Audi in Ingolstadt Four Rings on the Danube - Audi MediaCenter
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Inhalt The origins of Audi – the history of the automotive company.................................. 4 Audi in Ingolstadt – a chronology......................................................................... 6 Decades of success – the Ingolstadt site.............................................................. 10 Vorsprung durch Technik – Technical Development....................................................... 12 Expansions – in the vicinity of Ingolstadt.................................................. 16 Digitalized production of the future...................................................... 20 Punctual, flexible and efficient – logistics............................................................................. 24 Premium quality for the digital age – quality assurance................................................................ 26 Economics and ecology in harmony – environmental protection at Audi......................................... 28 Top performance from top employees – human resources................................................................ 32 Young recruits are the future – training and development................................................... 34 Audi experience – including in culture and sport.............................................. 36 Strong roots – Audi is committed to the region........................................... 38 Audi production sites – worldwide.......................................................................... 42 Audi models – fuel consumption and emissions figures............................... 46
The origins of Audi – the history of the automotive company Employees of the former Auto Union AG made a new start in Ingolstadt. Many came from the eastern regions of Germany – from Zschopau, Chemnitz and Zwickau. Like a phoenix rising from the ashes, an extraordinary car manufacturer developed over the following decades. Hot off the line: a DKW Junior in front of the “new plant” in Ingolstadt (today’s site), 1960. Auto Union GmbH was founded in 1949, and Ingolstadt has been steam-driven vehicles – called “Dampfkraftwagen” in German, the home of the four rings ever since. AUDI AG is the region’s which was the origin of the abbreviation DKW. After producing largest employer. The company currently employs around 44,000 motors for toys and auxiliary motors for bicycles, the company people in Ingolstadt alone. The trademark – four interlocking rings began manufacturing motorcycles. The first DKW car was built – was created in 1932 when the brands Audi, DKW, Horch and in 1928. Wanderer joined to create Auto Union AG, with headquarters in Chemnitz. The roots of Wanderer reach back to 1885. On February 15, 1885, Johann Baptist Winklhofer and Richard Adolf Jaenicke founded The history of DKW can be traced back to 1904, when Danish the firm “Chemnitzer Velociped-Depot Winklhofer & Jaenicke” in industrialist Jørgen Skafte Rasmussen founded a company in Chemnitz, which sold and repaired bicycles. The first Wanderer Chemnitz that manufactured and sold steam boiler fittings. motorcycle was built in 1902. The company founders presented Production was relocated to Zschopau in 1907; the company the first prototype car – the “Wanderermobil” – back in 1905. was renamed to “Zschopauer Maschinenfabrik J. S. Rasmussen” Volume car production began in 1913. in 1912. Between 1916 and 1919 the firm experimented with The history of the automobile brand with the four rings is closely linked with the name August Horch. This businessman opened his Site of the Auto Union GmbH plant at Ingolstadt’s Esplanade: first workshop in Cologne back in 1899. In 1904, he founded the a DKW Schnelllaster van transporting a DKW RT 200 H motorcycle, 1952. “August Horch Motorwagenwerke AG” in the city of Zwickau in Saxony. Five years later a dispute arose between the founder and the supervisory board. August Horch left the company and on July 16, 1909, launched a new firm under the name August Horch Automobilwerke GmbH, which was changed to Audi Automobil- Werke m.b.H on April 10 of the following year. Audi is the Latin translation of the German word Horch, which means “listen!”. 5
Audi in Ingolstadt – a chronology 1945 Founding of Zentraldepot für Auto Union Ersatzteile Ingolstadt GmbH in Ingolstadt, Schrannenstraße 3 1946 Start of spare parts production 1948 In August, removal of the “old” Auto Union from the commercial register in Chemnitz. In Ingolstadt, start of development of a delivery truck. 1949 Establishment of Auto Union GmbH as a production company. Start of production of DKR Schnelllaster van and DKW RT 125 W motorcycle. 1954 Inauguration of the new motorcycle plant in Ingolstadt 1958 On April 24, acquisition of majority share in Auto Union by Daimler-Benz AG; wholly-owned subsidiary through end of 1964. Cornerstone laid for new car factory in Ingolstadt; end of motorcycle production. 1959 First DKW Junior from the new plant in Ingolstadt 1962 In June, sale of facilities in Düsseldorf to Daimler-Benz In front of the headquarters of Auto Union GmbH: AG; vehicle production primarily in Ingolstadt an Auto Union 1000 SP on Ettinger Straße in 1964 In December, acquisition of majority share in Auto Ingolstadt, 1962. Union by Volkswagenwerk AG; wholly-owned VW subsidiary since end of 1966 1965 First post-war Audi from Ingolstadt. Production of DKW 2011 Ten-millionth automobile from the Audi 80/Audi A4 models is gradually discontinued. series 1969 Merger of Auto Union GmbH and NSU Motorenwerke AG 2013 Opening of a production facility in Münchsmünster creates NSU Auto Union AG with headquarters in Neckarsulm 2014 Opening of Audi Neuburg: Audi driving experience center and Motorsport Competence Center/Audi Sport 1972 The Audi 80 is launched – a bestseller made in Ingolstadt. 2015 Opening of the Light Assistance center in the Technical Development division. Opening of Audi Akademie in 1980 Start of production of the Audi quattro in Ingolstadt the center of Ingolstadt, IN-Campus: land for future 1985 Company renamed to AUDI AG with headquarters in technology center. Ingolstadt. Products and company have borne the same 2016 Launch of the new Audi Q2 SUV model, commissioning name ever since. of the new paint shop and office complex 1992 Opening of the Audi Customer Center in Ingolstadt 2017 New production and logistics building at GVZ Logistics 2000 Inauguration of the Audi Forum Ingolstadt Center and opening of new Design Center 2009 Centennial of the Audi brand. 60th anniversary of the main site in Ingolstadt 6 7
The Audi site in Ingolstadt covers an area of 2,737,500 square meters (29,466,204.8 sq ft) in the north of Ingolstadt. Added to this is an area of 506,000 square meters (5,446,538.7 sq ft) at the GVZ Logistics Center, in top left of photo. 8 9
