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Overhead shot of the industrial shelving that houses all the different car parts.

Inside Mini

The future in motion.

Published July 2024

Photography: Alastair Philip Wiper  
Words: Anna Allen

Home to the MINI Countryman, the first member of the MINI family fully produced in Germany, the BMW Group Plant Leipzig continues to push the boundaries of not only what’s possible now, but what’s best for the future. Since its inception, its commitment to stewardship—environmentally, socially, and economically—has fueled this automotive pioneer’s Big Love for people, progress, and the planet.

We joined internationally recognized photographer Alastair Philip Wiper, renowned for capturing the “unintended beauty” of complex processes and for showcasing what collaboration and the human mind can create, and ventured into the heart of the plant to see where the new MINI Countryman comes to life, visions of the future become reality, and to meet the people that make it all possible.

Arms crossed and wearing the plant’s mandatory vests, Plant Director and MINI Countryman Project Lead Sonja Hengstler share a glance as they stand in front of stored, unpainted car bonnets.

“It’s where all technologies meet, where all people meet.”

Petra Peterhänsel, Plant Director.

LOVE FOR ZEIPZIG.

Before the ground was even broken in 2001, the BMW Group Plant Leipzig aimed to revolutionize automotive manufacturing, beginning with an international architectural competition to select its design. Over 200 architects from around the globe responded to the tender, charged with designing the central building to seamlessly integrate core production areas and a central communications hub, all while prioritizing transparency, diverging from industry norms.

The “nerve centre”-inspired design by renowned architect Zaha Hadid won over the jury unanimously. The open office in the Central Building fosters direct and transparent communication between production areas, facilitating collaboration, and serving as the central meeting point for over 9,000 workers across the expansive 241-hectare worksite.

“It’s where all technologies meet, where all people meet,” explains Plant Director Petra Peterhänsel.

Overhead, high above desks and cafeteria tables, model frames parade down the assembly line, serving as a poignant reminder of the interconnectedness among departments and people—from line workers to executives—each playing a vital role in the production process.

Having the assembly line in public view was deliberate, a mandatory requirement outlined in the architectural competition, as part of the plant’s mission to foster transparency and accessibility in the manufacturing process.

The production halls, extending like “fingers”, fulfill the plant’s initial ambition of being future-proof. Designed with expansion and innovative manufacturing processes in mind—and the ability to add “new fingers”—its layout allows for easy modifications and flexible growth over time.

A commitment to the plant’s “future flexibility” was instrumental in its selection as the production site for MINI cars made in Germany. Alongside Oxford and Zhangjiagang, Leipzig is an important location for MINI production, with each site playing a strategic role for the brand and the BMW Group as a whole.

“The decision to locate in Leipzig was a strategic one, and I think it was an excellent choice for the plant,” says Peterhänsel.

Embracing sustainability from the outset was a key strategy for Leipzig, a concept that becomes easier with each new facility. While the plant remains dedicated to resource-efficient practices, all BMW Group plants are now committed to this approach.

The first BMW Group plant to produce multiple brands on the same line, the plant continues to drive change into the future as it has sought out to do since its inception.

Rolling off the same assembly line as three BMW models, the seamless integration of the MINI Countryman into the plant’s production process was no small feat. “We have three drives: internal combustion, plug-in hybrid, and now, with the MINI Countryman models, a fully electric offering. We have two brands, MINI and BMW, and we run everything on one line,” elaborates Peterhänsel.

Sonja Hengstler, now MINI Countryman Project Lead, was responsible for building up the measurement room at the plant in the early 2000s. She describes the feeling of the new MINI Countryman rolling off the Leipzig production line as a reunion of sorts.

“The Leipzig plant is of course one of the plants that has a very long experience, also in the production of all-electric vehicles. The legendary BMW i3 was built here,” Hengstler explains.

“It was essentially the first high-volume electric vehicle of the BMW Group. The team in Leipzig was really eager to finally be able to build a fully electric vehicle again. And with the all-electric MINI Countryman,” she continues. “It was like coming home for both sides.”

LOVE FOR PEOPLE.

Behind every innovative feat, every car that rolls off the line, every milestone the plant has set for the automotive industry, are the people who make it possible.

“For me, there is almost no better task in a corporation like the BMW Group than being a vehicle project leader, from the early phase, from the early design phase through the many, many steps, together with a great team,” Hengstler shares.

Each day, a team of over 9,000 workers joins forces to enable the production of up to 1,300 cars.

Together, Peterhänsel and Hengstler are actively fostering an innovative spirit. This spirit is evident not only in the production processes but also in the cultural values that drive the plant—and industry—forward.

“Social stewardship is not just an afterthought; it’s at the heart of our manufacturing strategy. We’re committed to designing a production process that benefits our employees, the plant, and the surrounding community,” notes Peterhänsel.

