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Production and Logistics

Audi Q2

For Audi, premium-quality automobiles mean high-quality car bodies – thanks to efficient production systems and new high-tech solutions. AUDI AG has one of the most flexible and efficient production systems in the entire automotive industry: the Audi Production System (APS), which is based on the principles of cycle, flow, pull and perfection. Audi systematically applies these principles in production and throughout the company, resulting in short cycle times, low inventories and large gains in productivity – up to 10 percent per year. A major focus here is on the continuous improvement process (CIP), because companies that neglect continuous improvement risk their long-term success. Increasing digitalization is paving the way for the smart factory – the intelligent, digitally connected production facility. New high-tech solutions in manufacturing are further increasing the already very high level of quality, while making assembly work easier and resulting in better ergonomics.

Press Folder

  • 11/17/16

    Audi TechDay Smart Factory

    Audi is making its production fit for the future with the smart factory. In this factory of the future, big data – the creation and intelligent connection of large volumes of data – will facilitate data driven and thus highly flexible and highly efficient manufacturing. A method of production in which Audi might no longer build its cars on an assembly line but according to a radically new, disruptive concept is modular assembly. In addition to this major project, Audi is pursuing many other exciting projects for the production of the future – from the application of virtual reality glasses to metal 3D printing.

Recent Press Releases

  • 08/03/17

    Human robot cooperation: KLARA facilitates greater diversity of versions in production at Audi

    New robot colleague in the assembly of Audi A4/A5 models: People and robot now work there side by side without a protective fence. With this human-robot cooperation (HRC), the smart factory comes closer to reality at the Audi plant in Ingolstadt. “Adhesive application with robot assistance,” abbreviated from the German as KLARA, provides support with the installation of roofs made of carbon fiber reinforced polymer (CFRP) in the new Audi RS 5 Coupe (fuel consumption combined in l/100 km: 8.7; CO2 emissions combined in g/km: 197*). So for the first time, Audi is using an HRC light robot in its main plant for applying adhesive in final assembly. Similar robots are already integrated into production in the body shops in Ingolstadt and Brussels as well as in engine assembly in Győr.
  • 05/30/17

    Smart Factory Hackathon: coding for Audi’s production of the future

    Anyone who masters algorithms and programming is exactly right for this event: From October 4 to 6, 2017 the Audi Production division in Ingolstadt is holding its second Smart Factory Hackathon. In this competition, talented young data scientists from all over the world have the opportunity to demonstrate their abilities. The goal is to work out practical solutions for production processes of the future within 25 hours. Interested students and young professionals can apply immediately.
  • 05/04/17

    Audi Tool Trophy: Prize for talented young engineers

    Sharp edges, tight radii – it is the design of their bodies in particular that makes the Audi models so unmistakable. In Production these precise lines can often only be manufactured with specialized tools from the Competence Center for Plant Equipment and Forming Technology. In its search for innovative toolmaking ideas, the “Audi Tool Trophy” student competition is now entering its ninth year. The winners received prize money of up to 2,500 euros on May 3.
  • 05/02/17

    New ratings system at Audi: sustainability is decisive for placing orders with suppliers

    AUDI AG has introduced sustainability ratings for its suppliers this April. The objective is that in the future, orders will only be placed with suppliers that obtain a positive rating. Audi is therefore increasing its commitment to achieving a sustainable value chain. The ratings are based on checks carried out at the suppliers’ production plants as well as on self disclosure. The premium car manufacturer is starting the ratings system with the selection of suppliers for the new Audi e-tron* electric SUV and for the successor to the Audi A3.
  • 04/05/17

    Looking ahead to the new Audi A8: Space Frame with a unique mix of materials

    Audi is writing a new chapter in its lightweight design success story. For the next generation of the Audi A8*, an intelligent mix of four materials is being used for the first time in the weight-bearing body structure – more materials than in any of the brand’s previous production models. The luxury sedan is thus once again rightfully claiming its role as an innovation driver in automotive lightweight design: Its low weight and impressive rigidity offer greater performance, efficiency and safety.
  • 02/15/17