Decades of success – the Ingolstadt site The heart of AUDI AG beats in Ingolstadt. More than half a million cars produced and around Up to 380 cars are delivered to their new owners 44,000 employees – those are the impressive each day at the Audi Forum Ingolstadt. statistics for the Ingolstadt site. An automobile drives off the assembly lines approximately every 30 seconds, or around 2,400 Audi models a day on average. The cars produced here are the Audi onto the market – pioneering lighting technology, lightweight Q2, Audi A3, Audi A4 and Audi A5 as well as their construction and driver assistance systems. A new item on this derivatives. Audi is the region’s economic engine list is the operating concept with touch displays featuring hap- and largest employer. The company has estab- tic and acoustic feedback. With the four-door concept car Audi lished a global reputation as a center of auto- Aicon, the brand with the four rings presents a fully self-driving motive manufacturing. Audi of the future – with no steering wheel or pedals. With about 400,000 visitors per year, the Audi Forum Ingol- stadt is a popular attraction for people in the region and visitors from all over the world, as well as for people picking up their The founding of Auto Union GmbH in Ingolstadt in 1949 start- new cars. It represents an urban, open philosophy, combining ed a new chapter for this car manufacturer, which was previous- production, tradition, shopping, a cinema, dining facilities, ly headquartered in the German state of Saxony. The company driving enjoyment, exhibitions and conference rooms in a single began production of spare parts, motorcycles and DKW vehicles location. Cultural events such as concerts ranging from jazz to in old buildings in the Ingolstadt fortress. In 1985, the automo- classical, art exhibitions, factory tours and the Audi museum tive company was renamed to AUDI AG. Both the company and mobile round out the range of experiences for the whole fami- its products have borne the same name ever since. The plant in ly. Kids and teens get fascinating insights in the themed attrac- the heart of Bavaria is not only the company’s largest production tions at Audi, with exciting activity modules, innovative driving facility, but is also home to the Audi Group headquarters and simulators and multimedia quizzes. Each day Audi delivers up to the Technical Development division of AUDI AG. As the econom- 380 cars to their new owners at the Audi Customer Center. Cus- ic engine for the region around Ingolstadt, Audi is committed to tomers who arrive for a new car pick-up by rail are greeted at the its home on the Danube. exclusive Audi Lounge in the main railway station in Ingolstadt with a very special service: A VIP shuttle brings them quickly and The company’s story of success included chapters for the Audi conveniently to the Audi Forum Ingolstadt. 80, Audi 100, the quattro and victories in rally racing. Audi con- tinued to develop steadily over the following decades. The Audi The AUDI AG plant in Ingolstadt covers the entire process of 80 became the Audi A4, the Audi 100 was followed by the Audi vehicle production – from development to the finished car. A6 and a highly diverse model range. After the legendary quattro Housed inside the production halls are a press shop, body shop, drive system – the embodiment of the slogan “Vorsprung durch paint shop and assembly line. Technik”, Audi introduced a long list of technical innovations 10 11
Vorsprung durch Technik – Technical Development The Technical Development (TE) division of AUDI AG has its headquarters in Ingolstadt. In keeping with the brand claim “Vorsprung durch Technik”, around 9,000 employees work here on innovations for the cars of tomorrow. Pioneering lighting technology from Ingolstadt: The tasks of Technical Development include an HD Matrix LED headlight with laser light from the Audi A8. everything from the development of new bodies, transmissions, engines, suspensions or vehicle concepts to design and electrical and Lighting the way: The Light Assistance Center is housed in the electronics development. basement of the SE Forum and is a very large light testing tun- nel which cars can drive into. From xenon plus headlights to Matrix LED headlights and laser lights, Audi has been putting Enhancing connected collaboration: 450 employees from pioneering innovations into series production for 20 years. Development, Model Series and Procurement work at the SE Forum with the task of shaping the automotive future. SE Perfect testing: The Acoustics, Performance, Mechanical Engi- stands for “simultaneous engineering” – products and process- neering, Material Strength and Corrosion departments work at es are designed in an integrated and simultaneous manner. This the Physics Center. All models undergo a realistic test program further shortens the development cycles of new models. The that includes everything from an exterior noise test rig to a road tallest building on the site is also home to a state-of-the-art simulator and flat road dynamometer. The new Tank Techni- test laboratory and testing equipment as well as an innovative cal Center reproduces test courses worldwide in the laboratory. IT center. Work on fuel, natural-gas and SCR systems is also conducted. The building includes facilities such as a laboratory for the HiL Digital design workshop: The light-filled, transparent new Design Center is (hardware-in-the-loop) test benches for suspension electronics, 107 meters (351.0 ft) long, 71 meters (232.9 ft) wide and around 21 meters motion test beds with environmental simulation, and climate, (68.9 ft) high. cold and acoustic chambers. New Design Center: Audi has developed a new, innovative design process that combines the advantages of cutting-edge 3D visualization with the strengths of traditional handcraft- ed modeling – a digital design workshop has been set up at the Ingolstadt site. On an area covering 37,180 square meters (400,202.2 sq ft), around 600 employees are engaged in the areas of design, class-A surfacing and advance engineering. 12 13
