Battery Production for Electrification: BMG as an Industrialization Partner for Series Manufacturing
How can highly complex battery systems be reliably transferred into automotive series production? In collaboration with Webasto, Bosch Manufacturing Solutions | BMG implemented a highly advanced, automated production line for battery module assembly. The key to success was not only the technical realization of the line, but also the close, trust-based collaboration among all project partners. The project demonstrates how closely product development, process design and equipment engineering must work together in modern battery production.
Dynamic Product Development meets Production Equipment Engineering
The key challenge was to advance product maturity and production readiness simultaneously. As the battery module evolved from B-samples through to series production, BMG continuously adapted the equipment engineering and, together with Webasto, secured it in preparation for SOP. Early alignment between product requirements and manufacturing technology enabled changes to be integrated into the line in a controlled manner. The following individual challenges had to be addressed:
Continuous Product Development
Changes to the battery module directly affected the design of the production line.
Dynamic Requirements Development
Product and process requirements were further refined throughout the project and developed and validated in parallel with the equipment development.
High Flexibility Requirements
Stations, processes, and software had to be repeatedly adapted and validated.
Demanding Time and Quality Requirements
The production line was designed in parallel with product development to achieve the required series-production output.
To successfully manage this complexity, BMG contributed not only its expertise in equipment engineering, but also deep process knowledge, many years of experience, and a comprehensive understanding of the project. As an industrialization partner, the team supported Webasto with process design and validation, simulation, virtual commissioning, and ramp-up.
- Simultaneous Engineering & Process Design: BMG provided intensive support to the customer in process development and design. This proactive approach enabled manufacturing constraints to be aligned early with the product’s functional requirements.
- Digital Twin and Simulation: Material flows, cycle times, and buffer strategies were simulated virtually well before physical implementation. The results identified potential bottlenecks and additional buffer requirements early, reducing risks for Webasto during commissioning and ramp-up.
- Testing & Validation: Critical processes were validated in BMG’s own laboratories and together with partners.
“It’s not just a project. It’s a partnership.”
Partnership as a success factor
The collaboration was characterized by trust, flat hierarchies, and a shared focus on the technological vision. This created a partnership of equals between Webasto and BMG.
Over several months, the manufacturing processes were jointly developed, assessed, and optimized. Challenges were addressed openly, decisions were made together, and solutions were developed collaboratively.
Despite the parallel development of the product and the line, the ramp-up of the C-sample prototypes was stable and successful. This project demonstrates how partnership-based collaboration and deep process expertise can make pioneering battery technology ready for industrialization.
