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YOU CAN ONLYCHANGE WHATYOU ARE AWARE OF
PROCESS MINING @ BMW GROUP PRODUCTION
03.04.2019
MarielouiseMieschner
Nicolas Größlein
Process mining @ BMW Group | April 2019 Page 2
TIMELINE.
Exploration
of the Process Mining
Technology at the example of
2 Proofs of Concept
2019, ff.2018Q1-Q3/2018Q3-Q4/2017Q2/2017Q3/2016
Evaluation
of the possibilities and chances
of Process Mining @ BMW
(initially 12 months)
First Discoveries
e.g. for the paint shop
processes and
Purchase-to-Pay
international
Setup of a
Process Mining Team
for the implementation of
the fast growing number
of requests by various
process owners from
all areas of BMW Group
Evaluation of the
possibilities of
Process Mining
for more than 40 processes
and all divisions
of BMW Group
Focus and Depth
of Process Mining
analyses for the
processes with highest
business value
+ potentially additional
prioritised discoveries
Process mining @ BMW Group | April 2019 Page 3
WHERE DO WE APPLY PROCESS MINING @BMW GROUP.
Minimize waste,
rework rates & create
transparency
Improvetransparency &
product quality.
Reduce development cycles
& increase standards.
Improve compliance &
increase automation rates
Get rid of unused system
functionalities & increase
ticket solution quality
Understand howto best add
value for our customers.
Improve “Sheer Driving
Pleasure” by better under-
standing our customers.
Faster and more reliable
financing decions
Purchasing
& Finance
Development
Change
Management
Production
Leasing
User
Experience
Aftersales
IT
Process mining @ BMW Group | April 2019 Page 4
WHERE DOES OUR DATA COME FROM ?
PRODUCTION ANALYTICS.
Data Sources:
Sensors (e.g. laser barriers, robots), Production Control, Quality data (e.g. paint quality), Intelligent power tools …
Process mining @ BMW Group | April 2019 Page 5
INTERNATIONAL BMW GROUP PRODUCTION NETWORK.
30 PRODUCTION SITES IN 14 COUNTRIES.
America
Spartanburg, USA – BMW X3,X4,X5,X6,X7
San Luis Potosí, Mexico – BMW 3s., as of mid 2019
Manaus, Brazil – Motorcycles
Araquari, Brazil – BMW 3s.,X1,X3,X4
Africa
Cairo, Egypt – BMW 3s., 5s., 7s.,X1,X3,X5,X6
Rosslyn, South Africa – BMWX3
Asia
Shenyang (China) – Engines
Shenyang (China) – BMW 5s.,X3
Shenyang (China) – BMW 1s., 2s., 3s.,X1
Chongqing (China) – Motorcycles
Kulim (Malaysia) – BMW 1s., 3s., 5s., 6s., 7s.,X1,X3,X4,X5, MINI Countryman
Rayong (Thailand) – BMW 3s., 5s., 7s.,X1,X3,X4,X5, BMW Motorcycles
Jakarta (Indonesia) – BMW 3s., 5s., 7s.,X1,X3,X5, MINI Countryman
Chennai (Indien) – BMW 3s., 5s., 6s., 7s.,X1,X3,X4,X5, MINI Countryman
Hosur (Indien) – Motorcycles
Germany
Munich – BMW 3s., 4s., Engines
Dingolfing – BMW 3s., 4s., 5s., 6s., 7s., 8er, E-Engines, Components
Regensburg – BMW 1s., 2s., 4s.,X1,X2, BMW M
Landshut – Components, E-Engines
Wackersdorf – Components
Leipzig – BMW 1s., 2s., BMW M, BMW i
Eisenach – Components
Berlin – BMW Motorcycles,Maxi-Scooter, Components
Europe
Oxford, UK – MINI, MINI Clubman
Hams Hall, UK – Engines
Goodwood, UK – Rolls Royce
Swindon, UK – Components
Debrecen, Hung. – under construction
Steyr, Austria – Engines
Born, Netherlands –
MINI Conv., MINI Countryman,
BMWX1
Graz, Austria –
BMW 5s., Z4
Kaliningrad, Russia -
BMW 3s., 5s., 7s.,X1,
X3,X4,X5,X6
AUTOMOBILES
MOTORCYCLES
ENGINES/ COMPONENTS
BMW GROUP PLANTS
JOINT VENTURES
CONTRACT MANUFACTURING
PARTNER PLANTS
Process mining @ BMW Group | April 2019 Page 6
PRODUCTION @BMW GROUP.
Press shop Body in white Paint shop Assembly
Process mining @ BMW Group | April 2019 Page 7
VIDEO.
Play
Process mining @ BMW Group | April 2019 Page 8
PRODUCTION @BMW GROUP.
FOCUS ON FINISH AREA.