Weatherproof: At the Engine Center, emissions and fuel con- sumption measurements are carried out on chassis dynamome- ters under various climatic conditions. Driving performance with all-wheel drive at altitudes up to 4,200 meters (13,779.5 ft) is tested in a simulation chamber. In the adjacent workshops and modern transmission test beds, units are set up and tested. Established in 2010, the Development and Test Center for Elec- trified Drive Systems features cutting-edge test beds for testing electrified drive concepts. Smart production from the outset: The Audi Pre-Series Center (VSC) groups the tasks of Technical Development and Produc- tion together in a single area of responsibility. This paves the way for economic production of the cars from the early develop- ment phase. Fully self-driving Audi of the future: the four-door design vision Audi Aicon – with no steering wheel or pedals. A tradition of testing quality: For over 20 years, Technical Development has been testing new developments in various Electronics? – Check! The Electronics Center is equipped with a driving situations at its own proving grounds in Neustadt an der wide range of measuring and testing equipment, such as bread- Donau. High-speed tests are conducted on the 4.7-kilometer boards of the entire vehicle electronics for testing complex (2.9 mi), three-lane oval track with two banked corners. Perfor- components and a climatic chassis dynamometer for simulating mance, fuel consumption, noise, temperature and braking are different weather and road surface conditions. Audio concepts also measured. are developed in an MMI laboratory (Multi Media Interface) and a sound laboratory. This is also the place for all aspects of in-car digitalization and connectivity. Windproof: The Ingolstadt plant has its own Wind Tunnel Center, where three test facilities are available: the aeroacoustic wind tunnel, the thermal wind tunnel and a climatic wind tun- nel. Optimal aerodynamics are honed at wind speeds up to 300 kilometers per hour (186.4 mph). The interior climate control and thermal management of the cars are developed here and the engineers are always working on reducing wind noise. “Get in” a virtual Audi: In the Design Check department, vehi- cle models can be viewed realistically and with accurate details before they are ever built. The virtual reality studios make this possible. The various materials appear tangible and life-like, giving the impression of a car the observer can get into. Great cinematic experience: Audi virtual cockpit and MMI touch response in the Audi A7 Sportback. 14 15
Expansions – in the vicinity of Ingolstadt A production facility is located in Münchsmünster while Neuburg is the home of a high-tech complex with driving course and Motorsport Competence Center. Audi Neuburg: The 47-hectare site is located approximately 18 kilometers (11.2 mi) west of Ingolstadt. The Audi Ingolstadt site has been growing for many years, mak- ing expansion in the region necessary. Münchsmünster is home to module and system assembly operations, thanks to its good Audi Neuburg is a high-tech complex that opened in Neuburg transport links to Ingolstadt. That site measures a total of 54 an der Donau in 2014. Around 400 people from three business hectares. A 31-hectare site houses the competence center for divisions of AUDI AG are employed here. The Audi driving expe- the production of die-cast aluminum structural body parts, hot- rience conducts driving and safety trainings on the course. Audi formed and cold-formed parts as well as suspension modules. customers and guests can experience a wide range of models Production is in full swing, with nearly 900 employees working from the brand with the four rings here – on the handling track, on a three-shift basis. More than 24 million car parts were man- on the large dynamic pad or on-road and off-road. The central ufactured in 2017, including structural parts such as the strut customer building offers presentation areas, conference rooms towers for the Audi A4. Münchsmünster is also where suspen- and a restaurant. From the terrace, visitors can enjoy a pano- sion modules such as wheel hubs and brake disks for all Audi ramic view of the entire site and watch the cars in action. Inter- models from the Audi A4 upward are manufactured. The state- est is high: The center attracted around 17,500 visitors in 2017 of-the-art press shop uses the latest press technology to make and hosted almost 850 events. 10,000 guests from 23 coun- advanced body components. tries attended driving training sessions. The German Association for Sustainable Building (Deutsche Gesellschaft für Nachhal- tiges Bauen, DGNB) has awarded the customer building of Audi Neuburg the platinum DGNB certificate for ecological construc- tion (published by DGNB, November 2015). Audi manufacturing in Münchsmünster: The 54-hectare site is located approximately 30 kilometers (18.6 mi) east of Ingolstadt. Neuburg is also home to the Motorsport Competence Center. Since the end of 2014, the Audi Sport motorsport team has coordinated all its racing activities worldwide in the DTM, For- mula E and World Rallycross Championship from its base in Neuburg. Under Audi Head of Motorsport Dieter Gass, the engi- neers here develop and design the racing cars for the brand’s works cars. Initial roll-out trials are also run on the courses in Neuburg. The race engines are built at the Audi Neckarsulm site. Audi Sport customer racing – the racing program for custom- ers of Audi Sport GmbH – has been supporting activities in this fast-growing sector from Neuburg since spring 2015. This includes GT3 racing, the TCR touring car racing category and the Audi R8 LMS GT4. 17
Digitalized production of the future For Audi, premium quality in automobiles means maximum body quality through efficient production systems and new high-tech solutions. Ergonomics is an important subject at Audi – The vision is of a digital, fully connected factory. the wheel assembly at the A4 production line. ment during the prototype phase. Production and Plant Planning with its approximately 1,600 employees establish all the condi- AUDI AG has one of the most flexible and efficient production tions for manufacturing the Audi models in maximum quality. systems in the entire automotive industry: The Audi Production System (APS) is based on the fundamental principles of cycle, Leading the way in metal 3D printing: Audi stands for the high flow, pull and perfection. Audi systematically implements these quality of car bodies – exemplified by tight radii, homogene- principles in production and throughout the company, resulting ous surfaces and exact dimensions. What is physically possible, in short throughput times, low inventories and a large increase in and what can be manufactured reliably? Planners and toolmak- productivity – up to ten percent per year. The main focus is on the ers are conducting research into 3D printing, working in close continuous improvement process (CIP). Increasing digitalization cooperation with designers and developers. As a general contrac- is paving the way for the intelligent, fully connected factory. New tor, Audi Toolmaking supplies both Audi and other brands of the high-tech solutions in production enhance the very high quality Volkswagen Group with forming tools and body-manufacturing level even further, while facilitating work on the assembly lines equipment. At the Metal 3D Printing Center at Toolmaking, Audi and ensuring better ergonomics at the workstations. experts produce steel and aluminum parts from metal powder using the laser melting process. This process is used in produc- Planned from A to Z: Production and Plant Planning is respon- tion tools. Components for limited production vehicles could also sible for the planning of all vehicle projects of the Audi brand, be produced using this method in the years ahead. Audi’s Tool- designing the product, the manufacturing process and the pro- making