieving significant efficiences at high production volumes, as well as being able to produce additional special versions of the engines at relatively small volumes across the network of engine plants.

To get a glimpse inside the Hams Hall engine plant, tune in to the new BBC2 series ‘Building Cars Live’, presented by James May, Kate Humble and Ant Anstead. The Hams Hall plant is one of the key suppliers to MINI production at the Oxford-based vehicle manufacturing plant that will feature in the programme this autumn.

The new five door MINI hatch rolls of Oxford production lines.

Plant Oxford today sees a production first as the new MINI 5-door Hatch comes off the production line.

The new 5-door is a first for MINI production at the Oxford plant and marks another phase in the roll-out of a £750 million investment programme across BMW Group UK’s production facilities from 2011 to 2015.

The car comes hot on the heels of the new MINI Hatch, which was launched in November. The new 5-door, which will go on sale in the autumn, is an exciting addition to the family of MINIs made in Oxford and opens up a whole new market segment.

Business Secretary, Vince Cable said: “The launch of the all-new 5-door MINI is a further boost for the UK’s manufacturing sector, and will help to secure jobs in Oxford and Swindon as part of BMW’s £750 million investment programme in the UK. BMW’s continued commitment and investment in the UK underlines the continuing success story that is UK automotive manufacturing.

“Through the UK Government’s industrial strategy we are backing the auto sector as it goes from strength to strength. We are providing the right environment to give businesses the confidence to invest and create high skilled jobs.”

The 5-door is the second member of the MINI family to be built on a new platform. The innovative approach to design increases the flexibility of the body manufacturing process, allowing more models of greater variation to be produced more efficiently, an essential element of the MINI’s build-to-order appeal.

Frank Bachmann, managing director of MINI Plants Oxford and Swindon, said: “This is an exciting day for us with the first ever 5-door MINI for the plant, which opens up a whole new market segment for the brand.

“BMW Group has invested in creating state-of-the-art technology and facilities at Oxford and Swindon for the launch of this new generation of MINI, demonstrating the company’s commitment to a long-term future for its UK production sites.”

Preparations for the new generation of MINI have seen the building of a new bodyshop at Oxford and significant investment in facilities and technologies at Plant Swindon, where the car’s body panels are pressed and a number of sub-assemblies made. Plant Oxford’s assembly employees also went through a programme of training to support the launch of the new model generation.

The new 5-door Hatch

Key statistics

• Measures 4m in length
• 161mm longer than the three-door
• 278 litres of boot space
• 15mm more headroom
• 61mm extra interior width
• Three rear seats

Production updates for the introduction of the new 5-door Hatch:

• Additional tooling for the body sides at Plant Oxford’s new bodyshop
• New equipment in the wax sealing line in the plant’s paintshop to accommodate the extra door and differences in the shaping of the rear of the car
• New paint colours, including the return of “Electric Blue”
• New rear door cells in the sub-assembly line at Plant Swindon
• New roof and panel tooling in Swindon’s press shop

Welcome new MINI to plant Oxford

The new MINI has made its worldwide debut today (18 November) at MINI’s UK production plant in Oxford and features all-new vehicle architecture , an evolutionary design and a range of new fuel-efficient engines to give owners even more fun behind the wheel. A £750 million investment across three of BMW Group’s UK manufacturing facilities marks the launch of the new car with a new 1,000-robot body shop at Plant Oxford, the debut of new technologies at the steel body pressings operation in Swindon, and new machining and assembly facilities to produce a new generation of three and four-cylinder engines at the Hams Hall engine plant near Birmingham.

Prime Minister David Cameron said: "I was lucky enough to get an early preview of the new Mini - a classic British icon - during a visit to the factory in Oxford last month. This £750 million investment is great news for both the local and wider economy, along with the 5,500 workers whose jobs are safeguarded by this launch.  

"Car manufacturing is a vital engine for growth. Production is back up to pre-recession levels and a car rolls off the line every 20 seconds in the UK. But we're not complacent. Our industrial strategy is a key part of the Government's economic plan and we’re helping to drive the car industry further and faster with over £4bn of investment."

Harald Krueger, BMW Group’s board member for production, said: “In our Oxford plant’s centenary year, we are continuing the MINI brand success story and today starting production of the third model generation. Our total investment of £750 million in our British production locations of Oxford, Swindon and Hams Hall between 2012 and 2015 underscores the importance of the MINI production triangle within our global production network. The UK is the heart of MINI production – thanks to the experience, competence and strong commitment of all our employees.”

The investment means additional job security for the 5,500 associates currently working in the UK MINI production network. Besides a new state-of-the-art body shop, the Oxford plant also benefits from upgrades to its paint shop, its final assembly area and from a series of initiatives reducing the operation’s carbon footprint and improving its waste management processes.  The introduction of the new MINI has also seen a significant investment in the most extensive workforce training programme undertaken at the plant.

Even though there’s instant recognition – something which comes from having such a globally identifiable design – the new MINI is completely new from the ground up in an effort to optimise its styling, function and performance. With its market launch in Spring 2014, the new car offers an enhanced standard specification, an extensive range of options to allow customers to adapt the car to their individual style, higher comfort levels, comprehensive safety technology including pedestrian protection and more innovative networking technology. Longer and wider than its predecessor, the new model provides more interior space for both the driver and passengers. Extensively revised suspension technology, reduced weight and increased rigidity have intensified the typical MINI go-kart feeling.  

Commenting on the new model, Peter Schwarzenbauer, BMW Group’s board member for MINI, BMW Motorrad, Rolls-Royce, Aftersales BMW Group said: “MINI is an inspiration for trend-setters and creative spirits the world over. And with our latest generation of MINI, we want to excite once again. To ensure the new generation of MINI is as successful as its predecessors, we have made just subtle modifications to its design. But beneath the outer skin is a brand-new car with state-of-the-art technologies seen for the first time at a small car”.