BMW’s first production facility established outside Germany, the Rosslyn plant, opened in 1973, would see the first-ever introduction of a third shift by the end of the year.

This would almost double capacity at the Tshwane plant to more than 90 000 cars a year, and create an additional 600 jobs.

Exports from the plant would make up around 85% of all production.

The BMW plant was officially reopened on Monday to start production of the new-generation 3 Series. The reopening followed a R2.2-billion investment from BMW South Africa’s German parent company, with around 21% of this investment structural, 34% production-related, and 35% flowing into the BMW supplier network.

The new model also saw the unveiling of some new local component suppliers. The new 3 Series would have a new local supplier for the front axle carrier. On the interior, BMW had developed a new supplier for the dashboard carrier – which required a new high-resolution camera-testing process completely new to South Africa. The door trim panel would also be produced by a new supplier.

Automation at the plant had also increased from 84% to 93%, but with no jobs lost. The body shop now used 149 robots, up from the previous 99.

The first new 3 Series models rolling off the assembly line were destined for the South African market, said BMW South Africa MD Bodo Donauer at the plant opening. Only then would the plant start production for countries such as the US, Japan, Australia, Singapore and Korea.

The US was BMW South Africa’s biggest market, with 50% of the vehicles exported going to North America.

The new 3 Series was to be launched in South Africa in March.

Announcing the expanded capacity at the plant, BMW management board member responsible for manufacturing, Frank-Peter Arndt, reiterated the company’s commitment to South Africa, saying that “BMW is here to stay. We truly believe in the potential of South Africa. We remain committed to this market and to this facility in Rosslyn”.

He added that there was no difference to a BMW made in South Africa than to those vehicles produced in any of the manufacturer’s other 24 plants around the world.

Arndt said the 3 Series was BMW’s “most important, high-value model”. The company had sold 12-million 3 Series models since its introduction in 1975.

“We are convinced the new vehicle will win the hearts of customers everywhere.”

The popularity of the model was important as BMW and, therefore, the BMW South Africa plant, built to customer order.

Arndt believed that the Rosslyn plant would top its previous model production record of 342 000 units of the previous 3 Series.

To subscribe to Engineering News's print magazine email subscriptions@creamermedia.co.za or buy now.