division currently employs more than 2,300 people at duction locations worldwide. In close cooperation with Technical five locations in Ingolstadt, Neckarsulm, Barcelona (Spain), Győr Development, Production and Plant Planning ensures producibil- (Hungary) and Beijing (China); approximately 1,100 of them work ity of the cars. The focus is on the customers and their require- in Ingolstadt. To meet the rising standards of quality, design and ments. Photo-realistic models help visualize, analyze and assess economic feasibility, Toolmaking and Press Shop collaborate very customer-relevant vehicle surfaces. The Pre-Series Center and closely and are organized together as the Equipment and Metal Toolmaking are involved in all aspects of new-vehicle develop- Forming Technology Competence Center. The high-tech press shop: From sheets to complex geometries: At the Ingolstadt press forming an Audi Q2 hood. shops, steel and aluminum sheets are formed into extremely pre- cise body parts. Sheeting that is cut away in the metal forming process and is not required for the production process is recycled. The modern large-capacity presses lead the field internationally in terms of productivity. The forming tools and tremendous press forces convert steel or aluminum rolls, called “coils,” into the complex geometries of the individual parts in up to six process steps. Particular attention is paid to surface quality. Around 1,300 21
This paint shop is very environmentally-friendly because it uses cutting-edge technologies such as air recirculation, dry separation and exhaust air treatment. Modern application systems conserve resources. Innovative production technologies: At the assembly shop, roughly 8,000 people working in three shifts assemble around 2,400 Audi models each day, with no two cars alike – each Audi is individual. The vision is to have the world’s most efficient and Robots in the paint shop: clear-coat exterior paint finish for an Audi Q2 body. sustainable premium assembly. At the assembly shop, the “elec- tronic quality check” (eQP) serves to ensure that the high quality requirements are fulfilled. The electronic vehicle job card (eWBK) people are employed at the press shops at the Ingolstadt site. is also in successful operation. It displays on monitors exactly Each day, they process roughly 1,675 metric tons of sheet metal, which component the employee needs for each car. Human-robot including 88 metric tons of aluminum, into 569,000 individual collaboration is also integrated into the A4/A5 assembly process: body parts. A new robot “colleague” works side-by-side with the employees without any safety fencing. The “adhesive application with robot Like magic: The Ingolstadt body shops for the Audi Q2, Audi A3, assistance” process, or “KLARA” for short, assists with fitting Audi A4 and Audi A5 model series are cutting-edge production large roofs. Due to the growing variety of models and variations, a facilities featuring innovative manufacturing technologies and new memory module that provides greater storage capacity has maximum flexibility. Reflecting the focus on efficiency and sus- been installed on the A3/Q2 assembly line. Automated guided tainability during their planning, they feature an automatic matrix vehicles (AGVs) such as “Paula” represent a core technology of the lighting control system, photovoltaic systems for renewable intelligent digital factory, revolutionizing conventional production power generation on the roof and energy consumption analyses. processes. Direct collaboration between humans and machines is already a reality here: A robot helps with the application of bonded seams in the body shop. In this human-robot collaboration (HRC), the employee lays out the body parts and starts application of the adhesive. The “Energy Productivity in Production” employee train- ing program, intelligent shutoff strategies and energy-efficient system components help to conserve energy. 3,450 employees and over 3,200 robots build car bodies with maximum precision at the Ingolstadt body shop. The perfect finish: At the Ingolstadt paint shop, it takes sever- This is the future: Automated guided industrial trucks locate and al linked stages of manufacturing to make a vehicle body shine move automatically using suitable sensors and control algorithms. in one of 30 standard colors. Quality is always top priority, from They can be used flexibly for various workshops and routes. cathodic electrocoating to base coats and clear coats. Every day, the roughly 2,500 paint shop employees ensure that innovative Audi designs of the Audi Q2, A3, A4 and A5 models gleam in all the right colors. The employees’ painting experience and intuition as well as a keen eye for detail are essential. Highly skilled young workers are trained on-the-job in the paint shop. Audi commis- sioned a new top coat paint shop at the Ingolstadt site in 2016. 22 23
Punctual, flexible and efficient – logistics Managing complexity with modern logistics is what makes model diversity in the plants possible. “Ray” AGV: Two parking robots autonomously transport finished Audi models to an intermediate area. From there, they organize and make these cars available according to their shipping destination so that logistics employees can load them onto railway freight cars. Logistics has become much more important in the automo- at the gate of the Audi site in Ingolstadt is the result of traffic tive industry. The growing variety of models is increasing pro- studies and serves to attract important logistics functions and cess complexity along the entire value chain. Logistics at Audi JIS systems suppliers. The advantages of the Logistics Center ensures that vehicle production and market supply are punctual for Audi are supply reliability, the ability to master complexity and flexible, with short throughput times and small inventories. and the reduction of logistics costs. Because the variety of models in the plants requires mastering complexity, the principles of the intelligent, fully connected fac- Clever material delivery: Module suppliers fabricate their prod- tory are already firmly established in logistics. ucts just in sequence at assembly centers and are responsi- ble for delivering them directly to the assembly lines. Electric Like at the airport: Audi Logistics at the Ingolstadt site has tow tractors deliver the materials to them. The 30,000 square introduced Truck Quick Check In. This system directs the trucks meter (322,917.3 sq ft) Hall B likewise houses a pre-assem- delivering vendor parts and admits them to the plant according bly center. This is where Audi employees assemble cockpit and to priority. The truck control point functions like an airport con- rear axle modules, in turn delivering them just-in-sequence to trol tower. The self-controlled delivery process is based on inno- the production lines. In addition, 13 external suppliers and ser- vative geofencing technology. vice providers currently supply Audi via the