How we create value with process mining by analyzing sensorData in our BMW production plants: People working on the finish line had the impression did before breaks and shift to end more cars than expected were delivered from previous processes. With process mining we found a way to prove did and to measure the effectiveness of our process improvements. Presenters: Marielouise Mieschner, Process Expert Order-to-Delivery l Project Lead Mining Process Order-to-Delivery, BMW Nicolas Groesslein, Project Lead Process Mining, BMW

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.