R50/53 What made the 02-06 Mini so expensive to make?
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6th Gear
Joined: Dec 2004
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From: SF Bay Area
I think it really depends case by case - yes there is costly lightening with aluminum, carbon fiber, forged wheels, hollow rug fibers and other extremes, then there can also be things like thinner plastics, insulation, and other materials that are simply less substantial without being expensive.
1st Gear
Joined: Aug 2005
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I did not read the entire thread - but the engine was a Brazilian made, chrystler designed engine that chrystler was supposed to use to lower the cost. Chrystler backed out and MINI was stuck footing the bill for the now very, very expensive engine.
Coordinator :: Super Secret Orange County MINI Cooper Club
Joined: Oct 2006
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From: Mission Viejo, CA
Why was it more expensive to make in south america than here? That seems like it would make it...cheaper.
5th Gear
Joined: Mar 2005
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It's not expensive yet because they are still under contract. Once the contract ends next year, the factory may be sold to China:
February 17, 2006
New York Times
China Seeking Auto Industry, Piece by Piece
By Keith Bradsher
CHONGQING, China, Feb. 16 — China is pursuing a novel way to catapult its automaking into a global force: buy one of the world's most sophisticated engine plants, take it apart, piece by piece, transport it halfway around the globe and put it back together again at home.
In the latest sign of this country's manufacturing ambitions, a major Chinese company, hand-in-hand with the Communist Party, is bidding to buy from DaimlerChrysler and BMW a car engine plant in Brazil.
Because the plant is so sophisticated, it is far more feasible for the Chinese carmaker, the Lifan Group, to go through such an effort to move it 8,300 miles, rather than to develop its own technology in this industrial hub in western China, the company's president said Thursday.
New York Times
China Seeking Auto Industry, Piece by Piece
By Keith Bradsher
CHONGQING, China, Feb. 16 — China is pursuing a novel way to catapult its automaking into a global force: buy one of the world's most sophisticated engine plants, take it apart, piece by piece, transport it halfway around the globe and put it back together again at home.
In the latest sign of this country's manufacturing ambitions, a major Chinese company, hand-in-hand with the Communist Party, is bidding to buy from DaimlerChrysler and BMW a car engine plant in Brazil.
Because the plant is so sophisticated, it is far more feasible for the Chinese carmaker, the Lifan Group, to go through such an effort to move it 8,300 miles, rather than to develop its own technology in this industrial hub in western China, the company's president said Thursday.
3rd Gear
Joined: Oct 2006
Posts: 225
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Not sure what costs more in the 02-06' models. It will be interesting to watch the first couple of years of this new design. If they really do start using cheaper parts we will see more posts of things going wrong.
Glad I got one of the last 06' models. Now I can watch and wait. If it looks good then I will trade in when the warranty is up.
Glad I got one of the last 06' models. Now I can watch and wait. If it looks good then I will trade in when the warranty is up.
If everything looks good in 3 years, I'll consider getting a new model.
2nd Gear
Joined: Jul 2006
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From: Butler, PA
My current wife is Peruvian and reliable most of the time, but not really technologically advanced. Still, she is a huge improvement over my Russian eX-wife who was very reliable ---predictable--- in her ability to spoil any otherwise meaningful occassion. She did, however, have an incredible supercharger. The whine was mind-blowing!
4th Gear
Joined: Oct 2006
Posts: 331
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From: Sunnyvale CA
That's exactly what I'm thinking. When I saw that the MINI was changing design I hurried up and made my order for an 06. I didn't want to be a beta tester for the new model. Also, I didn't really like the new interior designs on the 07's.
If everything looks good in 3 years, I'll consider getting a new model.
If everything looks good in 3 years, I'll consider getting a new model.
6th Gear
Joined: Jul 2002
Posts: 4,293
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From: Cincinnati, Ohio
I believe that the unprecedented nature of the current MINI's runaway sales success has contributed to the expensive nature of its fabrication. BMW never thought that it would have to add additional production lines in Oxford, nor run three shifts to meet demand for the car. Think about it, you gear up to employ say 5,000 and within a couple of years you're employing 12,000, running the factory 24/7 and having to construct more production capacity, purchase unbudgeted materials, etc.