Logistics Center. The Logistics Center includes a Consolidation Center housing the Smart logistics: Another new development is automated trans- CKD (completely knocked down) packaging plant. With short port of parts and vehicles. Since January 2017, Audi has rou- paths between logistics and production, the logistics areas close tinely been using automated guided industrial trucks for auto- to the production line are ideal. mated material handling in Hall B of the Logistics Center. Audi is also the world’s first car manufacturer to combine tradition- History and facts: The Logistics Center, which opened in al storage in a parts supermarket with automated guided vehi- 1995, has two investors and owners: IFG Ingolstadt, a whol- cles (AGV). With this new way of order picking according to the ly owned subsidiary of the city of Ingolstadt, and LGI GmbH, a goods-to-person principle, the parts are automatically retrieved joint subsidiary of IFG Ingolstadt and AUDI AG. The 122-hec- and transported to a fixed picking station. Loading of vehicles tare site is home to 17 workshops with 486,000 square meters has also been automated. “Ray” is a parking robot that picks up (5,231,260.5 sq ft). The Logistics Center creates new jobs and the new cars at a transfer station, sorts them by destination and provides a boost to the economy of Ingolstadt. marshals them for loading onto railcars. Just-in-sequence delivery to the Logistics Center: Fast informa- tion flow and short transport distances are important aspects of modern logistics. The location of the Logistics Center directly 24 25
Premium quality for the digital age – quality assurance Quality is core area of expertise at Audi. Process-oriented quality management now focuses on digitalization. Aiming to create the virtual master jig: fully automated digitalization of a vehicle body in the photometry measuring cell. For example, engineers and technicians use tactile and, increas- ingly, optical measuring techniques on the master jig, which pro- Audi customers and users have high expectations when it comes vides the zero-reference environment for the setup of all vehicle to the function, comfort and reliability of their car. The overall components. The findings from the datasets on vehicle bodies and impression of quality provided by every Audi model is determined interiors are fed into the development of a new model up to two by the reliability of the vehicle functions, the precision of the sus- and a half years before it goes into production. In the develop- pension and the degree of perfection achieved in the gap sizes, as ment phase, all different components are qualified together with well as by the highest possible standards in materials, build qual- the suppliers – from electronic components to environmentally ity and visual appeal. This is the task of Audi Quality Assurance at friendly paints or special glass for touch screens. The semiconduc- all plants worldwide. It follows the products using process-ori- tor laboratory – the only one in the European automotive industry ented quality management – from development through produc- – and the material technology laboratory allow specialists to ana- tion up to technical service and ongoing success in the markets. lyze components and materials using, for example, scanning elec- tron microscopes and computer tomographs. In the digital age, quality assurance also takes on additional and new tasks. With the goal of making a mark as the quality leader New Audi models are put through comprehensive road tests at an in the premium segment, the challenge is to validate the quality early stage. In the validation run in Quality Assurance, the cus- of alternative drives and assure the car’s connectivity both with tomer perspective is the priority. It starts about six months before itself and with its environment. Another focal issue is automated start of production. Pre-series vehicles are tested at temperatures driving, the reliability of which is crucial to customer confidence in ranging from minus 30 to plus 50 degrees Celsius (-22 to +131 °F) the new technology. Digital methods and processes are increas- at 17 stations worldwide in all climate zones. The teams increas- ingly used here. ingly employ digital scenarios to analyze complex data swiftly and thoroughly. In the acceptance road test, new models receive offi- cial whole vehicle release for series production. In the final inspec- tion for the production line, at “checkpoint 8”, every Audi is sub- Quality assurance in the semiconductor laboratory: High-performance jected to a final examination by members of Quality Assurance. microelectronics are behind more than 80 percent of all innovations in the car. The Technical Service area serves as the bridge between Audi and dealerships. One core task is technical vehicle analytics worldwide, with a focus on steadily improving the methods employed. In the future, the integrated vehicle sensor system will be able to trans- form the car into an analytics tool with remote access – provid- ing the customer gives their consent. This also improves technical expertise at dealerships and unlocks an optimum service experi- ence with a personal dimension for the customer. 26 27
Economics and • For the period from 2018, it has defined a new target figure of 35 percent for the year 2025. Based on figures from 2010, ecology in harmony – the five metrics mentioned are to be reduced further, giving greater weighting to global factors such as energy and CO2 environmental emissions. protection at Audi A car factory goes green – examples at the Ingolstadt site: • Using circulation systems: Audi has been operating a highly Audi is committed to the sustainable use of environmentally compatible paint shop at the Ingolstadt site raw materials and resources for the conservation since 2016. Dry separation of the paint particles, air recircu- of the environment. lation and exhaust air treatment significantly reduce thermal energy and water consumption as well as CO2 emissions com- pared to conventional systems. Emissions of VOCs are reduced Audi openly communicates about its environmental protection by over 90 percent. work and involves all employees in these activities. This allows the • Water recycling: To save water, Audi has built a membrane company to sustainably implement its environmental policy objec- bioreactor in Ingolstadt. Three treatment stages turn waste- tives. As a party to the fifth Bavarian Environmental Pact, AUDI AG water back into hygienically safe industrial water. In future, provides an important contribution to environmental protection. this will allow up to a third of fresh water to be saved in pro- duction. On the road to sustainable mobility: It is essential that the • Green electricity: Audi started producing cars in Ingolstadt environmental balance of a car during its entire life cycle is opti- using only green electricity in early 2012. Audi Neuburg and mized before the first kilometer is driven. AUDI