    Audi wins VDA Logistics Award for automated vehicle transport

    A prize for a pioneering achievement: Audi has won the Logistics Award for 2017 from the German Association of the Automotive Industry (VDA) in recognition of its FTS driverless vehicle transport system. The autonomously operating system has been in production operation at the Ingolstadt site since the beginning of the year. The parking robot named Ray sorts up to 2,000 cars per day for loading onto railway freight cars. This application is the only one of its kind to date in the automotive industry.
  • 01/24/17

    Audi etches symbols into car paint

    Audi has developed a process for the partial matting of painted surfaces. A special powder roughens the clear lacquer on the surface to a depth of a few thousandths of a millimeter so that individual markings become visible. With this process, the Audi exclusive program offers personalized design of the side blades for all R8 customers.
  • 12/09/16

    Audi Brussels wins environment award “Trends Business Tour 2016”

    Audi Brussels has received the environment award “Trends Business Tour 2016.” The brand with the Four Rings succeeded against strong competition, including the energy giant EDF, the consulting company Energiris, and the bio-drink producer Simone a Soif. The jury stated that the key criterion for the decision was the convincing overall sustainability concept of Audi Brussels.
  • 11/28/16

    Audi uses wearables in logistics

    Scanner-gloves now make work easier for international logistics employees at the Audi plant in Ingolstadt: For the worldwide dispatch of car components, they now use the “ProGlove” by the name of “Mark” with its embedded barcode scanner. This means they have both hands free and can work more ergonomically. After a four week pilot phase, Audi employees are now using these wearables in five positions in the Ingolstadt plant.
  • 11/11/16

    Audi production in Münchsmünster in full swing

    Audi is reaching top form in Münchsmünster. In 2016 alone, the competence¬ center for high-tech chassis components, aluminum structural components and pressings will turn out more than 23 million components. That is far more than the original planned output of 21 million. The location now employs over 800 people and all sections of the plant are operating on a three-shift basis. The smart factory – intelligent and connected – is likewise gradually becoming a reality in Münchsmünster.
  • 10/25/16

    Smart Factory Hackathon: Talented data-science specialists develop solutions for the factory of the future

    “Data drives our production – you innovate from our data” is the motto of the Smart Factory Hackathon, which was held at the Audi Forum Ingolstadt from October 19 to 21. Talented young data-science specialists from the fields of IT, mathematics and engineering developed innovative software solutions for the factory of the future, based on genuine but anonymized data sets from Audi’s production. On Friday afternoon, the winners of the IT competition were awarded their prizes: The “Happy Unicorns” team won first prize with its idea on the subject of container management.
  • 10/01/16

    Audi México: state-of-the-art technology for top quality

    The Audi plant in San José Chiapa officially opened today. The guiding principle here is “made by Audi”: The Audi Production System (APS) implements a uniformly high standard for quality worldwide. To validate its premium quality, the company is networking its new plant with other sites in the Audi global production network. Working in the production control center, known as P-Control, are 105 employees from various technical disciplines, who monitor how the new Audi Q5 is produced from a bird's-eye view. In combination with the site’s quality laboratory and training center, Audi ensures compliance with the quality standards that apply to its production facilities worldwide.
  • 09/20/16

    Audi opens new, highly efficient paint shop

    Audi has put a new topcoat paint shop into operation at its plant in Ingolstadt. Board of Management Member for Production Prof. Dr. Hubert Waltl opened the 12,000 square meter building (129,000 sq. ft.) on Tuesday together with Plant Director Albert Mayer and Group Works Council Chairman Peter Mosch. Up to 900 car bodies a day can be painted there on three floors. Thanks to environmentally friendly technology, the modern application equipment will conserve resources. Ergonomically designed workplaces will make the employees’ work easier.
  • 07/08/16

    Audi awards prevention prizes for health and safety at work

    Prevention is better than cure: That’s one of Audi’s fundamental principles, especially in connection with health and safety at work. High standards of working safety and promoting good health traditionally have high priority at the company. Employees contribute towards continuous improvements with their optimization suggestions. This year, the brand with the Four Rings once again awarded certificates and trophies in several prize categories for such suggestions. Teams from the German and international production sites received the awards in Neckarsulm on Thursday.
  • 07/06/16

