Development and Production
Before BMW's ownership, the traditional Mini had been made at both Cowley, Oxfordshire and Longbridge, Birmingham. In time, production was rationalised to just Longbridge and so this was where the last of the cars were made, making Longbridge the "natural home" for the new Mini prior to BMW splitting up the company. However, as a result of the change of ownership, BMW redeveloped the entire Cowley plant, demolishing much of the factory, to create a new factory and renamed this "Plant Oxford", on the site of what was historically the Pressed Steel Company's Cowley Body Plant and next door to what was historically the Morris factory.
Since 2006, Plant Hams Hall produces the new Mini petrol engines, Plant Oxford is responsible for the body shell production, paint and assembly, and Plant Swindon produces body pressings and sub-assemblies, creating the "Mini Production Triangle". Mini claim that 60% of components of the Mini Mk II come from suppliers based in the UK compared to 40% for the 2001 model. The Countryman is the first modern Mini assembled outside the UK, with the contract won by Magna Steyr in Austria.
At Plant Oxford 4,000 employees, referred to as 'associates', produce up to 800 cars each day (approximately 240,000 per year). The bodyshop at Cowley holds 429 robots, assembling 425 body panels; the bodyshells are then moved to the neighbouring paint shop where paint robots apply the 14 exterior colour options and optional contrasting roof colours. Final assembly is performed at Cowley, which involves the fitting of 2,400 components to produce the numerous variants that may be ordered.
All Prince four-cylinder petrol engines for Mini and BMW are produced at the Hams Hall Plant near Birmingham, United Kingdom, which has around 800 employees. Diesel engines are manufactured by BMW's Plant Steyr in Austria, having previously been manufactured in France and England by PSA.
Mini sub-assemblies and pressings such as doors are supplied by the plant at Swindon, where 1,000 are employed and 280 pressed parts are produced using 135 welding robots. The Swindon plant was originally Swindon Pressings Ltd, founded in 1955 by the Pressed Steel Company and became a wholly owned subsidiary of the BMW Group May 2000.
Minis are primarily developed in the United Kingdom by BMW's Development Division.
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