- BMW Group is expanding its use of humanoid robots at its Spartanburg, South Carolina, plant by deploying Figure AI’s next-generation Figure 03 robot for logistics after an earlier Figure 02 manufacturing pilot.
- Figure 03 will sort unsorted components into sequencing trolleys for delivery to assembly lines, a logistics task BMW said could be scaled across automotive production while building on the Figure 02 pilot that supported production of more than 30,000 BMW X3 vehicles.
- The deployment is part of BMW’s broader iFACTORY strategy, which combines humanoid robots with AI-powered quality inspection, virtual factory simulations and digital production tools to increase automation and improve manufacturing operations.
BMW Group is expanding its use of humanoid robots at its Spartanburg, S.C., plant with a new logistics deployment of Figure AI’s Figure 03 robot.
The automaker said Figure 03 will work on complex sequencing applications in logistics at Plant Spartanburg, where BMW is using artificial intelligence, digital factory tools and robotics to reshape parts of its production system.
BMW said the aim is not only to automate work but also to protect employees and improve how they are used on the production floor.
The new deployment follows an 11-month Figure 02 pilot at Spartanburg, where the humanoid robot supported production of more than 30,000 BMW X3 vehicles over 10 months. In that earlier use case, Figure 02 inserted sheet-metal parts for welding in the body shop, a repetitive task that requires speed, accuracy and physical effort, according to the company.
BMW said the work showed humanoid robots can safely perform precise, repeatable tasks under real production conditions. The company is now moving the technology into logistics, where Figure 03 will sort parts for assembly operations.
“Plant Spartanburg is the birthplace of humanoid robotics in BMW Manufacturing’s operational day-to-day activities. Having already successfully completed a pilot with Figure 02 in our body shop, we are now looking forward to deploying Figure 03 for a sequencing use case in logistics,” noted Ulrich Wieland, vice president of production control and logistics for BMW Manufacturing.
What Will Figure 03 Do?
At the plant, delivered components arrive in larger containers in an unsorted state. Figure 03 will pick up the components and place them into a sequencing trolley. The trolley will then move to a collection point before an automated tugger train or Smart Transport Robot carries the parts to the installation area.
The goal is to provide parts to assembly employees “just in sequence,” meaning components arrive in the order they are needed for a specific vehicle build. BMW said the process is common in automotive production logistics and could offer room for further development and scaling.
According to BMW, Figure 03 adds several capabilities intended to broaden the robot’s use in manufacturing. BMW said the robot includes soft components designed to improve safety, wireless charging to support higher availability, audio functions for speech-to-speech communication and improved hands with tactile sensors and palm cameras to increase precision and dexterity.
BMW’s iFactory
The project is also tied to the digital transformation of Plant Spartanburg’s assembly operations. Hall 52, where variants of the BMW X3 are assembled and where the electrified BMW iX5 will be built in the future, has been expanded and updated as part of BMW’s iFACTORY approach.
BMW said it used digital applications during planning and continues to use them in daily production. Before parts reach the line, virtual 3D simulations help optimize processes and reduce errors. The BMW Virtual Factory is also used to simulate human movement sequences, refine manual processes and improve ergonomics.
“Our 11-month deployment of Figure 02 proved that humanoids are no longer lab experiments — they can be a valuable asset in establishing a flexible, reliable manufacturing workforce,” added Figure AI founder and CEO Brett Adcock. “We are excited to continue our work in Spartanburg as Figure tackles the complexity of the assembly and logistics hall.”
BMW pointed out that is using AI in quality assurance as well. At Plant Spartanburg, BMW’s AIQX system uses cameras and sensors for visual and acoustic inspections during line operations. The system gives employees immediate feedback through smart devices and is being assessed for possible use by suppliers.
The Spartanburg project builds on BMW’s wider use of humanoid robotics across its production network. AI Insider previously reported that BMW was also deploying humanoid robots at its Leipzig plant in Germany as part of a European pilot focused on Physical AI in vehicle production.
Image credit: BMW
