Munich/Spartanburg, USA. BMW Group intensifies the
usage of digitalization and the use of artificial intelligence (AI) in
production. With so-called Physical AI, which connects digital AI with
real machines and robots, intelligent systems such as humanoid robots
can be integrated into real production processes. Following a
successful deployment with the humanoid robot Figure 02 at BMW Group
Plant Spartanburg in the USA, the further-developed successor, Figure
03, will now start at Spartanburg, working on complex sequencing
applications in logistics.
“Plant Spartanburg is the birthplace of humanoid robotics in BMW
Manufacturing’s operational day-to-day activities. Having already
successfully completed a pilot with Figure 02 in our body shop, we are
now looking forward to deploying Figure 03 for a sequencing use case
in logistics,” says Ulrich Wieland, Vice President of Production
Control and Logistics, BMW Manufacturing.
“Our 11-month deployment of Figure 02 proved that humanoids are no
longer lab experiments – they can be a valuable asset in establishing
a flexible, reliable manufacturing workforce,” says Brett Adcock,
Founder & CEO of Figure AI. “We are excited to continue our work
in Spartanburg as Figure tackles the complexity of the assembly and
logistics hall.”
The BMW Group already gained important experience with humanoid
robotics at Plant Spartanburg in 2025. In collaboration with the
technology company Figure AI, the Figure 02 robot supported the
production of more than 30,000 BMW X3 vehicles over ten months. In the
body shop, the robot inserted sheet-metal parts for the welding
process – a task that demands high speed and accuracy and can be
physically demanding.
The collaboration demonstrated that humanoid robots can safely
perform precise, repeatable work steps under real production conditions.
Next step with the next-generation Figure 03 robot
The findings gained from this project form the basis for the next
step with the successor model, Figure 03. “The robot introduces
several new features for expanded applications. These include soft
components designed for enhanced safety, wireless charging designed
for higher availability and audio functions for speech-to-speech
communication, along with improved hands with tactile sensors and palm
cameras designed to increase precision and dexterity,” explains Adcock.
In the new sequencing use case application, delivered components
initially arrive in larger containers, unsorted. Figure 03 will pick
them up and sort them into a sequencing trolley. The trolley will then
be taken to a defined collection point for onward transport. An
automated tugger train or a Smart Transport Robot will then transport
the parts to the installation location, where they will be provided to
assembly employees “just in sequence”. This use case occurs frequently
in automotive production logistics and offers potential for further
development and scalability.
The use of humanoid robots is part of the BMW Group’s broader
strategy to expand its automation portfolio with Physical AI. Humanoid
robotics is a value-adding complement to existing automation. Its
potential lies particularly in monotonous, ergonomically demanding, or
safety-critical activities. The aim is to protect and most effectively
utilize employees while further improving workplaces.
BMW iFACTORY applications in Plant Spartanburg Assembly Hall
The new project is closely linked to the digital transformation of
production at Plant Spartanburg. Hall 52, where variants of the BMW X3
and, in the future, the electrified BMW iX5 will be assembled, has
been extensively expanded and updated. Digital applications were
already used during planning and continue to be implemented in the BMW
iFACTORY approach in daily production operations. Before components
arrive at the production line, virtual 3D simulations help optimize
processes and enable error-free implementation from the outset.
The BMW Virtual Factory makes complexity manageable and supports
employees by simulating human movement sequences. This tool refines
manual processes from planning through to the production line. A key
objective is to optimize employee ergonomics.
Artificial Intelligence is also being used in quality assurance. With
AIQX (Artificial Intelligence Quality Next), Plant Spartanburg uses
AIQX for visual and acoustic quality inspection to ensure consistent
quality in a dynamic production environment. BMW has established AIQX
as a standard and is assessing options to make the system available to
suppliers as well. It uses camera systems and sensors during line
operations and provides line employees with immediate feedback via
smart devices.