The powertrain development area has had a presence in Győr since 2001. It supports Production with its development work for series production. There are more than 400 employees working on a variety of development projects in simulation, design engineering, mechanics development, engine management system applications, engine acoustics optimization and powertrain testing. The core task in powertrain development at Audi Hungaria is to develop and support series production operations for gasoline and diesel engines as well as for electric axle drives. Powertrain development in Győr currently operates 24 test benches: 20 for combustion engines and four for electric axle drives, including special acoustics, thermodynamics and climate test benches. The Engine Development Center includes a workshop equipped with cutting-edge technology. The experts of Audi Hungaria can test the entire range, from electric motors to twelve-cylinder combustion engines, on the running test benches.
In January 2012, Technical Development at Audi Hungaria was expanded to include a area for Whole Vehicle Development. The now nearly 100 employees are engaged primarily in the virtual development of system and whole vehicle properties by means of numerical simulations. Focal points are questions relating to strength, acoustics and both thermal and energy management. Powertrain and vehicle tests in the laboratory are also important components of the competence portfolio in Győr. These are performed using state-of-the art test equipment and methods, including the Volkswagen Group’s only centrifuge test bench for the strength analysis of electric motors and a roller dynamometer on which vehicles can be analyzed on a simulated road at speeds up 280 km/h (174.0 mph).
All development activities are based on close collaboration with Product Data Management as a strategic partner and technical conformity of AUDI AG.
Toolmaking shop celebrates 15th anniversary
The largest toolmaking shop in Eastern Central Europe celebrated its 15th anniversary in Győr in 2020. In 2005, Audi Hungaria opened the toolmaking shop, in which the equipment for the press shops and body shop are made. It also produces assemblies for the Group’s supercar models in an exclusive series. The most notable equipment are the large presses. With a tool weight of 50 tons, these can exert up to 25,000 kilonewtons of press force on the individual pieces. The most notable equipment are the large presses. With a tool weight of 50 tons, these can exert up to 25,000 kilonewtons of press force on the work pieces. The toolmaking shop has been continuously expanded, with new presses and 3D laser cutting machines now in operation. Around 700 employees in the roughly 50,000-square meter (538,195.5 sq ft) Győr toolmaking shop produce body assemblies for exclusive and supercar models from the Audi and Volkswagen Group. Expansion of the toolmaking shop began in 2016, as part of which floor space was expanded in 2017 by 15,000 square meters (161,458.7 sq ft) to create capacity for future projects. Four new large presses with a press force of up to 2,500 metric tons were commissioned in 2017. Capacity in exclusive series production was increased in 2018. Thanks to this higher capacity, the toolmaking shop will in future deliver body parts for 120 vehicles every day. Tooling and plant engineering as well as the exclusive series production exemplify first-class technology. The product spectrum is focused on production equipment for outer skin body parts, mostly of aluminum.
The hang-on parts for the Audi e-tron GT are produced exclusively at Audi Hungaria. Toolmaking shop employees produce the doors, fenders, hood and tailgate of the Gran Turismo. As part of the Audi Group’s international production network, Audi Hungaria is a key contributor to the project. The highly complex aluminum hang-on parts for the electric-powered Gran Turismo are produced at the toolmaking shop in Győr.
Győr produces the highly complex outer skin parts, such as hoods, doors, tailgates, fenders and side panels used in Audi sports models such as the Audi RS models and for the Audi R8, the Lamborghini models and the Bentley Bentayga.
Flexible and efficient logistics
- The company adopts intelligent solutions not only in production, but also in logistics. Audi Hungaria established a modern logistics infrastructure to ensure smooth production operations. Integrated smart solutions, such as modern automated guided systems and vehicles, along with digital tools support the logistics processes. Automated guided vehicles transport the components automatically to workstations – such as in the electric motor production facility at Audi Hungaria, which does not have a conventional assembly line. They use laser scanners to orient themselves in the shop and find the optimum route. This highly flexible procedure is made possible by algorithms and machine learning, controlled by a smart IT system in the control station. This enables IT to keep track of all systems, all automated guided vehicles, and the product, even without a fixed assembly line sequence.
