Leipzig. The BMW Group Plant Leipzig has achieved significant milestones as it commences the production of the MINI Countryman. This marks the first time a MINI model is being manufactured in Germany, alongside the BMW 1 Series and 2 Series, demonstrating the plant’s flexibility and adaptability. The BMW Group has invested €700 million over the past five years in preparing the plant for increased production and MINI-specific requirements. The workforce in production is expected to increase by over 900 by the end of 2024. The new MINI Countryman also drives innovations towards sustainable production.
“By launching production of the MINI Countryman here in Leipzig, we are introducing multibrand operations to our flexible production system,” explained Milan Nedeljković, Board Member for Production. “Plant Leipzig also offers a number of highlights in terms of resource conservation in production, providing further evidence of the successful rollout of our long-term masterplan: the BMW iFACTORY.”
Seamless integration through flexible structures
The BMW Group is leveraging the flexibility of Plant Leipzig to seamlessly integrate the production of the new MINI Countryman alongside the BMW 1 Series, BMW 2 Series Gran Coupé, and BMW 2 Series Active Tourer. The plant’s flexible assembly structures enable the production of two brands with three different drives – combustion, plug-in-hybrid, and fully electric – all on the same production line. The third-generation MINI Countryman will be available with a petrol, diesel, or fully electric powertrain, with the high-voltage batteries for the MINI Countryman Electric also being made in Leipzig, and it’s scheduled to reach dealerships on 17 February 2024.
Investments and recruitment to increase production volume
The BMW Group has made substantial investments in Leipzig to ramp up production volume for new models. This includes expansions and upgrades to the bodyshop, paintshop, assembly, and logistics. Production capacity has been increased from 250,000 units previously to up to 350,000 units a year at present. The investment of around €200 million to adapt the production system to MINI-specific requirements is expected to result in a production capacity of 500 MINI Countryman cars a day during the course of next year, creating up to 900 new jobs in vehicle production alone.
Electromobility and MINI production drive development
Plant Leipzig is transitioning to electromobility, with plans to produce the next fully electric car, the MINI Countryman Electric, and manufacture high-voltage batteries in-house. The plant will run the entire production process for the current fifth generation of high-voltage batteries, with capacity for e-component production increasing since 2021. This makes Plant Leipzig an important supplier across the BMW production network, and it currently employs over 800 people in e-component production, with plans to further develop and invest in this area.
Sustainable materials and production
The MINI Countryman Electric reflects the MINI brand’s responsible approach to materials and production, with innovations in sustainability. The model features a range of sustainable materials, including the use of recycled textiles in the interior, reducing CO2 emissions along the value chain and requiring less water to manufacture. The model also incorporates a new, resource-friendly painting method for the contrast roof, known as overspray-free painting, which contributes to saving CO2 emissions and energy.
Plant Leipzig – Built for sustainability
Plant Leipzig has a strong focus on efficient processes and a long-term strategy for energy generation and consumption. The plant has four wind turbines that generate electricity, delivering approximately 25 GWh/year, and a battery storage farm equipped with up to 700 second-life high-voltage batteries from BMW i3 vehicles. There are also plans to decarbonize production by replacing fossil fuels with green hydrogen, with a regional hydrogen grid in the works, from which Plant Leipzig is set to benefit.
MINI Countryman SE ALL4 (combined electricity consumption: 18.5 – 17.0 kWh/100 km according to WLTP; combined CO2 emissions: 0 g/km).
MINI Countryman with combustion engine (combined fuel consumption according to WLTP: 8.3 – 4.8 l/100 km, combined CO2 emissions: 188 – 125 g/km)
*All technical data is provisional.