Press shop Body in white Paint shop Assembly
Finish
Challenge
This isthe area where our BMWs first touchthe ground and run under their own power for the very first time. Fromthere onthe
process flow is not predefined by conveyors anymore and can vary.
Variations are caused by:
• Parallel test stations andtesting lines
• Audit
• Analysis
Process mining @ BMW Group | April 2019 Page 9
PROCESS DESCRIPTION FINISH AREA.
FINISH LINES.
~ 1000 Cars per Day
in finish Area
Direct deliveries
~ 600 Cars per day
Indirect deliveries
~ 400 Cars per day
parked cars
~ 50 Cars per day
 50x doublehandling
Rush hours:
10:30-11:15
12:30 – 14:30
Process mining @ BMW Group | April 2019 Page 10
Offline Cars (indirect)
water test, roadtest,
analysis, audit
Inline Cars (direct)
Short Track
P
P
P
P
P
PROCESS DESCRIPTION.
DRIVING ON FINISH LINES.
Process mining @ BMW Group | April 2019 Page 11
IFYOU CANNOT MEASURE IT,YOU CANNOT IMPROVE IT.
HOW WE IDENTIFIED PARKED CARS IN OUR DATA.
Measuring throughput time between
previous process and finish in
Celonis.
Which cars have been
parked?
Manual check.
Setting a limit for analysis and
comparing to manual validation.
Process mining @ BMW Group | April 2019 Page 12
FIRST STEP PROCESS IMPROVEMENT SHORT-TERM.
EXTENSION OF DRIVEWAYON TO FINISH.
Process mining @ BMW Group | April 2019 Page 13
ABC ANALYSIS OF PROCESS.
50% REDUCTION OF PARKED CARS AFTER THE FIRST MONTH.
Bucket A: Normal process - drive on finish takes approx. 30s
Bucket B: Short waiting times are included. Drive ontakes more than 30s.
Bucket C: Car has been parked because no empty slot was available.
Before After
50%
Process mining @ BMW Group | April 2019 Page 14
NEXT STEP PROCESS IMPROVEMENT LONG-TERM.
ALREADYTESTING POSSIBLE SOLUTIONS BY MATERIALFLOW SIMULATION.
Actual Increasing speed of production/finishLess distance between cars
Process mining @ BMW Group | April 2019 Page 15
OUR PROCESS MINING JOURNEY HAS JUST STARTED.
THERE ARE STILL MANYSERPENTINES AHEAD OF US.

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BMW: You Can Only Change What You Are Aware of - Production Analysis

  • 1. YOU CAN ONLYCHANGE WHATYOU ARE AWARE OF PROCESS MINING @ BMW GROUP PRODUCTION 03.04.2019 MarielouiseMieschner Nicolas Größlein
  • 2. Process mining @ BMW Group | April 2019 Page 2 TIMELINE. Exploration of the Process Mining Technology at the example of 2 Proofs of Concept 2019, ff.2018Q1-Q3/2018Q3-Q4/2017Q2/2017Q3/2016 Evaluation of the possibilities and chances of Process Mining @ BMW (initially 12 months) First Discoveries e.g. for the paint shop processes and Purchase-to-Pay international Setup of a Process Mining Team for the implementation of the fast growing number of requests by various process owners from all areas of BMW Group Evaluation of the possibilities of Process Mining for more than 40 processes and all divisions of BMW Group Focus and Depth of Process Mining analyses for the processes with highest business value + potentially additional prioritised discoveries
  • 3. Process mining @ BMW Group | April 2019 Page 3 WHERE DO WE APPLY PROCESS MINING @BMW GROUP. Minimize waste, rework rates & create transparency Improvetransparency & product quality. Reduce development cycles & increase standards. Improve compliance & increase automation rates Get rid of unused system functionalities & increase ticket solution quality Understand howto best add value for our customers. Improve “Sheer Driving Pleasure” by better under- standing our customers. Faster and more reliable financing decions Purchasing & Finance Development Change Management Production Leasing User Experience Aftersales IT
  • 4. Process mining @ BMW Group | April 2019 Page 4 WHERE DOES OUR DATA COME FROM ? PRODUCTION ANALYTICS. Data Sources: Sensors (e.g. laser barriers, robots), Production Control, Quality data (e.g. paint quality), Intelligent power tools …
