With its total length of approximately 700 meters – including the logistics area – and large windows providing light from outside, the assembly hall is one of the most impressive buildings of the plant expansion in Győr. According to the herringbone principle, pre-assembly groups are located to the left and right of the main line – for the doors, the cockpit and the combination of drivetrain and suspension. The so-called “wedding,” where the car bodies come together with the mechanical components, is full automated in the third of the five assembly sections; with its 56 screw and bolt connections, it is the most complex stage of assembly.
Approximately 1,000 people will work here on floor space of 58,000 square meters; many of them will come from the previous TT assembly. On average, each group consists of ten employees who exchange activities every two hours.
Audi Hungaria places great importance on ideal ergonomic conditions. Each section of the assembly line has a height adjuster for the frames (“skids”) or for the suspended conveyor that moves the car bodies. Ergonomically designed assembly seats are installed in the section for door pre-assembly – employees can work in a sitting position. Handling devices such as for installing the battery and the seats or for fueling the cars relieves them of physically strenuous work.
An A3 Sedan consists of up to 10,000 parts and practically each one is unique – the many configuration possibilities that Audi offers its customers result in several million variants. For this reason, the assembly work is supported by complex logistics. “Supermarkets” related to particular assembly sections in the assembly hall supply the parts to be assembled; at the eastern end of the hall there is a logistics area for the supermarkets with floor space of 30,000 square meters.
The logistics employees who put together the load carriers here for part-specific transport wagons are supported by an online system, which ensures that they have taken the right part from the shelf. A pick-by-voice system is also used for parts commissioning. The logistics employees have to speak a reference number allotted to the part into the microphone of their headset; they then receive acoustic feedback as to whether or not the right part was selected. This system is new at Audi.
There are also numerous assembly assistance systems on the line that guarantee secure processes and high quality. They range from photo-sensors, which check whether the employees have taken all the components out of the load carrier or the shelf, to electronically regulated torque wrenches.
The last assembly stations of the Audi A3 Sedan are the startup and checking areas. When in operation, the road-driving simulation system installed there creates considerable waste heat, which is fed into the hall’s heating system.