NEWS n 5 THE BMW GROUP IS launching a pilot project to use humanoid robots at its Leipzig plant in Germany, with the aim of integrating humanoids into series production of its cars, and exploring their use in the production of batteries and components. BMW is working with the Swiss humanoid developer, Hexagon Robotics, which launched its first humanoid robot, called Aeon, in June 2025. Unusually, the robot has wheels instead of feet, allowing it to move rapidly in any direction. A variety of hand and gripper elements, or scanning tools, can be attached flexibly to the robot’s arms. Following an initial theoretical evaluation and successful laboratory tests on the Aeon robot, BMW started to test the humanoid at the Leipzig plant in December 2025. It is now planning further tests, before the full-scale pilot trial begins in the summer. “Our focus is on step‑by‑step integration into our production system to explore a wide range of applications,” explains Michael Ströbel, BMW’s head of process management and digitalisation. “The emphasis is on researching multifunctional use of the robot in various production areas such as battery manufacturing for energy modules, and component production for exterior parts.” The European pilot follows BMW’s first deployment of humanoid robots, at its Spartanburg plant in the US last year. This trial was based on Figure AI’s Figure 02 robot which was use to move and position sheet metal parts for welding – a task that is demanding in terms of speed and accuracy, as well as being physically exhausting. The trial showed that the humanoid added measurable value under real-world conditions. In ten months, the robot moved more than 90,000 components and completed around 1.2 million steps, working ten-hour shifts, five days a week. In total, it operated for around 1,250 hours and supported the production of more than 30,000 of BMW’s X3 model. www.drivesncontrols.com April 2026 BMW and Figure AI are now evaluating potential applications for Figure’s latest (03) robot. The US trial confirmed that humanoid robots can safely perform precise, repetitive work steps – such as positioning components with millimetre precision. It also provided important insights for the further deployment of physical AI in BMW’s operations. One key finding was that the transition from the laboratory to an actual production environment was faster than expected. Motion sequences trained in the laboratory could be transferred rapidly into stable shift operations. To ensure smooth coexistence with existing systems, the robot was integrated into BMW’s Smart Robotics ecosystem via standardised interfaces. BMW believes that a prerequisite for using AI effectively in production is to adopt a unified IT and data model across the entire production system. It has therefore transformed isolated data silos into a unified production data platform, with all of the data being consistent, standardised and available at all times. This allows digital AI agents to take on increasingly challenging tasks autonomously and in complex environments, while continuously learning and becoming available for new applications. BMW says that the introduction of intelligent and autonomous decision‑making agents marks “a paradigm shift” in production. “Our aim is to be a technology leader and to integrate new technologies into production at an early stage,” says Michael Nikolaides, BMW’s senior vicepresident for production network and supply chain management. “Pilot projects help us to test and further develop the use of physical AI – that is, AI‑enabled robots capable of learning – under real-world industrial conditions. “The successful first deployment of humanoid robots at our BMW Group plant in Spartanburg in the USA proves that a humanoid robot can function not only under controlled laboratory conditions but also in an existing automotive manufacturing environment,” he adds. BMW sees humanoid robots as potentially adding value to its automation systems. They are particularly promising for monotonous, ergonomically demanding or safety‑critical tasks. The aim is to relieve employees and improve working conditions. BMW will use humanoids for first time in Europe at a German plant BMW sees humanoid robots as adding value to its automation systems, especially in monotonous, demanding or safety‑critical tasks CYBERSECURITY IS NOW A bigger concern for automotive manufacturers than cutting costs, introducing flexible manufacturing, or adopting AI, according to a new survey conducted by ABB Robotics. The poll of 473 automotive industry decision-makers around the world reveals “a fundamental shift” in how manufacturers view digital risk, operational continuity and the future of vehicle production, according to the company. The Automotive Manufacturing Outlook Survey shows a high level of consensus, with 95% of respondents regarding cybersecurity as “significant”, and 53% identifying it as being “extremely significant”. Respondents in all regions, and across OEMs, and Tier 1 and 2 suppliers, all ranked cybersecurity as the industry’s top priority for the coming five years. ABB says that the results reflect the rapid expansion of connected technologies on the factory floor. Advanced robotics, vision systems, analytics, digital twins and AI are delivering major gains in productivity, quality and flexibility. But they also require secure, controlled connections to deliver their full value. “Cybersecurity is no longer something manufacturers are thinking about for the future – it is something they must address at the heart of production today,” says Joerg Reger, managing director of ABB Robotics’ automotive business. “As factories become more connected, software-driven and data-intensive, cybersecurity has become a core manufacturing discipline.” This survey’s findings differ from those conducted in previous years, when cybersecurity was just one of a broader set of concerns. Today, says ABB, manufacturers increasingly recognise that cyber-incidents do not simply affect IT systems – they can halt production, disrupt supply chains and affect finished products, even in environments where equipment is not directly connected to the Internet. With more than 90% of respondents expecting to increase their use of AI and big-data management, and a similar number planning greater adoption of digital twins and simulation, secure connectivity is no longer optional, according to ABB. www.abb.com/global/en/areas/robotics/industries/automotive/ manufacturing-outlook-survey Cybersecurity is now a bigger worry for car-makers than costs
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