BMW is sharpening its production edge with a new artificial intelligence (AI) system now live at its Regensburg, Germany plant, tasked with customising quality inspections for every car that rolls off the line.
Dubbed GenAI4Q, the pilot project is already scanning data and tailoring checklists for each of the 1400 vehicles built daily - right down to individual customer specifications.
Smarter than your average clipboard
Each new X1 or X2 built in Regensburg undergoes rigorous inspection before delivery, and now AI is stepping in to support that final check.
Instead of a one-size-fits-all protocol, the GenAI4Q system analyses both static vehicle data and live production inputs to create an inspection plan for each car. Think equipment variant, powertrain type, even the order of assembly tasks - it all feeds into an app-based checklist that workers follow in real time.
“The use of artificial intelligence supports the digital transformation of BMW Group production towards an intelligently connected factory,” says Armin Ebner, head of Plant Regensburg. “We are using AI for quality control in vehicle assembly… creating added value for our products and, ultimately, for our customers.”
Designed for humans, built by data
It’s not just about smarts, either, as the system is also built for usability. The inspection app features voice input, auto-transcription, and easy access to functions. “Intuitive usability makes it easy to record findings,” says Rüdiger Römich, who oversees test floor and finish. “Employees can also access additional functions when needed - for example, a microphone icon in the app activates voice recording.”
The tech, co-developed with Munich-based startup Datagon AI, also prioritises speed. With a vehicle rolling off the line every 57 seconds, the AI’s rapid-fire analysis ensures quality control doesn’t become a bottleneck.
One line, many drivetrains
From combustion to plug-in hybrid and fully electric, Regensburg produces them all on a single flexible line - no easy feat when almost every car is a one-off. Yet the AI adjusts seamlessly, recognising correlations and patterns to structure inspection flows intelligently.
The GenAI4Q system is part of BMW’s broader iFactory strategy, which leans into digitalisation and flexible production for future models, including the incoming Neue Klasse lineup.
Regensburg, already crowned “Factory of the Year” for large-series assembly in 2024, appears well-positioned to keep setting benchmarks in smart manufacturing.