    Audi wins Digital Economy Award

    On its way to becoming a digital car company, Audi is making its production sites fit for the digital future. In recognition of this, the company received the “Digital Economy Award” from Initiative Deutschland Digital (IDD) in Bonn this Tuesday. The brand with the Four Rings took first place in the category Company 4.0.
  • 07/01/16

    A small car makes a big impression: the new Audi Q2

    A new car for the main plant of AUDI AG in Ingolstadt: The Audi Q2 has now entered series production there. With this compact SUV “made in Ingolstadt,” the brand with the Four Rings has entered a completely new segment while showing its commitment to its main site on the River Danube. Innovations such as a fully automatic module store in the assembly process help to master increasing production complexity.
  • 06/01/16

    Audi Tool Trophy: prize for innovative student work

    Whether developing efficient tools for production, applying alternative production concepts like 3D metal printing or new methods for checking the quality of components in the press shop – the spectrum covered by toolmaking has many aspects. That has been demonstrated once again by student work in the areas of press-shop tools and car-body assembly equipment, which was given recognition with the award of the Audi Tool Trophy by the Audi Toolmaking division on Tuesday. For the eighth time now, the company has organized this student competition that is unique in the whole of Europe. The six best entries in the categories of “Master’s Dissertations” and “Bachelor’s Dissertations / Term Papers” were awarded prize money of up to 2,500 euros.
  • 03/11/16

    Audi develops a new generation of tools

    Audi Toolmaking is racing into the future. The company’s tooling specialists have now passed an important milestone. They have developed a new, highly efficient generation of tools that is up to 20 percent lighter and ten percent more stable than the previous generation. This has been made possible by lightweight and composite construction methods that are used in car body construction. The new tools are already being used in the press shop in Ingolstadt.
  • 03/04/16

    Albert Mayer to be new plant director in Ingolstadt – Fred Schulze to be product line manager as of April

    Albert Mayer is to become plant director at the Audi site in Ingolstadt as of April 1, 2016. He will succeed to Fred Schulze, who will move to a newly created key position as product line manager for all top end SUV models. Mayer is currently head of production and plant planning at AUDI AG.
  • 01/20/16

    Audi production network: ready for electric mobility

    Audi is preparing its international production network for the mobility of the future. Large series production of the first purely electric driven SUV from Audi will begin at the site in Brussels in 2018. The plant will also assembly its own batteries. The company will transfer production of the Audi A1 from Belgium to Martorell in Spain. The Audi Q3, which is currently produced in Spain, will be built in Győr (Hungary) in the future.
  • 12/17/15

    Audi’s logistics of the future: Goods being commissioned move autonomously to employees

    The process of commissioning the other way around: Starting today, logistics employees at Audi will no longer have to fetch the required goods from the material shelves. Instead, the goods will come to them fully automatically on driverless transport systems (DTS). Audi is thus the world’s first automobile manufacturer to implement such a DTS based goods to person concept. The company is currently testing the new method with the commissioning of driver’s manuals at the Audi plant in Ingolstadt.
  • 11/25/15

    Medical gloves for improved ergonomics in production at Audi

    Audi’s Production division is improving ergonomics as well as health and safety in its factories. Employees at the plants in Ingolstadt, Neckarsulm, Brussels and Győr are currently testing new medical gloves. These so called production orthoses reduce pressure stress with many assembly tasks by more than 50 percent. It is planned to put the special glove into series application this year.
  • 11/12/15

    Audi Toolmaking is the best in the industry

    Audi is for the fourth time the “Toolmaker of the Year.” That is the result of the renowned industry competition “Excellence in Production” organized by the Toolmaking Laboratory (WZL) of RWTH Aachen University and the Fraunhofer Institute for Production Technology (IPT). Audi Toolmaking succeeded against more than 290 toolmaking and mold making departments from companies in the German speaking countries. Michael Breme, Head of Toolmaking at AUDI AG, was presented with the winner’s cup at the 15th “Toolmaking with a Future” international colloquium in Aachen on Wednesday evening.
  • 11/10/15

