The Powertrain Development department 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 was expanded to include 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.
Audi Hungaria expanded its development activities in late 2011 with the Total Vehicle Development department, which currently employees almost 100 engineers. The focus here is on developing the characteristics of the overall vehicle: the development stage for all the different drive unit component and vehicle tests. Various loads placed on the car by the customer are modeled, in part by means of vehicle and component simulation.A new swerve test facility for electric motors is being built for strength-testing various drive unit and vehicle components. The experts of Audi Hungaria can investigate the acoustic, strength and road characteristics of all Audi models in the Total Vehicle Development technical center. Total Vehicle Development further extended its analytical expertise in 2017. Additional test benches for components and complete vehicles were commissioned. The experts at Audi Hungaria use the only total vehicle test bench of its kind in Hungary to test entire automobiles with respect to energy management, strength and acoustics. The vehicles can be analyzed at speeds up to 280 km/h (174.0 mph) on a simulated road without moving.
Expanded toolmaking shop
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 workpieces. 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.
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.
Quality assurance – focused on perfection
The goal of Quality Assurance at AUDI HUNGARIA Zrt. is to ensure premium quality under all circumstances. The company’s quality management system was developed on the basis of EN ISO 9001 from the International Organization for Standardization and the VDA 6.1 standard. Quality assurance covers the entire production sequence, from start to finish. Premium quality is the goal:
- Optical 3D measurements for bodies precision-fit to a tenth of a millimeter
- Parts inspected via CT and a digital microscope
- Robots that detect leaks and measure the haptics
- Quality Assurance is responsible for managing quality processes for manufactured engines and vehicles by using numerous quality tests. This ensures the premium quality of all Győr products.
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 CO2-neutral production locations by 2025.
A car factory goes green – examples at the site:
- 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 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 about 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 250 GWh of geothermal energy since 2015, enabling CO2 emissions to be reduced by 50,000 tons.
- Audi uses DB Cargo for the carbon-neutral transport of components, engines and vehicles between its plants in Ingolstadt, Brussels and Győr.
- Audi Hungaria, in partnership with E.ON Hungaria, has 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. The solar panels installed on a building on the Audi Hungaria site in Győr are the largest photovoltaic facility in Europe. It has a peak output of 12 megawatts.
- Audi Hungaria has been operating with a carbon-neutral footprint on balance since January 1, 2020.