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...flexibility also extends to the rhythm of work: BMW has struck deals with its heavily unionized workforce that enable it to run its factories more or less as demand dictates. Its newest plant in Leipzig, where the 3-series and new 1-series hatchback cars are built, runs anywhere from 60 to 140 hours per week. Instead of classic two- or three-shift rosters, the company juggles some 300 working-time permutations to determine optimal use of its teams of workers, some of whom are contract "permatemps" more common...

Author: /time Magazine | Title: BMW Drives Germany | 7/5/2007 | See Source »

...earnings last year rose 25%, to $5.5 billion, despite the soaring cost of raw materials and the strong euro. It has easily outpaced its historic rival, Mercedes (part of DaimlerChrysler), to become the leading premium-car brand. BMW is pushing a worldwide expansion. This spring it opened an assembly plant in India, and the company is building out a plant in Spartanburg, S.C., as part of its strategy to be less vulnerable to foreign-exchange fluctuations...

Author: /time Magazine | Title: BMW Drives Germany | 7/5/2007 | See Source »

Drop in on BMW's Leipzig plant, and you can see what he means. It's the firm's newest, having opened just two years ago, with a luminous open-plan central building that houses white-collar workers and managers. It was designed by London-based architect Zaha Hadid, and its most striking feature is a conveyor belt that meanders inside the building just below roof level, carrying a steady stream of cars from the body shop to the paint shop. You can see it from almost everywhere in the building, including the cafeteria...

Author: /time Magazine | Title: BMW Drives Germany | 7/5/2007 | See Source »

...into the right sequence. The complexity is visible to the naked eye: halfway along the line, just past the section where car bodies are bolted onto the drivetrain and chassis, a gray three-door 1-series sticks out amid a convoy of silver 3-series cars. In theory, the plant is set up to handle five or six different BMW models simultaneously, although for the moment it handles...

Author: /time Magazine | Title: BMW Drives Germany | 7/5/2007 | See Source »

...been designed so that new production processes can be added to the assembly line at any time without disrupting the work flow. That's a huge advantage over more traditional lines, which need to be shut down for any changeover or addition. Several key suppliers are based in the plant, rather than in a nearby supplier park. Jörg Baumheuer says that makes for easy communication when problems arise. He's a manager at the French auto-parts firm Faurecia, which assembles cockpits and seats for BMW in Leipzig and some other plants. The advantage for Faurecia is that...

Author: /time Magazine | Title: BMW Drives Germany | 7/5/2007 | See Source »

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