    Audi shows toolmaking innovations at the “formnext” trade fair

    Audi Toolmaking yesterday, today and tomorrow: The brand with the Four Rings is presenting numerous exhibits at the “formnext” trade fair for toolmaking and mold making in Frankfurt am Main. From November 17 to 20, visitors can find out about toolmaking developments and gain an insight into the production methods of the future.
  • 11/05/15

    Audi Toolmaking prints “Auto Union Typ C”

    From powder to a component: With a 3D printer, Audi Toolmaking has produced a model of the historical Grand Prix sports car “Auto Union Typ C” from the year 1936. The company is now examining further possible applications of metal printers for the production of complex components. At the same time, Audi is creating important synergies with toolmaking in other parts of the Volkswagen Group.
  • 10/30/15

    Hybrid locomotive at Audi plant in Ingolstadt

    This Audi drives on rails: A 1,000 horsepower plug in hybrid locomotive manufactured by Alstom replaces the plant locomotives previously used at the Audi plant in Ingolstadt as of today. This means that components and finished Audi models will now reach the plant’s loading stations in a more climate friendly way.
  • 10/06/15

    Audi tests gesture control for virtual assembly

    Even before Audi produces the first prototypes of a new car, engineers in the Pre Series Center check individual assembly steps in a 3 D projection. They assemble components virtually, thus determining whether this process is feasible and ergonomic for the employees on the production line. As part of a pilot project, they are now for the first time moving the components in the virtual space using simple gestures.
  • 09/18/15

    Audi A3 celebrates 20th anniversary

    A production milestone has been reached at the Audi plant in Ingolstadt: Exactly 20 years ago, on September 18, 1995, the first Audi A3 came off the assembly line here. Since then, the Audi Group has built over 3.5 million units of the successful model worldwide. Today, one out of five Audi cars delivered comes from this model line. At the same time, the Audi A3 is a ground breaking car when it comes to alternative drive systems – as demonstrated by the flexible production of the A3 Sportback e-tron, A3 Sportback g-tron and classic A3 models. They are all built on the same production line at the Ingolstadt plant.
  • 07/22/15

    Audi production in Münchsmünster is picking up speed

    The new Audi production site in Münchsmünster is approximately 30 kilometers (18.6 mi) east of the main production facility in Ingolstadt. Hot and cold formed pressed parts, high tech chassis components and lightweight aluminum structural components, among others, are being produced here for the new Audi Q7. By 2017, a total of 900 employees will be working at the site and shipping out 26 million parts worldwide annually. The production site in Münchsmünster, the high tech Audi Neuburg complex and the future innovation campus (abbreviated “INCampus”) are making the Audi Ingolstadt site a key force behind growth in Bavaria.
  • 07/16/15

    Audi celebrates topping out of new paint shop

    The Audi plant in Ingolstadt continues to grow: A new paint shop is being built in the north of the plant site. Just over a year after the start of construction, the company is now celebrating the topping out. As of June 2016, Audi employees will paint the first series car bodies for the new Audi A4.
  • 07/10/15

    New managing director at Audi Hungaria: Peter Kössler to succeed to Thomas Faustmann

    Peter Kössler (56) has been appointed managing director of Audi Hungaria as of October 1. He will move from the automobile manufacturer’s main site in Ingolstadt, where he has been plant director for more than eight years. Kössler will succeed to Thomas Faustmann (52), who, after eleven years as managing director in Győr, will move to Neckarsulm. There, he will succeed to Fred Schulze (48) as plant director. Schulze is to become the director of the plant in Ingolstadt.
  • 06/30/15

    Audi Production Lab: journey into the future

    In the Audi Production Lab, production planners of the premium manufacturer are working together with experts from various departments of the company on innovative technologies for the production processes of the future. A promising technology is hand projection. In the future, it could support production employees with testing and installing components.
  • 05/22/15

    Smart factory: Audi shows intelligent production

    Humans and robots working hand in hand, car-body parts emerging from a 3D printer and cars driving in piloted mode from the assembly line: Audi is pursuing this vision of the factory of the future: the smart factory. In the Encounter magazine under that heading, the automobile manufacturer is now providing a wide-ranging insight on how intelligent Audi’s production processes already are and which leaps of innovation will occur in the coming years. Audi presented the publication on Friday at the company’s annual shareholders’ meeting.
  • 03/06/15