With the plant’s commitment to uniting workers in mind, it also rolled out a fresh uniform policy to underscore the powerful message of everyone being a part of the same team. Office and line workers alike don blue utility vests with their names visible.

“I believe it’s also a sign for the team. You belong here, that’s essential,” emphasizes Peterhänsel.

“I always have it on, I like to wear it very much, that’s also the first thing I do when I come to the office: jacket off, vest on.”

“I believe it’s also a sign for the team. You belong here, that’s essential.”

Petra Peterhänsel, Plant Director.

Factory worker in blue overalls stands to the side of an unfinished car body shell, framed by the neon orange PVC panel that encloses the production cabin.

Explore the MINI Countryman S ALL4

Before the first MINI rolled off Plant Leipzig’s production line in November 2023, the plant underwent various upgrades while its team undertook extensive training to learn the intricacies of producing a MINI.

“Building a MINI in addition to a BMW is a different challenge,” explains Peterhänsel. “This means that we have also invested a great deal of time in training our employees, getting to know the car and then also getting to know their activities on the vehicle.”

Aside from bringing in a “bit more color”, the integration of MINI at the plant was a “great fit from day one,” says Hengstler.

“It’s a part of the factory now, and of course BMW is also here as a very strong brand alongside MINI,” she adds. “And they can just coexist perfectly; you don’t have to worry about any competition.”

As we explored the plant, a harmonious interlude played out among humans and machines, regardless of the brand or model being produced. Alastair, our photographer known for his penchant for capturing the human essence in even the most complex structures and processes, was able to convey the plant in motion, showcasing what’s possible when people work together with, not against, automation.

In the main assembly building, robots handle highly specific and tedious tasks, as well as undertake the more dangerous processes, all the while allowing workers to manage from a safe distance and focus on other roles.

“Since 2018, we have started to expand the plant here from 250,000 to 350,000 units. And this is characterized, among other things, by the integration of the new MINI Countryman. Of course, this has a future for us, for the plant itself. We are very proud of it,” shares Peterhänsel.

The human-machine connection on display in the plant is also reflected in the new MINI Countryman itself.

“[The new interactive features] naturally creates a connection to the digital world or a connection between human and machine, which should also feel easy and uncomplicated. So, one doesn’t have to navigate through complicated menus, but rather, there’s simply an intuitive connection via the MINI UI (User Interface) between the MINI driver and their MINI,” explains Hengstler.

LOVE FOR PROGRESS & THE PLANET.

Though the plant’s initial construction was completed in 2005, it remains a growing ecosystem, a steadfast automotive trailblazer nearly 20 years on. Fueled by its original mission, it persists in its commitment since day one: continually reevaluating, redefining, and rethinking mobility, stewardship, and inclusivity.

Located on biodiverse greenery, the plant’s mission includes being both a reliable employer and good neighbor.

“What we look at, of course, is where we can create opportunities. Stewardship is not only ecological, it is also economic and social,” emphasizes Peterhänsel.

As one of Leipzig’s major employers and a crucial partner in the city’s journey towards modern mobility solutions, the BMW Group Plant plays a pivotal role in shaping the future.

The plant has capitalized on several key opportunities, notably its shift towards electromobility and innovative material sourcing.

A crucial player in supplying e-components across the entire BMW production network, the plant handles the full production process for the fifth generation of high-voltage batteries. It currently employs around 1,000 people in e-component, with plans for further development and investments exceeding €900 million.

Harnessing the power of nature, the plant installed four wind turbines in 2013, generating enough electricity to power approximately 5,000 homes annually. Additionally, in 2017, a battery storage farm was introduced, utilizing recycled batteries from BMW i3 vehicles to store excess energy from the turbines and other sources, contributing to improved energy management and grid stability.

For the contrast roof of the MINI Countryman, the plant implemented a pioneering paint application system, OFLA, Overspray-Free Painting, a world-first.

Bright red body shell mounted on an elevated platform, with the factory’s production line in the background.

“It’s like an inkjet printer, meaning there’s no paint mist, which is also more efficient,” describes Peterhänsel. “No paint mist goes down because it’s sprayed directly onto the surface where it should be. And the drying line is converted with hydrogen burners.”

Even the pre-painting process keeps responsible resourcing in mind. The emu feathers employed to guarantee the absence of dust or particles on the car are humanely sourced, each naturally shed feathers of emus, ensuring a lasting lifespan of 15 years.

“Stewardship truly permeates through here completely, both practically and in terms of the spirit among the employees throughout the plant,”

Sonja Hengstler, MINI Countryman Project Lead.

This spirit, set in motion two decades ago, continues to live on, and we’re happy to report from the heart of BMW Group Plant Leipzig, shows no sign of stopping.