The Audi A3 Sedan and the S3 Sedan roll off the assembly line in Győr. This Audi site in northwestern Hungary is the world's largest engine-production plant. The TT Coupé and Roadster as well as the A3 Cabriolet have been assembled there for years. The company invested 900 million euros in Győr to create a cutting-edge automobile manufacturing plant with a complete process chain. Spread out over some 250,000 m2 (2,690,977.60 square feet), every single production step takes place here – from sheet pressing to final assembly. Audi Hungaria thus created 2,100 new jobs; suppliers and service providers have hired an additional 15,000 people.
At the core of this new facility lies the central building. It houses the Analysis and Pre-Production Center, Quality Assurance and office space for 900 employees. The central building is situated between the press and body-manufacturing shop, paint shop and assembly line. A compact layout facilitates efficient communication.
A state-of-the-art industrial press known as Servo-PXL dominates the press shop. Driven by 14 electric servomotors, it generates 8,100 metric tons of clamping force. As its plungers decelerate while falling, this press recovers some of the energy expended – rendering it about 10 percent more energy-efficient than conventional units. Switching tools takes just three minutes, which also sets a new standard.
The new body-manufacturing shop is every bit as cutting-edge. In its ultimate configuration, this shop will rely on 563 industrial robots; 373 welding tongs; 289 geometry, process and handling units; 73 adhesive application systems; 20 welding and soldering systems; and seven folding machines. An in-line laser measurement system inspects the dimensional accuracy of vehicle bodies at 23 stations, while an ultrasonic imaging system conducts spot checks. As for high-precision joins and radii, the Audi A3 Sedan raises the bar.
Another innovation is the paint shop. Air-recirculation systems in the spray booths drastically reduce the need to heat and cool as well as humidify and dehumidify air, resulting in energy savings of some 60%. A device known as a dry separator filters atomized paint. And in the topcoat booths, a special apparatus removes solvent residues from exhaust air before the latter is discharged into the atmosphere. With the exception of clear coats, only water-miscible coating systems are used to paint vehicles.
At the energy control center – which supplies electricity, heating, and air conditioning – Audi likewise prioritizes efficiency and resource conservation. A stand-alone building, the energy control center is home to three gas-fired boilers and one block-type thermal power station. In the latter, a low-emission natural-gas turbine drives electric generators. Their waste heat is then used for heating. Moreover, the Győr site is supplied with district heat from an offsite cogeneration power plant. Numerous heat wheels throughout the site recover energy to boost efficiency. And the lines for power, natural gas, water, air and compressed air were laid in such a way to keep losses to a minimum.
Expansion of the Audi plant in Győr began in 2011, with the cornerstone being laid in July. It will boast a larger toolmaking facility and a new test track some 1,200 meters (3,937.01 ft) in length. With production facilities becoming operational in June 2013, Audi Hungaria Motor Kft. can also look forward to celebrating its 20th anniversary. Since being founded in 1993, the company has emerged as one of Hungary’s most important exporters and highest-revenue businesses. Audi Hungaria manufactured 1,915,567 engines and 33,553 vehicles in Győr in 2012.
The equipment and data specified in this document refer to the model range offered in Germany. Subject to change without notice; errors and omissions excepted.