  • 5. Process mining @ BMW Group | April 2019 Page 5 INTERNATIONAL BMW GROUP PRODUCTION NETWORK. 30 PRODUCTION SITES IN 14 COUNTRIES. America Spartanburg, USA – BMW X3,X4,X5,X6,X7 San Luis Potosí, Mexico – BMW 3s., as of mid 2019 Manaus, Brazil – Motorcycles Araquari, Brazil – BMW 3s.,X1,X3,X4 Africa Cairo, Egypt – BMW 3s., 5s., 7s.,X1,X3,X5,X6 Rosslyn, South Africa – BMWX3 Asia Shenyang (China) – Engines Shenyang (China) – BMW 5s.,X3 Shenyang (China) – BMW 1s., 2s., 3s.,X1 Chongqing (China) – Motorcycles Kulim (Malaysia) – BMW 1s., 3s., 5s., 6s., 7s.,X1,X3,X4,X5, MINI Countryman Rayong (Thailand) – BMW 3s., 5s., 7s.,X1,X3,X4,X5, BMW Motorcycles Jakarta (Indonesia) – BMW 3s., 5s., 7s.,X1,X3,X5, MINI Countryman Chennai (Indien) – BMW 3s., 5s., 6s., 7s.,X1,X3,X4,X5, MINI Countryman Hosur (Indien) – Motorcycles Germany Munich – BMW 3s., 4s., Engines Dingolfing – BMW 3s., 4s., 5s., 6s., 7s., 8er, E-Engines, Components Regensburg – BMW 1s., 2s., 4s.,X1,X2, BMW M Landshut – Components, E-Engines Wackersdorf – Components Leipzig – BMW 1s., 2s., BMW M, BMW i Eisenach – Components Berlin – BMW Motorcycles,Maxi-Scooter, Components Europe Oxford, UK – MINI, MINI Clubman Hams Hall, UK – Engines Goodwood, UK – Rolls Royce Swindon, UK – Components Debrecen, Hung. – under construction Steyr, Austria – Engines Born, Netherlands – MINI Conv., MINI Countryman, BMWX1 Graz, Austria – BMW 5s., Z4 Kaliningrad, Russia - BMW 3s., 5s., 7s.,X1, X3,X4,X5,X6 AUTOMOBILES MOTORCYCLES ENGINES/ COMPONENTS BMW GROUP PLANTS JOINT VENTURES CONTRACT MANUFACTURING PARTNER PLANTS
  • 6. Process mining @ BMW Group | April 2019 Page 6 PRODUCTION @BMW GROUP. Press shop Body in white Paint shop Assembly
  • 7. Process mining @ BMW Group | April 2019 Page 7 VIDEO. Play
  • 8. Process mining @ BMW Group | April 2019 Page 8 PRODUCTION @BMW GROUP. FOCUS ON FINISH AREA. Press shop Body in white Paint shop Assembly Finish Challenge This isthe area where our BMWs first touchthe ground and run under their own power for the very first time. Fromthere onthe process flow is not predefined by conveyors anymore and can vary. Variations are caused by: • Parallel test stations andtesting lines • Audit • Analysis
  • 9. Process mining @ BMW Group | April 2019 Page 9 PROCESS DESCRIPTION FINISH AREA. FINISH LINES. ~ 1000 Cars per Day in finish Area Direct deliveries ~ 600 Cars per day Indirect deliveries ~ 400 Cars per day parked cars ~ 50 Cars per day  50x doublehandling Rush hours: 10:30-11:15 12:30 – 14:30
  • 10. Process mining @ BMW Group | April 2019 Page 10 Offline Cars (indirect) water test, roadtest, analysis, audit Inline Cars (direct) Short Track P P P P P PROCESS DESCRIPTION. DRIVING ON FINISH LINES.
  • 11. Process mining @ BMW Group | April 2019 Page 11 IFYOU CANNOT MEASURE IT,YOU CANNOT IMPROVE IT. HOW WE IDENTIFIED PARKED CARS IN OUR DATA. Measuring throughput time between previous process and finish in Celonis. Which cars have been parked? Manual check. Setting a limit for analysis and comparing to manual validation.
  • 12. Process mining @ BMW Group | April 2019 Page 12 FIRST STEP PROCESS IMPROVEMENT SHORT-TERM. EXTENSION OF DRIVEWAYON TO FINISH.
  • 13. Process mining @ BMW Group | April 2019 Page 13 ABC ANALYSIS OF PROCESS. 50% REDUCTION OF PARKED CARS AFTER THE FIRST MONTH. Bucket A: Normal process - drive on finish takes approx. 30s Bucket B: Short waiting times are included. Drive ontakes more than 30s. Bucket C: Car has been parked because no empty slot was available. Before After 50%
  • 14. Process mining @ BMW Group | April 2019 Page 14 NEXT STEP PROCESS IMPROVEMENT LONG-TERM. ALREADYTESTING POSSIBLE SOLUTIONS BY MATERIALFLOW SIMULATION. Actual Increasing speed of production/finishLess distance between cars
  • 15. Process mining @ BMW Group | April 2019 Page 15 OUR PROCESS MINING JOURNEY HAS JUST STARTED. THERE ARE STILL MANYSERPENTINES AHEAD OF US.