- Following on from the previous Figure 02 manufacturing pilot, BMW Group is expanding its use of humanoid robots at its Spartanburg, South Carolina, plant by introducing Figure AI’s next-generation Figure 03 robots into logistics.
- In Figure 03, unsorted parts are sorted into sequencing trolleys and delivered to the assembly line. BMW says this logistics work can be expanded across vehicle production, building on the Figure 02 pilot, which supported the production of more than 30,000 BMW X3 vehicles.
- The implementation is part of BMW’s broader iFACTORY strategy, which combines humanoid robots and AI-powered quality inspection, virtual factory simulation and digital production tools to enhance automation and improve manufacturing operations.
BMW Group is expanding its use of humanoid robots at its Spartanburg, South Carolina, plant with the new logistics deployment of Figure AI’s Figure 03 robot.
The automaker said Figure 03 will address complex sequencing applications in logistics at the Spartanburg plant. So BMW is using artificial intelligence, digital factory tools and robotics to restructure some of its production systems.
According to BMW, the aim is not only to automate tasks, but also to protect employees and improve the way they are used on the production floor.
This new deployment follows the 11-month Figure 02 pilot in Spartanburg, where humanoid robots supported the production of more than 30,000 BMW X3 vehicles over 10 months. According to the company, in a previous use case, Figure 02 inserted a sheet metal part for welding in a body shop. This is a repetitive task that requires speed, precision, and physical effort.
BMW said the study showed that humanoid robots can safely perform accurate, repeatable tasks under real-world production conditions. The company is now moving this technology into the logistics field, where Figure 03 sorts parts for assembly operations.
“The Spartanburg plant is the birthplace of humanoid robots in BMW Manufacturing’s daily operations. We have already successfully piloted the Figure 02 in our body shop and are now looking forward to implementing the Figure 03 for sequence use cases in logistics,” said Ulrich Wieland, Vice President Production Management and Logistics at BMW Manufacturing.
What does Figure 03 do?
At the factory, delivered parts arrive unsorted in large containers. Figure 03 picks up the components and places them on the sequence trolley. The trolley then moves to a collection point, after which an automated tow train or smart transport robot transports the parts to the installation area.
The goal is to provide assembly employees with parts “in order.” This means that the parts arrive in the order required for the production of a particular vehicle. BMW said this process is common in automotive production logistics and may have scope for further development and expansion.
According to BMW, the Figure 03 has several additional features aimed at expanding the use of robots in manufacturing. BMW says the robot includes soft components designed to improve safety, wireless charging to support high availability, audio capabilities for voice-to-voice communication, and improved hands with tactile sensors and a palm camera to improve precision and dexterity.
bmw i factory
The project also involves the digital transformation of the Spartanburg plant’s assembly operations. Hall 52, where variants of the BMW X3 are assembled and, in the future, the electrified BMW iX5, has been expanded and updated as part of BMW’s iFACTORY approach.
BMW said it used digital applications during planning and continues to do so in day-to-day production. Virtual 3D simulation helps optimize processes and reduce errors before parts hit the line. BMW Virtual Factory is also used to simulate human movement sequences, refine manual processes and improve ergonomics.
“The 11-month rollout of Figure 02 has proven that humanoids are no longer a laboratory experiment; they can be a valuable asset in establishing a flexible and reliable manufacturing workforce,” added Brett Adcock, Founder and CEO of Figure AI. “We are excited to continue our work in Spartanburg as Figure grapples with the complexities of assembly and logistics halls.”
He pointed out that BMW also uses AI for quality assurance. At the Spartanburg plant, BMW’s AIQX system uses cameras and sensors for visual and acoustic inspection during line operations. The system provides instant feedback to employees through smart devices and is being evaluated for potential use by suppliers.
2025 Figure 02 Pilot
Figure AI reported that the 11-month implementation of the Figure 02 at BMW Group’s Spartanburg plant in 2025 went from initial setup to factory testing within six months, and reached full implementation on an active assembly line running daily within 10 months.
During the installation, the Figure 02 performed 10-hour shifts Monday through Friday, loaded more than 90,000 parts, logged more than 1,250 hours of operation and contributed to the production of more than 30,000 BMW X3 vehicles. According to Figure AI, the robot walked an estimated 1.2 million steps, or more than 200 miles, and performed sheet metal loading tasks that required an 84-second cycle time, a 37-second load time, a placement success rate of over 99% per shift, and a goal of zero human intervention.
Figure AI says the introduction of BMW introduced lessons in hardware and reliability that carried over to Figure 03. The company said minimal hardware failures were recorded in Figure 02, but the forearm was the biggest point of failure due to tight packaging, manual dexterity requirements, and thermal constraints. In Figure 03, we redesigned the wrist electronics to remove the power distribution board and dynamic cables, allowing each wrist motor controller to communicate directly with the main computer.
The Spartanburg project builds on the extensive use of humanoid robotics across BMW’s production network. AI Insider previously reported that BMW is also deploying humanoid robots at its Leipzig, Germany, factory as part of a European pilot focused on physical AI in car production.
Image credit: BMW
