“Plant Woodruff plays a key role in the ramp-up of electromobility in the U.S.,” says Raymond Wittman, a member of the board of management of BMW AG responsible for production. “With our Gen6 high-voltage battery, we’re not only taking a major technological leap—we are also setting new standards in production.”

According to Wittman, cylindrical cells are integrated directly into the batter, based on the “cell-to-pack” principle. “All production steps are continuously monitored inline and comprehensively documented in real time,” he explains. “In-house developed AI assistants and agents analyze this data and, together with more than 300 employees and 250 robots at Plant Woodruff, ensure the zero-defect battery production.

“Extensive use of artificial intelligence enhances overall equipment efffectiveness in production,” explains Wittman. “Well before commissioning, digital twins of production and virtual reality applications support planning and employee training.”

“All production staff complete a VR training program developed on site,” adds Rich Everly, vice president of production at BMW Group Plant Woodruff. “Within a virtual factory, they can practice real manufacturing operations under realistic conditions.

“This virtual environment replicates the plant’s production lines in meticulous detail, requiring only a set of VR goggles and a PC,” says Everly. “The training helps employees develop an understanding of relevant processes and builds confidence in operating the equipment before using the actual manufacturing systems for the first time.”

BMW sources battery cells from several suppliers. “Upon receipt of goods, additional measurements—such as voltage checks—are carried out,” Everly points out. “Next comes cell clustering, where the battery cells are connected to coolers. This step ensures optimal insulation and cooling of the cells.”

The cell clusters and cell contact system are then laser-cleaned and welded with pinpoint precision. The inline inspection continuously monitors each weld seam in real time. An innovative foaming process follows, ensuring that all elements are protected as a mechanical unit.

The hardened foam guarantees the safety, stability and durability of the high-voltage battery. The housing is then closed, sealed and riveted. In the final assembly step, the central control unit is installed. A permanently elastic sealing adhesive is applied to ensure a reliable seal. Finally, each high-voltage battery undergoes a 100 percent end-of-line inspection before being shipped to the assembly plant in Spartanburg.