The logistics of the future: from data goggles to electric trucks

Innovation, digitalisation and sustainability are key success factors
for logistics

Testing of future technologies in everyday operation

Continuous expansion in CO2-efficient carriers

 

Munich. The BMW Group will increasingly rely on
innovation, digitalisation and sustainability for logistics in the
future. A fully-networked supply chain, autonomous transport robots
and the use of existing vehicle information for the delivery process
will make logistics even more flexible and efficient. Every day, a
total of 30 million parts need delivering to the right place at the
right time, so that around 9,000 new vehicles can be produced at the
BMW Group’s 31 production locations worldwide.

“Logistics is the heart of the BMW production system – and the use of
innovative and digital technologies will become a key factor in our
complex logistics processes,” according to Jürgen Maidl, head of
Logistics for the BMW Group production network. He continued: “At the
same time, sustainable, resource-efficient solutions are also
important to us. We are already testing the technologies of the future
in a whole series of pilot projects.”

From augmented reality goggles to autonomous transport systems to
electric-powered trucks, the BMW Group is testing a wide variety of
different technologies and innovations. Marco Prüglmeier, project
manager for innovation and industry 4.0 for BMW Group inbound
logistics: “We have a clear vision of the future and are already
exploring the technologies of tomorrow. We have identified potential
for innovation in all phases of the logistics process, from inbound
delivery of parts to our plants to outbound delivery of new vehicles
to dealers all over the world.”

 

Connected Supply Chain: full data transparency

The BMW Group supply chain consists of a globally distributed
supplier network, with close cooperation with various logistics
service providers. In the future, full data transparency throughout
the supply chain will enable us to know where each item is and whether
it will be delivered on time. This information allows us to respond
immediately if there is any delay. If, for example, a truck is
involved in an accident, the Connected Supply Chain automatically
calculates alternative courses of action and initiates corresponding measures.

At the same time, the status of process-critical parts can be
monitored by sensors, using so-called “condition monitoring”. This
enables early identification of damaged parts and whether a
replacement delivery is needed, thereby reducing costly extra runs and
alternative processes and allowing any errors in the process to be resolved.

 

First fleet of autonomous transport robots in everyday operation

Autonomous driving also plays an increasingly important role in
logistics. An initial fleet of ten self-driving Smart Transport Robots
(STR) is transporting components through logistics at the Wackersdorf
plant. What is unique is that the self-driving transport robot does
not need floor-mounted induction loops for navigation, but moves
freely through the logistics hall, powered sustainably by pre-used
batteries from the BMW i3 and is able to transport containers weighing
up to 500 kilograms. The STR measures the distance to wireless
transmitters to calculate its exact position and route. Using sensors
to identify and react to critical situations, it is able to share the
route with humans and other vehicles. After five months of prototype
operation, the project will be transferred to pre-series production,
where the ten STRs will be used for the first time in everyday
operations and perform transport assignments independently. In the
next phase of development, a 3D camera system will enable even more
precise navigation. The BMW Group has launched this project in
conjunction with the Fraunhofer Institut IML in Dortmund.

 

Autonomous tugger trains in assembly

Autonomous tugger trains are being piloted in the halls of BMW Group
Plant Dingolfing. The self-navigating tugger trains are used for
supplying assembly logistics – especially for longer distances between
individual warehouses and assembly areas. From a technical point of
view, the independent steering and navigation of tugger trains relies
on laser signals. By evaluating their reflection, the tugger train
generates a digital 2D room profile in real time, which enables it to
manoeuvre through the assembly hall and logistics areas along certain routes.

 

Augmented reality data googles to support logistics staff

Augmented reality data goggles support logistics staff and signal to
the person sorting parts where to find the right piece and where to
place it. In another scenario the usage of data goggles goes even
further: The part for sorting is visually recorded by the data goggles
and undergoes an optical quality check. In parallel, the image
information is compared in the background with a previously compiled
database. Within a few milliseconds, the system reports back whether
the component is flawless. Using artificial intelligence, the data
goggles are able to recognise different types of defects independently.

 

Connected Distribution: Greater transparency for vehicle delivery

For future deliveries from the plant to the dealer, the vehicle will
become an intelligent sensor that can send or receive important
information. When the vehicle is switched off, it relays its current
geolocation and status to the logistics centre via mobile connection.
This information helps improve on-time delivery and reduce lead times.
In a second phase of development, the vehicle display in the interior
will be used to send notifications or receipts for necessary work
steps in the transport chain to dealers. In this way, for example,
route information can be displayed directly in the vehicle, making
delivery more efficient overall.

 

Sustainability: Rail transport reduces CO2 emissions

Logistics helps the BMW Group achieve its sustainability goals,
focusing on continuously expanding the percentage of CO2-efficient
carriers. One measure to reduce CO2 emissions is to increase rail
transport. Today, for example, more than 60 per cent of all new
vehicles leave our production plants by rail.

Rail also plays an important role in supplying plants with production
material. For example, a train with vehicle parts from Regensburg and
Leipzig takes the Trans-Siberian Railway all the way to northern China
twice a week, transporting around 2,500 containers a year with vehicle
parts to Shenyang, almost 11,000 kilometres away. With a transit time
of less than 20 days, these direct trains are more than twice as fast
as the combination of sea freight and transportation through the
Chinese interior, with roughly the same CO2 emissions. Using rail, it
is possible to respond at short notice to production fluctuations and
follow-up orders, without requiring air transportation. This
alternative transport option has significantly reduced costs and CO2
emissions for urgent deliveries to the company’s Chinese plants in
recent years.

 

Electric trucks: Emission-free over short distances

In cooperation with logistics service providers, all-electric trucks
are already driving on the roads in Munich and Leipzig, making local
deliveries. The initial aim is to get to know the different drive
technologies better and gain experience. Over the long term, the BMW
Group is striving for cost-efficient use of alternative drive technologies.