Cost Reduction Strategies and Emerging Technologies in Automotive Manufacturing

Automotive IQ recently sat down with Maximilian Fischer, Predevelopment Additive Manufacturing at BMW Group, to discuss cost-reduction strategies, modifying legacy platforms and automation technologies that have led to measureable reductions in labour and cost. Maximilian also shares insight into which emerging trends or technologies have the greatest potential to reshape traditional manufacturing methods. 

Automotive IQ: To start us off, could you share a bit about your current role at BMW and what your day-to-day responsibilities look like?

Maximilian: As a PhD student specialising in additive manufacturing of tool components at the BMW Additive Manufacturing Campus, my role involves a blend of research, experimentation and collaboration. My day-to-day responsibilities include conducting experiments to optimise additive manufacturing processes, analysing the properties of produced components, and developing new methodologies to enhance production efficiency. I also engage in regular meetings with my supervisors and peers to discuss progress, share findings, and brainstorm innovative solutions to challenges we encounter in our research.

Automotive IQ: When your team began exploring ways to reduce costs by modifying legacy processes, what type of research or analysis guided those decisions?

Maximilian: We relied on a combination of reviews of current solutions in other technical processes, benchmarking studies, and data analysis. We examined existing manufacturing workflows and identified bottlenecks that contributed to inefficiencies. Additionally, we conducted cost-benefit analyses to evaluate the potential impact of implementing additive manufacturing technologies compared to traditional methods. This research provided a solid foundation for our decision-making process, allowing us to prioritise changes that would yield the most significant cost savings.

Automotive IQ: Were there any unexpected challenges or resistance when it came time to implement those changes on the ground?

Maximilian: Implementing changes to legacy processes is never without its challenges. There is a learning curve associated with adopting new technologies. To address this, we involved the affected colleagues during an early stage of the development and organised training sessions and workshops to demonstrate the benefits of additive manufacturing and how it could enhance our operations. Over time, confidence was progressively strengthened, and collaboration was refined, culminating in an increasing number of successful applications within the group.

Automotive IQ: For manufacturers reading, what practical steps can they take to begin applying similar cost-reduction strategies in their own operations?

Maximilian: I recommend starting with a thorough assessment of current processes and respecting the strengths of the existing solutions. The new isn’t generally better and the existing isn’t generally bad! Identify areas where inefficiencies exist and gather data to support your findings. Next, consider pilot projects that allow you to test new technologies or methodologies on a smaller scale before full implementation. Engaging employees in the process is crucial; their insights can provide valuable perspectives on potential improvements. Lastly, continuously monitor and analyse the results of any changes made to ensure they are delivering the desired outcomes.

Automotive IQ: Has your organisation implemented any automation technologies that led to measurable reductions in labour or operational costs? If so, could you share an example?

Maximilian: Yes, our organisation has implemented several automation technologies that have led to measurable reductions in labor and operational costs. For instance, we introduced automated post-processing systems for additive manufacturing components, which significantly reduced the time and labor required for finishing operations. This automation not only streamlined our workflow but also improved the consistency and quality of the final products. The integration of these technologies has allowed us to allocate resources more effectively and focus on higher-value tasks.

Automotive IQ: What key advice would you offer to other manufacturers who are considering optimising long-standing or standardised processes?

Maximilian: My key advice is to foster a culture of continuous improvement. Encourage employees to share their ideas and feedback on existing processes, as they often have firsthand knowledge of inefficiencies. Additionally, be open to experimenting with new technologies and methodologies, even if they deviate from traditional practices. Emphasising collaboration and communication across departments can also facilitate smoother transitions during optimisation efforts.

Automotive IQ: Looking ahead, what emerging technologies or industry trends do you believe have the greatest potential to reshape traditional manufacturing methods?

Maximilian: “Reshaping traditional manufacturing methods” is a big task. I believe that several emerging technologies and industry trends have the potential to add to traditional manufacturing methods. For instance, advancements in artificial intelligence and machine learning can enhance predictive maintenance and quality control processes. Further, the continued evolution of additive manufacturing technologies will likely lead to more complex and efficient production capabilities.