The BMW Group is taking a significant step in the evolution of intelligent manufacturing with the European launch of its first pilot project involving humanoid robots.
Building on earlier successes in the United States, the company is expanding its use of “Physical AI” – the combination of digital artificial intelligence and real-world robotics – to enhance efficiency, flexibility, and workplace ergonomics across its production network.
At the heart of this development is the integration of humanoid robots into series production at BMW Group Plant Leipzig. The initiative aims to explore how AI-enabled robots can support vehicle manufacturing as well as the production of batteries and components. According to Milan Nedeljković, Member of the Board of Management for Production, digitalisation paired with engineering expertise is unlocking “entirely new possibilities” within BMW’s global operations.
The move follows a successful 2025 pilot at BMW Group Plant Spartanburg in the United States, where the humanoid robot Figure 02 handled demanding tasks such as positioning sheet-metal components with millimetre precision. Over ten months, the robot completed more than 1,250 operating hours, covering 1.2 million steps and moving over 90,000 parts—demonstrating that humanoid robots can reliably perform repetitive, physically intensive work in a real automotive environment.
BMW attributes much of this progress to its unified IT and data architecture. By replacing fragmented data silos with a single, cohesive platform, the company has created an environment in which AI agents can operate autonomously, learn continuously, and take on increasingly complex tasks. When combined with advanced robotics, these agents form the basis of BMW’s Physical AI concept.
https://www.youtube.com/watch?v=RTuovEBewkA
The pilot project in Leipzig is being conducted in collaboration with Hexagon Robotics, whose humanoid robot AEON was first introduced in 2025. Following laboratory tests and a preliminary deployment in late 2025, the robot will undergo a further testing phase from April 2026 before full pilot integration in the summer. AEON’s human-like shape and modular design allow for adaptable tooling, making it particularly suited to multifunctional tasks such as assembling high-voltage batteries and manufacturing components.
Humanoid robotics are seen as a complement—not a replacement—for existing automation. BMW emphasises that such systems are best suited to monotonous, ergonomically challenging, or safety-critical activities, thereby improving working conditions for employees.
To coordinate these advancements, the BMW Group has established a new Center of Competence for Physical AI in Production. This hub will standardise evaluation processes, support pilot projects, and ensure that knowledge gained across global plants is shared throughout the organisation.
As BMW continues to explore additional applications, including future deployments of Figure 03, the company is reinforcing its position as a technological leader in intelligent, AI-driven manufacturing.
Staff Writer
Reporting from the front lines of the automotive industry, delivering expert analysis and the technical updates that drive the South African motor sector forward.