AG has set itself Audi manufacturing in Münchsmünster are likewise run 100 the target of reducing its specific CO2 emissions by 25 percent percent on electricity generated from renewable resources. based on the 2010 level by the end of 2018. • Audi Logistics pioneers climate protection: Since mid-2017, • Beyond this, there are plans to lower CO2 emissions associat- all rail shipments at the Audi Ingolstadt and Neckarsulm sites ed with the supply of energy at the German locations by 40 have been CO2-free, making Audi logistics traffic by rail entire- percent per reference unit by 2020. Audi is also pursuing its ly climate-neutral. vision of manufacturing all vehicles made in Ingolstadt com- • Emissions-free locomotives: Two modern plug-in hybrid loco- pletely CO2-neutral and with zero wastewater. motives are used at Ingolstadt for shunting work. • Environmental protection also entails conserving resources. • Photovoltaics: Audi has installed different photovoltaic mod- Using 2010 as the baseline, the Group is striving for a 25 per- ules at its headquarters in Ingolstadt to test innovative tech- cent improvement in the key environmental metrics for ener- nologies. All together, the systems at the Ingolstadt site gen- gy, fresh water, waste and volatile organic compounds (VOC) erate roughly 1,800 megawatt hours per year. by the end of 2018. • Using waste heat: Since 2004, the Ingolstadt site has been supplied via district heating with waste heat generated at Quieter, cleaner and more efficient: Two modern plug-in hybrid the municipal waste processing plant and since 2012 from a locomotives are in use at the Ingolstadt site. They save up to neighboring refinery. Around 70,000 megawatt hours of ener- 120 metric tons of CO2 emissions each year. gy from waste heat were used in 2017. • Sustainable building: Audi has received the Gold Certificate of the German Association for Sustainable Building for the sustainable construction of the customer building. • Biodiversity: Audi has developed a comprehensive biodiversity concept for the site in Münchsmünster to create semi-natural habitats for a wide range of animal and plant species. 28 29
Fall 2017: first day of work for around 550 apprentices and degree apprenticeship students for Audi at the Ingolstadt site. 30 31
Top performance from top employees – human resources A company is only as good as its employees. At Audi, human resources management goes far beyond hiring and supporting employees. short and long vacation periods. Support for women also plays an important role at Audi: The company is working to further increase the percentage of women employed by the Group, from apprentices through to upper management. Audi has taken numerous measures to ensure that employees remain fit and healthy into old age. The focus here is on preven- As an attractive employer, Audi offers its employees a modern tion. Ergonomic working conditions were established in pro- work environment, space for innovation and diverse possibilities duction and at the offices of the Ingolstadt site. Free health for individual development with a high level of job security. Audi screening – the Audi Checkup – is available to all employees and employees are actively helping to shape future topics such as plays a major role in the workforce’s very good state of health. electric mobility, digitalization and the Smart Factory. A central pillar of the corporate culture are the Audi leadership principles, which are based on trust and respect. Several recent rankings, such as the surveys carried out by trendence and Universum, document the high attractiveness of AUDI AG as an employer. The company requires experts, especially in its innovation fields. Audi has a firm focus on its own development of talent: from supporting interns, PhD students and students preparing aca- demic theses to degree apprenticeship programs. The Audi Group further increased its workforce in 2017 and now employs around 91,000 people worldwide, of which about 61,000 work at AUDI AG in Germany. Almost 44,000 people work at the Ingolstadt site. With more than 200 working hours models and the option of mobile working from any location, Audi is responding to the various life phases of its employees. The company is continually expanding the “Audi Play Space” childcare concept, which com- bines all activities relating to childcare. This includes places at nearby childcare facilities, flexible short-term childcare for chil- dren of employees at Ingolstadt’s miedelHaus and programs for Career launch into the digital future: Mechatronics technicians learn how to use modern production equipment at Audi. 32 33
Young recruits are the future – training and development Welcome to Audi – the company offers an array of possibilities for training and development. Training tomorrow’s skilled employees is a key component. Around 800 young people began apprenticeships or degree apprenticeships at Audi in 2017, with around 550 of them The Audi Akademie is located centrally in the heart of located at the Ingolstadt site. Overall, more than 2,700 train- Ingolstadt, near the Neues Schloss (New Castle). ees are currently involved in vocational education within the company. Audi also allows many young people to combine prac- tical training with a university course. The “Focus Money” mag- The percentage of female apprentices is high for the industry azine again declared Audi to be “Germany’s Best Apprenticeship – in 2017 it was at around 30 percent. Audi is highly interest- Provider” in the “Car Manufacturers” category in 2017 (pub- ed in developing enthusiasm among girls and young women for lished in “Focus,” no. 14, April 1, 2017). careers in science and engineering – before they select a study course or begin an apprenticeship – with programs specifical- The range of apprenticeship vocations offered by Audi to young ly tailored to young women and mentoring seminars for female men and women is as diverse as the challenges and require- students presented by women already working at Audi. The ments in the automotive sector: from mechatronics technicians company’s Girls’ Day and Girls for Technology Camp programs and production mechanics to model builders, warehouse logis- have proven highly successful. tics specialists and plant firefighters. Audi trains tomorrow’s skilled employees in 20 vocations. For prospective academics, Audi offers a wide range of ways to join the company: from preliminary and basic internships often In all apprenticeship vocations, Audi prioritizes mobile and dig- completed before attending university to degree apprentice- ital learning. The brand with the four rings is the first automo- ships and internships as well as support during preparation of tive manufacturer to implement widespread use of tablet PCs academic theses and doctorates. as learning tools based on a stringent didactic plan. With this, Audi not only promotes individual responsibility and creativi- The topic of further training also has high priority at Audi. The ty among young people, but also focuses very specifically on IT dissemination and transfer of knowledge are more important and media competence. than ever as tools for equipping employees to handle future issues such as digitalization and electric mobility. Audi Akade- Audi is also active in training internationally. Apprentices can mie is available to the employees of the Audi Group in all mat- work and acquire important career experience during a three- ters of competence development and practice-oriented training month stay abroad in Spain, Hungary or the United Kingdom, and education. The spectrum of subjects ranges from human for example. resources development to personality and behavioral training as well as courses for technical qualifications and language skills. 34 35
