BMW Group’s Hams Hall plant near Birmingham is celebrating 25 years of engine production, having delivered more than 7.6 million power units since series production began in 2001. The British facility has become a strategic hub in BMW’s global manufacturing network, supplying efficient internal combustion engines for BMW, MINI and Rolls-Royce vehicles worldwide.
Located in the heart of the UK’s automotive corridor, the BMW plant has grown from a new four‑cylinder production site into a multi-line operation building everything from three‑cylinder units to high‑performance V8 engines. The site’s scope also includes exclusive production of V12 engines for Rolls‑Royce Motor Cars, underscoring its role at the top end of the luxury market.
Engines for BMW, MINI and Rolls-Royce
Over its 25-year history, Hams Hall has supplied powertrains for a wide range of BMW Group models, including conventional petrol vehicles and plug‑in hybrid applications. Today, the plant produces three- and four‑cylinder petrol engines alongside performance‑oriented V8 units that are shipped to BMW and MINI vehicle plants around the world.
Rolls‑Royce’s V12 engines are assembled exclusively at Hams Hall following a bespoke, low‑volume process. Specially trained engineers and technicians handle each V12, which is completed in the UK before final installation at the Rolls‑Royce “Home of Rolls‑Royce” facility in Goodwood, England.
Strategic Role in BMW’s Global Network
BMW positions Hams Hall as a core component of its global powertrain production network. “The Hams Hall plant is an integral part of our global production network,” said Harald Gottsche, Head of Engine Production at BMW AG, highlighting the site’s combination of technological expertise and flexibility.
BMW plant Director Dirk Dreher emphasized the competitiveness and continuous improvement mindset of the workforce, noting their passion for refining manufacturing processes and strengthening the site for the future. Hams Hall’s output supports BMW Group’s “technology‑open” strategy, which continues to invest in efficient internal combustion engines alongside electrified powertrains.
Sustainability and the BMW iFACTORY Vision
The plant has been built and developed in line with BMW’s iFACTORY strategy, which focuses on sustainability, electrification, digitalisation and profitability. Since its first full year of production, Hams Hall has reduced the energy required per engine built by 61 percent, keeping total site energy consumption flat despite significantly higher volumes.
Today, the plant purchases 100 percent of its externally sourced electricity from renewable energy providers and has taken steps to cut natural gas usage. These measures position Hams Hall as a key benchmark within BMW’s engine network for low‑carbon, resource‑efficient manufacturing.
BMW SpOTTO: Robotic Dog on the Shop Floor
A four‑legged autonomous robot nicknamed “SpOTTO” joined the Hams Hall team in 2024, bringing advanced sensing and monitoring capabilities to the shop floor. Developed by Boston Dynamics as “Spot,” the agile robot can climb stairs, traverse rough terrain and navigate complex factory environments while carrying an array of sensors.
At Hams Hall, SpOTTO uses visual, thermal and acoustic sensors to scan production equipment, feeding data into the plant’s digital systems and supporting preventive maintenance. The robot also contributes to the site’s digital twin with real‑time information, effectively acting as a mobile “watchdog” for machinery health and production stability.
Fully Connected Digital Twin
The digital twin at Hams Hall sits at the center of the plant’s digital transformation, building a comprehensive virtual model of the site. It operates across three levels: a 3D representation of the physical plant, a large data layer, and an application layer where specialized software turns raw data into actionable insights.
Input arrives not only from SpOTTO, but also from manufacturing equipment and IT systems, ensuring a continuous flow of production data. Engineers and planners use dedicated apps to leverage this information for production planning, quality assurance and process optimisation, tightening the feedback loop between the physical and digital factories.
Timeline of Key Milestones
Since opening, BMW Hams Hall has followed a trajectory of continuous expansion in technology and product scope. Selected milestones highlight how the plant evolved from a single engine family to a multi‑line, high‑value site within BMW’s powertrain portfolio.
- 2001: Launch of series production with new four‑cylinder engines, introducing BMW’s Valvetronic variable valve control technology into large‑scale manufacturing for the first time.
- 2006: Start of engine production for the MINI brand as an additional engine family is integrated into the plant’s operations.
- 2013: Hams Hall becomes the exclusive manufacturer of the award‑winning three‑cylinder engine for the BMW i8 plug‑in hybrid sports car and adds new lines for three- and four‑cylinder petrol engines.
- 2013: Expansion of the processing hall for crankshafts, crankcases and cylinder heads to support higher levels of in‑house component machining.
- 2022: Takeover of V8 and V12 engine production, significantly increasing the plant’s business value and positioning it as a producer of BMW’s flagship combustion powertrains.
- 2026: Celebration of 25 years of production, marking more than 7.6 million engines built and shipped to BMW Group plants worldwide.
Part of a Wider Powertrain Network
Hams Hall operates alongside several other BMW Group powertrain sites that collectively underpin the company’s “technology‑open” approach. In Steyr, Austria, BMW runs its largest engine facility, which develops and produces diesel and petrol engines as well as sixth‑generation electric motors.
BMW Electric motor production for the fifth generation is based in Dingolfing, Germany, while BMW’s Munich plant manufactures mechanical components for V8 and V12 engines. Plant Landshut produces special engines, and BMW Brilliance Automotive in Shenyang, China, builds engines for the local market, forming a global network in which Hams Hall serves as a key British pillar.