When production of Audi models started, all production areas of the plant received investments as well as more energy efficient latest‑generation equipment. In addition, hundreds of employees were trained in order to guarantee the highest quality of production.
A new line has been installed in the body shop comprising168 robots. The new equipment includes laser welders, which join the different body parts using light beams, and a new Eco Framer, a modern piece of equipment that establishes the geometry of the car body to within a tenth of a millimeter precision and also puts the internal and external side panels in place, bringing with it qualitative advantages. Also in the welding 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 joining process, through systems that evaluate the points worked on 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 when it comes to the application of the materials. This equipment guarantees qualitative excellence of the production process as well as a cell for installation of the panoramic sunroof on the Audi A3 Sedan, with a manipulator robot for the actual placement.
On the assembly line, the main change was in the area where the chassis parts of the vehicle (the engine, transmission and suspension) are joined to the body – a process known as “the marriage”. The new system makes the process even more efficient, as well as keeping track of the tightening of all screws used in this stage.
Inaugurated in January, 1999, the São José dos Pinhais plant is one of the Volkswagen Group’s most modern factories worldwide. The unit was built using a pioneering layout: the body shop, paint shop and final assembly areas converge into the Communication Center, a triangular-shaped building where management offices, indoor gardens, restaurants and canteens are located. The objective of this configuration is to integrate all areas in the information flow, facilitating the continuous improvement of quality. The idea is to allow all work areas to interact with each other. The laboratories and measuring facilities are also situated at the Communication Center. The unit has an advanced logistics 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 domestic and foreign markets.
Certified to ISO 14001, the standard that attests good environmental management, the São José dos Pinhais plant supports many initiatives benefiting the environment. Along with keeping a nursery to produce tree saplings for reforestation, the plant has an advanced effluent treatment process and its own weather station. This is located at the paint shop building and it monitors weather changes in order to precisely control the volume of cold and hot water used in climate control for the paint cabins, thereby optimizing the consumption of energy and natural gas.
In the administrative areas, the glass-framed indoor gardens utilize natural lighting on a large scale, thus reducing energy consumption and providing a pleasant working environment with a natural feel to it. 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 atmosphere as in conventional systems with roof outlets. This system is also an improvement when it comes to reducing energy consumption.
Facts and Figures
Chairman of the Board of Management: Prof. Rupert Stadler
Chairman of the Supervisory Board: Matthias Müller
Employees (AUDI AG): 60.655 (as of December 31, 2016)
Employees (Audi Group): 88.453 (as of December 31, 2016)
Deliveries to customers (2016): 1.871.350 automobiles of the Audi brand
Production (2016): 1.903.259 automobiles (including Lamborghini and CKD)
(all information as at December 31, 2016)
Audi do Brasil
Site: Volkswagen do Brasil Indústria de Veiculos Automotores Ltda. in Curitiba, Brasil
Surface area: 1,300,000 square meter
Audi start of production: 2015
Models (2016): Audi A3 Sedan, Audi Q3
Production (2016): 7.846 automobiles
Fuel consumption of the models named above
Audi A3 TFSI Flex:
Combined fuel consumption in l/100 km: 7,1-3,7**
Combined CO2 emissions in g/km: 164-98**
Audi Q3 TFSI Flex:
Combined fuel consumption in l/100 km: 8,6 – 4,2**
Combined CO2 emissions in g/km: 203 - 109**
**Figures depend on the tire/wheel sets used