- The internal material flow is controlled so that only those parts that are directly required for production are made available. This eliminates costly intermediate stores, and productivity increases as a result. Environmentally protective rail transport is the primary mode for basic materials, parts, finished engines and automobiles. The new rail network installed as part of the plant expansion is eight kilometers (5.0 mi) long. The railway inside the plant grounds was lengthened by 30 percent.
- Audi Hungaria has continuously expanded the logistics infrastructure in recent years. The company inaugurated its second Logistics Center with an area of 80,000 square meters (861,112.8 sq ft) in 2015. Also added were a new bridge and an additional incoming goods hall.
Corporate quality – focused on perfection
Quality is considered worldwide to be a core competence of Audi and thus is a basic element of both our corporate and Q strategies. The objective of corporate quality of AUDI HUNGARIA Zrt. is to serve as a strong partner for ensuring the quality of the products produced in Győr and to guarantee process quality for overall value creation within the company. The aspiration is therefore no less than uncompromising top quality in all work processes and, of course, in each individual product from the company. This is characterized primarily by high visual and finish quality as well as reliability. These are the key prerequisites for maximum customer delight and customer satisfaction.
Audi Hungaria’s quality management system is based on EN ISO 9001 from the International Organization for Standardization and the VDA 6.1 standard.
The Corporate Quality Powertrain area at the Győr site systematically monitors and for years has continuously advanced the high quality level of the engines and electric motors produced here. Measurements and analyses are conducted using state-of-the-art technology in the high-tech laboratories and on the modern test benches.
Audi environmental program “Mission:Zero” encourages more environmental protection
Mission:Zero is the Audi environmental program for consistently sustainable production. All activities and measures for reducing the ecological footprint at the Audi sites worldwide, in Production and Logistics are bundled here. The focus is on Audi’s key challenges of decarbonization, water use, resource efficiency, and biodiversity. One of the key objectives is to achieve carbon-neutral production locations by 2025.
Mission:Zero at the Győr site – examples of measures:
- Sustainability is a top priority of Audi Hungaria’s corporate strategy. Minimizing environmental pollution and conserving natural resources are therefore every bit a part of the corporate philosophy as careful workmanship and the high quality of the materials used. Audi Hungaria set up an environmental management system in 1999. This system complies with the extremely strict standards of the European Union’s EMAS Regulation, and meets the requirements of the international environmental standard ISO 14001. The company’s certified energy management system has been implemented according to ISO 50001 since 2011 and integrated into the environmental management system. Audi Hungaria’s environmental management system has the EMAS registration number 1 in Hungary – clear proof of the company’s commitment to the environment.
- Audi Hungaria is the largest user of industrial geothermal energy in Hungary. The company has met more than 70 percent of its thermal energy needs with geothermal energy since 2015. The system supplies Audi Hungaria with at least 82,000 MWh of thermal energy each year. The company has used 430 GWh of geothermal energy since 2015, enabling CO2 emissions to be reduced by 87,500 metric tons.
- Audi uses DB Cargo for the carbon-neutral transport of components, engines and vehicles between its plants in Ingolstadt, Brussels and Győr.
- Under the Aluminum Closed Loop project launched in 2021, aluminum waste arising during production is returned to the supplier, who uses it to produce aluminum coils of original quality and returns these to Audi. This closes the loop and enables sustainable production.
- Audi Hungaria, in partnership with E.ON Hungaria, installed a solar energy park covering around 160,000 square meters (1,722,225.6 sq ft) on the roofs of its two Logistics Centers in 2020.The solar panels installed on a building on the Audi Hungaria site in Győr are thus the largest photovoltaic facility in Europe. It has a peak output of 12 megawatts.
Audi Hungaria has been carbon-neutral since January 1, 2020. Audi Hungaria thus follows Audi Brussels as the second carbon-neutral site of the Audi Group. The site in Győr, Hungary, employed three levers to decarbonize. The first was the switch to green electricity, which was accomplished by bringing Europe’s largest rooftop photovoltaic system online and the purchase of electricity generated from renewable resources. The second is the use of geothermal energy for heat. Audi Hungaria compensates for CO2 emissions that cannot currently be avoided, such as from engine test benches, with internationally recognized and certified carbon credits. That is the third lever, which represents roughly 5 percent of the CO2 emissions.