Plastic component painting for BMW: process optimization and 10% cost reduction
This case study shows how replacing a two-layer paint system with a single-layer alternative reduced production cost of a BMW Z4 interior component by 10%, while maintaining all visual, durability, and functional requirements.
For decades, Okula has been a reliable supplier of high-precision plastic components for the automotive industry. With a strong focus on injection molding, surface finishing and painting technologies, Okula supports leading OEMs and Tier-1 suppliers across Europe.
One of our long-standing partnerships is with BMW, for whom the company has delivered a wide range of components across multiple vehicle generations, from interior visible parts requiring high-quality surface finishing, to functional and structural plastic components with demanding dimensional and performance requirements.
This includes, for example, painted center console components for the BMW Z4 (G29), air vent grilles for the BMW 3 Series Touring and roof-mounted interior frames, as well as various interior mounting and technical parts used across different BMW platforms.
This long-term experience with premium automotive standards formed the basis for the following project.
Can painting costs be reduced without compromising quality?
In 2023, one of our automotive customers faced increasing cost pressure on the center console used in the BMW Z4 (G29), a painted interior component with strict requirements on visual appearance, durability, and dimensional precision. The objective was clear: identify technical cost-saving opportunities without affecting functionality or premium quality standards.
However, reducing cost in a premium automotive interior component without compromising quality is rarely straightforward.
What was the main cost driver in the painting process?
We approached the task through a detailed review of the existing production process. The analysis identified the originally specified two-layer paint system as a major cost driver.
Based on internal know-how in painting technologies and experience from similar premium interior components, we proposed a technically viable alternative: replacing the two-layer system with a single-layer paint system, while maintaining the required surface quality, scratch and chemical resistance, and overall visual standards expected in a BMW interior.
How was the new paint system validated?
To verify the feasibility of the proposed change, we prepared sample parts using the single-layer paint system.
Validation included internal evaluation of surface appearance and adhesion, as well as external laboratory testing conducted in coordination with the customer. The goal was to ensure that all functional and visual requirements remained fully met.
As part of a partnership-oriented approach, we offered these paint trials free of charge, demonstrating commitment to helping the customer through a difficult economic period and confidence in the proposed solution.
Aligning technical and commercial aspects
In parallel with technical validation, the commercial framework of the project was aligned. A revised unit price was agreed, and historical open items were addressed based on a mutually accepted proposal. Following both technical and commercial confirmation, we proceeded with planning of paint tests and sample availability for further steps.
What were the measurable results of the optimization?
The implemented solution delivered clear and measurable outcomes:
- simplified painting process,
- 10% reduction in component production cost,
- full compliance with functional, durability, and visual requirements of the BMW Z4 interior.
In general, paint system optimization in automotive components can deliver significant cost savings when supported by process validation and material expertise, while maintaining the standards expected in a premium OEM environment.
Moreover, this case study highlights our role not only as a manufacturing supplier but as a true engineering partner — driving value for customers through smart technical improvements rather than purely commercial negotiation.
