BMW Scales Virtual Factory with Accelerated Computing, Digital Twins, and AI
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BMW Group Virtual Factory. User Interface of NVIDIA Omniverse. Photo courtesy of BMW Group
MUNICH—The BMW Group is expanding the use of its Virtual Factory, a digital twin-based system that allows production processes to be simulated and optimized virtually—before physical implementation. This technology enables faster and more efficient production planning across more than 30 global sites and is projected to reduce planning costs by up to 30%.
As a key component of BMW’s iFACTORY strategy, the Virtual Factory integrates data from buildings, equipment, logistics, and vehicles using real-time 3D simulations powered by NVIDIA Omniverse. This allows planners to model factory layouts, simulate manual tasks, and optimize robotics and logistics systems.
One major application is the automated collision check, a critical step before launching new vehicle models. What once took up to four weeks of physical testing—sometimes requiring entire sections of the plant to be cleared—can now be completed virtually in just three days. This process uses 3D scans and design data to simulate a vehicle's path through the production line, ensuring it fits and moves safely without collision.
The Virtual Factory is also evolving to include AI-driven assistants, human simulation for ergonomic evaluations, and automated mapping for intelligent transport systems.
BMW plans to virtually prepare more than 40 new or updated vehicle models for production between now and 2027, ensuring plant readiness from day one.
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