    Audi plant uses robots to move cars

    Audi is testing systems for the intelligent factory of the future: In a pilot phase at the Audi plant in Ingolstadt that started in February, two robots independently transport cars from production to an interim storage area. From there, they later place the sorted Audi models into position according to their shipping destinations, so that logistics employees can load them onto railway wagons. Audi is now preparing the first industrial application. The company is also examining additional areas of application for such robots.
  • 02/26/15

    Chairless Chair for improved ergonomics in Audi’s production plants

    The health of its employees has top priority for Audi. For this reason, at its plant in Neckarsulm, the company is testing a new technology that eases many assembly activities: the so-called “chairless chair.” This high-tech carbon-fiber construction allows employees to sit without a chair. At the same time, it improves their posture and reduces the strain on their legs.
  • 02/12/15

    New human-robot cooperation in Audi’s production processes

    Direct cooperation between man and machine: At its main plant in Ingolstadt, Audi has for the first time deployed a robot that works “hand-in-hand” with humans – without a safety barrier and ideally adapted to the employees’ working cycles. It is the first human-robot cooperation at the Volkswagen Group to be applied in final assembly. This innovative technology makes work easier for the assembly employees and makes ergonomic improvements.
  • 11/21/14

    On the line and on time: Production of the Audi A3 Sportback e-tron

    Approximately 50 cars every day, with the same timing and on the same assembly line as the other models: Audi is now ramping up production of the Audi A3 Sportback e-tron*. The premium manufacturer is producing its first plug-in hybrid model at the brand’s main plant in Ingolstadt.
  • 11/21/14

    On the line and on time: Production of the Audi A3 Sportback e-tron

    Approximately 50 cars every day, with the same timing and on the same assembly line as the other models: Audi is now ramping up production of the Audi A3 Sportback e-tron*. The premium manufacturer is producing its first plug-in hybrid model at the brand’s main plant in Ingolstadt.
  • 11/19/14

    Audi’s production wins innovation prize

    Audi’s production has won the “Best Open Innovation Award” in the category “Best Cross-Industry Innovation.” The Dr. Manfred Bischoff Institute for Innovation Management of the Airbus Group at Zeppelin University Friedrichshafen recognizes the most innovative companies in Germany, Austria and Switzerland with this prize. Alois Brandt, Head of Technology Development Innovation Management, and Felix Schwabe, Innovation Management Production, accepted the prize on Audi’s behalf at the flagship event “Innovation 2014” in Munich on Tuesday evening.
  • 10/08/14

    Audi Logistics: 30 years of the car loading platform

    Jubilee at the Four Rings: 30 years ago today, Audi put a new loading station into operation at its site in Ingolstadt – with a car-loading platform that was unique in the European automobile industry at that time. The innovative idea for the moving platform came from an employee at Audi Logistics. Since then, approximately eight million automobiles have left the Audi plant in Ingolstadt by rail via this platform – faster and more efficiently than before.
  • 07/24/14

    Audi Hungaria: Start of production of the new Audi TT Coupe

    The third generation of the Audi TT* and the TTS Coupe is now going into series production at AUDI HUNGARIA MOTOR Kft. Following last year’s start of production of the Audi A3 Sedan, the S3 Sedan and the new A3 Cabriolet, the new Audi TT is now also leaving the assembly lines at the automobile plant in Győr. Audi produces this model there with the full depth of manufacturing. The most impressive features of the Audi TT are its sporty character and emotive design, as well as innovative technologies in its drivetrain and its operating and display concept.
  • 04/02/09

    Audi brings automotive logistics to life

    “Logistics makes it possible.” True to this motto, AUDI AG is again participating in the nationwide “Logistics Day”. On Thursday, April 16, students and university graduates, young professionals and all other interested people will have the opportunity to learn about this exciting area from Audi through a series of presentations and discovery tours. Last year the initiative met with great interest, with around 200 participants coming to the Audi sites in Ingolstadt and Neckarsulm.

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