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BMW
Transforming a static, fixed IT system into an agile, cloud-based platform
In brief
BMW worked with Gloster to transform its previously static, on-premises IT infrastructure into a dynamic, cloud-based system that now forms the basis of its global production logistics. Over a multi-year transformation process, Gloster designed a cloud-native, microservices-based architecture that acts as a scalable gateway between on-premises systems and modern cloud platforms.
The system significantly reduces installation time, increases agility, and ensures 24/7 availability for business-critical operations. Today, this system performs bill of materials (BOM) calculations on all BMW production lines worldwide, supporting just-in-time manufacturing across all brands and geographic regions.
Gloster's integrated DevOps model and full lifecycle management ensure business continuity and operational flexibility during the transition.
Founded in 1913 and known worldwide for its automotive innovation, BMW plays a leading role in the industry in the areas of premium electric mobility and manufacturing efficiency. With factories across Europe, Asia, and North America, BMW relies on real-time digital systems to coordinate highly synchronized manufacturing and supply chain processes.
The system developed by Gloster is one of BMW's most critical IT systems, supporting demand calculations and logistics for short-, medium-, and long-term production planning for all of the BMW Group's global brands, including Mini and Rolls-Royce.
The challenge
BMW faced significant challenges with its existing system:
- The previous static, fixed IT infrastructure had reached its natural limits and was unable to support the scale and adaptability required for increasingly complex logistics requirements.
- Lack of integration with cloud-native technologies
- High costs and the risk of downtime, factory-level delays can cost millions every day.
- Slow service and fragile infrastructure
Gloster was selected through a five-year tender process to implement and operate a DevOps model supporting BMW's global production logistics. While several partners were involved in the modernization, Gloster played a central role as the DevOps provider—delivering CI/CD automation, platform reliability, and agile delivery through a complex, distributed architecture.
Our approach
Change management and human factors
Gloster has adopted a gradual, risk-aware transformation strategy based on Agile, DevOps, and cloud-based design best practices.
Key elements:
1. Micro-service ecosystem (60+ services)
The modular architecture enabled independent development, testing, and deployment of both core and support services. This parallelized workflows and improved system flexibility.
2. Cloud migration
To support global scalability and high availability, BMW needed a modern, cloud-based architecture. Gloster implemented this using infrastructure as code and managed services (e.g., cloud databases, caching layers), significantly reducing deployment time and operating costs.
3. CI/CD and blue/green deployment
Automated CI/CD pipelines and blue/green deployment models reduced release time from 5 hours to less than 5 minutes. This enabled biweekly production deployments—alternating with BMW's quarterly release cadence and better aligned with evolving business priorities.
4. Proportionate data processing
Gloster processed, transformed, and stored over 500 GB of structured production data overnight in Apache Solr for high-performance analytics and service. Over 40 factories receive daily updated demand data, supporting just-in-time manufacturing accuracy.
5. DevOps integration model
Gloster plays the role of DevOps Provider within BMW's organizational matrix, integrating the results of multiple Scrum teams, maintaining test coverage, and coordinating production start-up. This central DevOps hub ensures continuous delivery, operational transparency, and accountability in the release pipeline.
The success of the project depended as much on people as it did on technology:
- Developing a strong "owner mentality" in all teams - Hungarian, German, Portuguese
- He overcame initial uncertainty by demonstrating reliability and a clear division of roles.
- Through on-site meetings and open cooperation, the sales approach has become that of an equal partner.
- Night shifts and 24/7 operational coverage were presented as opportunities for team building and career development.
Through successive sprints and releases, the teams jointly refined not only the technical stack, but also their collaboration model—transforming early coordination challenges into a foundation of mutual trust and operational excellence.
Business impact
Business continuity is ensured: This way, we have minimized risk and guaranteed uptime.
Increased efficiency:
- Installation time reduced from 5 hours to 5 minutes
- Automated demand forecasting and material calculation, updated nightly for 40+ factories.
- Reduced failure rate thanks to proactive monitoring and automatic validation
With the transition, BMW teams gained direct control over infrastructure scaling, instant recovery capabilities, and resource optimization, ensuring flexibility and agility in a globally distributed production environment.
Partnership evolution:
Partnership evolution:
Gloster is now a recognized DevOps leader within BMW, entrusted with forward-looking initiatives. The team has evolved from a feature development team to a full lifecycle steward of a globally critical production system.
Differentiating factors:
- Weekly installation cycles
- Integrated delivery from multinational Scrum teams
- Responsibility for resolving incidents and enforcing processes
What's the next step?
BMW and Gloster are continuing to develop the system to support future initiatives, with Gloster securing a five-year contract due to its outstanding performance and reliability:
- AI/ML optimization: Internal LLM hosting and process analysis to optimize demand forecasting
- Ecosystem integration: Extension to other BMW divisions and supplier interfaces
- Advanced observability: Advancements in alerting and diagnostic telemetry
Technologies used
Java
JakartaEE
Payara-Micro
Apache Solr
Docker
IBM DB2 /MQ
Grafana
Prometheus
PostgreSQL
Microsoft Azure
Contact us!
How can Gloster contribute to your business success?
Contact us at info@gloster.hu or simply click on the link below!
Contact us at info@gloster.hu or simply click on the link below!
Gloster has established an abuse reporting system in accordance with Act XXV of 2023 on complaints, public interest disclosures, and rules relating to the reporting of abuse, which is available to all our employees, clients, contracted partners, and anyone else who comes into business contact with Gloster.
Reports can be made in the following ways: By email to visszaelesbejelento@gloster.hu
Reports can be made in the following ways: By email to visszaelesbejelento@gloster.hu
