BMW Changing Factories to Cope with Aging Workforce

German automakers are facing a looming age problem. Its workers are growing older, and there are not enough qualified workers to replace them. BMWBMWGermany, 1918 > present87 models
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has been trying to find a solution, and it has discovered that the best way to deal with the older workers is making its factories easier for them to work in. 

The average age of a BMW employee in Germany will be 47 in 2017, but BMW had this data far enough in advance to cope with it. In 2007, BMW began an experiment as its Dingolfing factory. It converted a production line with special hoists, height-adjustable work benches and wooden floors catered to older workers. It staffed this experimental line with some of its oldest workers. It found that the workers on this line were outperforming the younger workers on its other lines. They produced as many parts but with fewer faults as the younger workers. Since then, BMW has setup special production lines for older workers at many of its other factories. 

The solution works partially because of the cars that BMW builds. When building luxury cars, quality is more imporatant than volume. There are more intricate, skill-based production tasks on BMWs than on a mass volume auto producer. 

AudiAudiGermany, 1909 > present83 models
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has also taken note of BMW's success and has begun to find places for older workers. About half of the staff that package the vehicle kits at Audi have some sort of physical impairment. These ktis are shipped out and are assembled in India and China. Since implementing more worker-friendly production techniques for these workers, productivity is up 40%. They are able to produce 96% of what unimpaired workers do. 

DaimlerDaimlerGermany, 1889 > present12 models
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appears to be the one outlier is adapting to an older workforce. Its average worker was 43 in 2010 and will be 47 in 2020. The labor union is requesting concessions that would mean less physical effort for factory workers, but Daimler has balked. It wants pay concessions in return for the changes. 

Source: Automotive News Europe