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6th Gear
Joined: Dec 2004
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From: SF Bay Area
I believe that the unprecedented nature of the current MINI's runaway sales success has contributed to the expensive nature of its fabrication. BMW never thought that it would have to add additional production lines in Oxford, nor run three shifts to meet demand for the car. Think about it, you gear up to employ say 5,000 and within a couple of years you're employing 12,000, running the factory 24/7 and having to construct more production capacity, purchase unbudgeted materials, etc.
"BMW spared no expense when it developed the current Cooper and rumors persist that the Mini is more expensive to produce than the 3 Series. The new car needs to be cheaper to build and it will be interesting to see how the Munich boffins solve this particular conundrum without diminishing its quality."
Welp, I guess unless someone from BMW pipes up we may never know - and besides, they probably do not want to describe any cost savings on the new car considering.
3rd Gear
Joined: Oct 2006
Posts: 181
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From: L.A.
BMW is one of the most operations efficent manufactures out there, apart of the reason they're having so much sucess today. BMW is applying what they've learned in using "just in time" manufacturing w/ the E9 3er gen cars @ their Leipzig faclity and applying that same know how, manufacturing methodlogy to all of it's plants to turn out the highest quality, least wasteful, and most personable customization lean manufacturing processes in the automotive manufacturing world. BMW isn't an American car company, they know their customers expect perfection and nothing less, looking at the new E90 3er sedan after it's first year, there have been very few problems.
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6th Gear
Joined: Dec 2004
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From: SF Bay Area
They are not reducing the number of options, interior/exterior selections or combos, and individual option choices (outside of packages) are they? That would be a way to reduce costs.
3rd Gear
Joined: Jun 2006
Posts: 296
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From: Canal Fulton, Ohio
Since I didn't see it posted I thought I read on MotoringFile that new MINI's were sharing their electronics from the current BMW 3-series at some level. I would think any such comonpent re-use/economies of scale would save money...
Also BMW's already switched MINI's paintshop over this spring to a much cheaper process than they used to use...they now use a "one-step" paint process (BASF) instead of the base and color process used on all the previous MINI's...the new paint's not baked either saving time and money. I was really concerned about the quality of my paint on my late '06 build MINI but it's nice, hopefully it holds up...so far so good. (NOTE: There were details about this on MotoringFile too...)
Also BMW's already switched MINI's paintshop over this spring to a much cheaper process than they used to use...they now use a "one-step" paint process (BASF) instead of the base and color process used on all the previous MINI's...the new paint's not baked either saving time and money. I was really concerned about the quality of my paint on my late '06 build MINI but it's nice, hopefully it holds up...so far so good. (NOTE: There were details about this on MotoringFile too...)
1st Gear
Joined: Oct 2004
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#1 The multi-link rear suspension, which is almost identical to that on a 3 series BMW.
#2 Costly fabrication process for the clamshell hood with cutouts for the headlights. They knew it would be an expensive part to make but they wanted to keep the look of the original Mini prototype with no seams on the hood. Same with the back end sheetmetal that has to have cutouts for the taillights.
#3 The Brazilian made engine. It would have been less expensive for BMW to develop an engine for the Mini in-house but it would have taken too long. The Brazilian engine is also a mediocre piece. It's pretty heavy with it's iron block and it doesn't have variable valve timing. The engine on the 07 Mini will be a big improvement.
#2 Costly fabrication process for the clamshell hood with cutouts for the headlights. They knew it would be an expensive part to make but they wanted to keep the look of the original Mini prototype with no seams on the hood. Same with the back end sheetmetal that has to have cutouts for the taillights.
#3 The Brazilian made engine. It would have been less expensive for BMW to develop an engine for the Mini in-house but it would have taken too long. The Brazilian engine is also a mediocre piece. It's pretty heavy with it's iron block and it doesn't have variable valve timing. The engine on the 07 Mini will be a big improvement.
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