Audi experience – including in culture and sport More than just an car manufacturer: Audi opens the door to creativity and supports top athletic performance. Audi has been sponsoring cultural activities for more than 50 years. The Audi Wind Philharmonic, a factory orchestra that arose from an employee initiative, was the starting point for the cultural involvement of Audi. Under the Audi ArtExperi- ence banner, the company now brings together a diverse cul- tural program that ranges from cooperation with world-famous cultural institutions to own events in the region and valuable Audi is partner to the Ingolstadt Triathlon; the German projects for young artists. In addition to involvement with the Championship will be taking place in Ingolstadt in 2018. Salzburg Festival, the Audi Young Persons’ Choral Academy and Audi Summer Concerts offer genuine art and cultural experienc- es in the Ingolstadt region. The Audi Kunstraum (Art Space) has On a regional level, Audi is active as a dependable sports spon- enhanced the Audi Forum Ingolstadt since 2011. As a found- sor. For more than a decade now, the brand has been a partner ing member and supporter of the Ingolstadt Concrete Art and of the ERC Ingolstadt ice hockey club – the 2014 German cham- Design Foundation, Audi presents changing exhibitions of works pions. Audi has a long-standing association with the soccer play- by foundation artists and others to customers and employees. ers of FC Ingolstadt 04 as principal sponsor. The home games of the Bundesliga team are played at the Audi Sportpark. Audi places special emphasis on youth development. For example, since the Audi Schanzer Soccer School was founded in 2009, Audi Kunstraum (Art Space) in the Audi Forum Ingolstadt: “Camill Leberer. Glanzstücke – Aluminium und Papier” (© VG Bild-Kunst, Bonn 2017 © AUDI AG). more than 30,000 children have attended its holiday camps. And talented young players of FC Ingolstadt 04 and ERC Ingol- stadt attend the Audi Sport Academy, which is a sports-oriented boarding school. In addition to these two clubs, Audi is also a partner of the MTV athletics department. Support is also provided for the Ingol- stadt Dukes and a wide range of sports events that are held as Bavarian championships or that draw a high number of partici- pants or spectators: the Ingolstadt Half-Marathon, for instance, as well as the Ingolstadt Triathlon, the Hagau Equestrian Days, the Ice Gala and the Night of Sports. 36 37
Strong roots – opportunity on the company intranet. Both Audi employees and nonprofit organizations from the region advertise volunteer pro- Audi is committed jects here. In addition, Audi departments are regularly active in the context of team activities in social institutions. to the region Audi employees also demonstrate social responsibility for the Audi not only builds cars in Ingolstadt, but also region through the annual Christmas fundraising campaign.The recognizes its responsibility to the region. works council’s annual appeal for donations at Christmas now goes back 40 years. Over 99 percent of Audi employees respond- ed to this appeal in 2017 and together with the company donat- ed a total of € 715,000. With this money, support was provided to 106 projects of charitable and social institutions in Ingolstadt and the surrounding districts. Audi also supports various social institutions in the region according to its funding guidelines. There are also refugee aid projects at the production sites in Ingolstadt, Neckarsulm, Brus- sels and Győr. Audi currently has an involvement in multiple vocational school classes in Ingolstadt, where young adult refu- gees are prepared for obtaining a German school-leaving certifi- cation and therefore for vocational education in the region. Working together for a good cause: Audi supports its employees with volunteering in the region, for example at the “Audi Volunteer Day” in summer 2017. The principle of putting responsibility into practice is firm- ly anchored in the Audi strategy. As the largest employer in the Ingolstadt region, Audi aims to enhance the quality of life here and therefore regularly collaborates with the city, local compa- nies, associations, and educational and social institutions. The company bundles community service activities and supports the volunteer efforts of its employees under the motto of “Audi Volunteers.” For example, the Ingolstadt site celebrated anoth- er Audi Volunteer Day in 2017, with Audi employees spending the day working in the region’s social institutions. For the “Give Time in Fall” initiative, employees devote some of their spare Audi supports classes for refugees: Students from places such as Eritrea time to helping in care institutions in the region. Audi employees and Afghanistan prepare together in Ingolstadt for German school-leaving who are interested in doing something to help others beyond certification, and also attend a road safety training day. the framework of such initiatives can find a suitable volunteering 38 39
Since 2012, AUDI AG has been cooperating with transport oper- ator Ingolstädter Verkehrsgesellschaft GmbH (INVG). Residents in the region also benefit from the expansion of the bus net- work. The company is continually expanding its mobility servic- es for employees. For example, the project to add a train stop directly at the site is now under way. This joint project of the city of Ingolstadt, the Free State of Bavaria, Deutsche Bahn and AUDI AG is aimed at relieving traffic congestion in the Ingolstadt region and provides improved mobility for Audi employees. The train stop is due to open in late 2019. “Audi Summer Children:” Children of employees test a giant soup ladle and whisks in the main kitchen at Audi Ingolstadt during the summer vacation program. Audi maintains intensive contacts with many universities. Research partnerships create ideal conditions for innovative solutions. Direct communication accelerates the knowledge transfer between research and industry. Audi currently collab- orates with more than 50 research establishments worldwide. Audi also provides support to young academics: Approximately 125 PhD students are currently conducting research on science projects financed by Audi. Under the motto of “Experiencing Science”, Audi also promotes an accessible form of knowledge transfer for the interested public with its “Science in dialog” series of lectures. The series of lectures began in 2004 and has since attracted around 27,000 audience members. Audi strengthens public transport in Ingolstadt: Four bus lines stop Audi cooperates closely with the schools in the region in order to at multiple points on the plant premises. support practice-oriented learning. Experts from Audi organize conferences and seminars for teachers and students and offer internships and factory tours. In addition, Audi supports young people who have not found an apprenticeship with programs for starter qualifications. 40 41
