In 2015, Audi started production of the Audi A3 Sedan* at the site São José dos Pinhais in Curitiba, Brasil. The plant is the only one to produce the model in Ethanol version. The Audi Q3 is scheduled to begin production in March 2016. To begin the manufacture of the model, all productive areas of the plant received investments and late-generation equipment, more energy efficient. Besides this, hundreds of employees were trained to assure the models’ manufacture excellence.
In the body shop a new line has been installed, with 168 robots. The new equipment includes laser welders, which joint the different parts using a beam of light, and a new Eco Framer, a modern piece of equipment that establishes the geometry of the car body to a precision of tenths of a millimeter and places the internal and external side panels, bringing qualitative advantages. Also in the weld division, 145 servo‑pneumatic welding tongs have been installed. These are used in the body welding process, and are faster and 30 percent more energy efficient. They guarantee 99 percent efficiency in the process of joining the parts, through systems that evaluate the points to be worked with at the time of welding.
The paint shop has also gained a new line of more modern robots for the application of PVC, Primer and Varnish, which have greater precision in the application of the materials. This equipment guarantees qualitative excellence of the production process; and a cell for installation of the panoramic sunroof of the Audi A3 Sedan*, with a manipulator robot for the actual placement of the sunroof.
In the assembly line, the main change was in the area– where the motor parts of the vehicle (the engine, transmission and suspension) are joined to the body – a process known as “marrying up”. The new system makes the process even more efficient, as well keeping track of the tightening of all the screws used in this stage.
Inaugurated on January 18 1999, the São José dos Pinhais plant is one of Volkswagen Group’s most modern factories worldwide. The unit was built following a pioneer layout: the Body Shop, Paint Shop and Final Assembly areas converge into the Communication Center, a triangle-shaped building where managing offices, internal gardens, restaurants and canteens are assembled.
The objective of this configuration is to integrate all areas in the information flow, facilitating the continuous quality improvement. The idea is to make all work areas to interact together. At the Communication Center are also located the laboratories and measuring rooms. The unit has an advanced logistic system, with 12 on-site suppliers, which form the Curitiba Industrial Park. Since its opening, the industrial complex has produced more than 2,4 million vehicles for the internal and external markets.
Certified by ISO 14001, the world's standard that attests good environmental management, the plant of São José dos Pinhais holds many initiatives benefiting the environment. Besides keeping a nursery to produce tree saplings for reforestation, the plant has an advanced effluent treatment process and its own weather station, located at the Paint Shop building, to monitor climate changes in order to precisely control the cold or hot water volume used in climate control at the paint cabins, optimizing the consumption of energy and natural gas.
In the administrative areas, the glass-framed internal gardens favor the natural lighting in large scale, reducing energy consumption and providing a pleasant, nature-integrated working environment. The air-conditioning, with air vents near the floor, allows immediate thermal comfort, as it is not necessary to wait for the cold air to descend to cool the ambient as in conventional systems, with roof outlets. This system also improves the energy consumption reduction.
Facts & Figures
Chairman of the Board of Management: Prof. Rupert Stadler
Chairman of the Supervisory Board: Matthias Müller
Employees (AUDI AG): 59,506 (as of December 31, 2015)
Employees (Audi Group): 84,435 (as of December 31, 2015)
Deliveries to customers (2015): 1,803,250 automobiles of the Audi brand
Production (2015): 1,830,334 automobiles (including Lamborghini and CKD)
Audi do Brasil
Site: Volkswagen do Brasil Industria de Veiculos Automotores Ltda.in Curitiba, Brasil
Surface area: 1,300,000 square meters
Audi start of production: 2015
Models (2015): Audi A3, Audi Q3
Fuel consumption of the models named above
Fuel consumption figures Audi A3 Sedan:
Combined fuel consumption in l/100 km: 7,1 - 3,7;
Combined CO2-emissions in g/km: 164 - 98
Fuel consumption figures Audi Q3:
Combined fuel consumption in l/100 km: 8,6 - 4,2;
Combined CO2-emissions in g/km: 203 - 109