Audi production sites – worldwide Germany 1. Audi in Ingolstadt Area: 2,737,500 square meters (29.5 million sq ft) 7 Employees: 44,217 (as of: December 31, 2017) 4 21 6 Production (2017): 538,103 cars 3 8 2. Audi in Neckarsulm 5 Area: Approx. 1.25 million square meters (13.4 million sq ft) (including Audi Asia Böllinger Höfe) Employees: 16,955 (as of: December 31, 2017) 8. Audi in Changchun Production (2017): 193,016 cars (including CKD) Site: FAW-Volkswagen Automotive Company Ltd., China Start of production: 1988 9 Europe Production (2017): 467,468 cars 11 10 3. Audi in Győr 9. Audi in Foshan Site: AUDI HUNGARIA Zrt., Hungary Site: FAW-Volkswagen Automotive Company Ltd., China Area: 5,167,366 square meters (55.6 million sq ft) Start of production: 2013 Employees: 12,307 (as of: December 31, 2017) Production (2017): 85,191 cars Production (2017): 1,965,165 engines, 105,491 cars 10. Audi in Aurangabad 4. Audi in Brussels Site: Skoda Auto India Private Limited (SAIPL), India Site: AUDI BRUSSELS S.A./N.V., Brussels, Belgium Start of production: 2007 Area: 540,000 m2 (5.8 million sq ft) Production (2017): 6,513 cars Employees: 2,792 (as of: December 31, 2017) Production (2017): 95,288 cars North America 5. Audi in Martorell 12 Site: SEAT, Spain 11. Audi in San José Chiapa Start of production: 2011 Site: Audi México S.A. de C.V., San José Chiapa, Mexico Production (2017): 114,372 cars Start of production: 2016 Employees: 6,276 (as of: December 31, 2017) 6. Audi in Bratislava Production (2017): 158,543 cars Site: VOLKSWAGEN SLOVAKIA, Slovakia Start of production: 2005 Production (2017): 106,640 cars South America 7. Audi in Kaluga 12. Audi in Curitiba Site: Volkswagen Group RUS, Russia Site: Volkswagen do Brasil Indústria de Veículos Automotores Ltda., Brazil Start of production: 2013 Start of production: 2015 Production (2017): 1.409 cars Production (2017): 5,159 cars 42 43
Each year Klenzepark, in the center of Ingolstadt, hosts the popular open-air classical music concerts during the Audi Summer Concerts series. Thousands of visitors take the opportunity to enjoy music over a picnic on a summer’s evening. In summer 2017, performers included the Audi Wind Philharmonic and the Georgian Chamber Orchestra Ingolstadt. 44 45
Audi models – Fuel consumption and emission figures Models in Combined fuel Combined Ingolstadt: consumption * CO2 emissions * Audi Q2 6.4–4.1 l /100 km 146–109 g/km Audi A3 7.1–3.9 l /100 km 163–103 g/km Audi A3 Sportback 8.4–3.9 l /100 km 192–103 g/km Audi S3 7.1–6.4 l /100 km 163–146 g/km Audi A5 Sportback g-tron Audi S3 Sportback 7.1–6.5 l /100 km 163–149 g/km Audi RS 3 Sportback 8.4–8.3 l /100 km 192–189 g/km Audi A4 8.8–3.7 l /100 km 200–95 g/km Alternative Combined Combined Combined Combined Audi A4 Sedan 7.7–3.7 l /100 km 174–95 g/km drives in fuel con- CO2 CNG con- energy con- Ingolstadt: sumption * emissions * sumption: sumption: Audi A4 Avant 8.8–3.8 l /100 km 200–99 g/km Audi A3 12–11.4 1.8–1.6 Audi A4 allroad quattro 6.8–4.9 l /100 km 154–127 g/km Sportback 40–36 g/km – kWh/100 l /100 km e-tron km Audi S4 Sedan 7.7–7.5 l /100 km 174–170 g/km 98–89 g/km Audi A3 Audi S4 Avant 7.9–7.7 l /100 km 179–175 g/km 5.5–5.1 (CNG) 3.6–3.3 Sportback – l /100 km 128–117 g/ kg/100 km Audi RS 4 Avant 8.8 l /100 km 200–199 g/km g-tron km (gasoline) Audi A5 Sportback 7.7–4.1 l /100 km 174–106 g/km 124–102 g/ Audi A4 6.5–5.5 km (CNG) 5.3–3.8 Avant – Audi A5 Coupé 8.7–4.0 l /100 km 197–105 g/km l/100 km 147–126 g/ kg/100 km g-tron km (gasoline) Audi S5 Sportback 7.7–7.5 l /100 km 174–170 g/km 135–102 g/ Audi A5 Audi S5 Coupé 7.7–7.5 l /100 km 174–170 g/km 6.3–4.1 km (CNG) 5.9–3.8 Sportback – l/100 km 143–110 g/ kg/100 km Audi RS5 Coupé 8.7 l /100 km 197 g/km g-tron km (gasoline) 46 47
Models in Combined fuel Combined Models in Combined fuel Combined Neckarsulm: consumption * CO2 emissions * Györ: consumption * CO2 emissions * Audi A4 Sedan 7.7–3.7 l /100 km 174–95 g/km Audi TT Coupé 8.4–4.6 l /100 km 192–122 g/km Audi A5 Cabriolet 8.0–4.4 l /100 km 181–114 g/km Audi TT Roadster 8.5–4.7 l /100 km 194–126 g/km Audi S5 Cabriolet 8.0–7.9 l /100 km 181–179 g/km Audi TTS Coupé 7.3–6.7 l /100 km 168–155 g/km Audi A6 Limousine 9.4–4.2 l /100 km 218–109 g/km Audi TTS Roadster 7.5–6.9 l /100 km 173–159 g/km Audi A6 Avant 9.6–4.4 l /100 km 224–114 g/km Audi TT RS Coupé 8.4–8.2 l /100 km 192–187 g/km Audi A6 allroad quattro 6.5–5.6 l /100 km 172–149 g/km Audi TT RS Roadster 8.5–8.3 l /100 km 194–189 g/km Audi S6 Limousine 9.4–9.2 l /100 km 218–214 g/km Audi A3 Sedan 8.4–3.9 l /100 km 191–102 g/km Audi S6 Avant 9.6–9.4 l /100 km 224–219 g/km Audi A3 Cabriolet 6.8–4.3 l /100 km 156–113 g/km Audi RS6 Avant 9.6 l/100km 223 g/km Audi S3 Sedan 7.1–6.4 l /100 km 163–148 g/km Audi RS6 Avant Audi S3 Cabriolet 6.8–6.7 l /100 km 156–153 g/km 9.6 l /100 km 223 g/km performance Audi RS 3 Sedan 8.4–8.3 l /100 km 191–188 g/km Audi A7 Sportback 7.2–5.5 l /100 km 163–142 g/km Audi S7 Sportback 9.3 l /100 km 215 g/km Audi RS 7 Sportback 9.5 l /100 km 221 g/km Models in Combined fuel Combined Martorell: consumption * CO2 emissions * Audi A8 8.0–5.6 l /100 km 182–145 g/km Audi Q3 8.6–4.2 l /100 km 203–109 g/km Audi A8 L 8.0–5.6 l /100 km 182–146 g/km Audi RS Q3 8.6–8.4 l /100 km 203–198 g/km Audi A8 L W12** 11.2–11.0 l /100 km 259–254 g/km Audi S8** 10.0–9.4 l /100 km 231–216 g/km Models in Combined fuel Combined Audi S8 plus** 10.0 l /100 km 231 g/km Bratislava: consumption * CO2 emissions * Audi R8 Coupé 13.4–12.4 l /100 km 306–283 g/km Audi Q7 7.6–5,5 l /100 km 199–144 g/km Audi R8 Spyder 13.6–12.6 l /100 km 309–286 g/km Audi SQ7 7.6–7.2 l /100 km 199–189 g/km Models in Combined fuel Combined Alternative Combined Combined Combined Combined Brussels: consumption * CO2 emissions * drives in fuel con- CO2 CNG con- energy con- Bratislava: sumption * emissions * sumption: sumption: Audi A1 7.1–3.7 l /100 km 166–97 g/km Audi Q7 1.9–1.8 19–18.1 Audi A1 Sportback 7.2–3.7 l /100 km 168–97 g/km 50–48 g/km – e-tron l /100 km kWh/100 km Audi S1 7.2–7.0 l /100 km 168–162 g/km Audi Q7 1.9–1.8 19–18.1 e-tron 50–48 g/km – l /100 km kWh/100 km Audi S1 Sportback 7.2–7.1 l /100 km 168–166 g/km quattro 48 49
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