Audi A5 new generation production commences at the Neckarsulm plant. Especially, debuting the Premium Platform Combustion (PPC) models that are partly built on electrified drive systems and advanced electronic architecture. Further, aligning Audi’s commitment to sustainability, as they aim for all vehicles produced at the Neckarsulm site to be net carbon-neutral by 2025 as a part of the “360factory” production strategy.
The focus of Audi is to improve its production efficiency, increase automation, and implement innovative technologies. As a result, it shall ensure they keep moving towards the net carbon-neutral goal. The renovated paint shop shall be among the most modern in the automotive industry by 2025.
Largest Start-Up Phase in Plant History at Audi Neckarsulm
Preparation and Expertise of the Audi Neckarsulm Team
It’s a historic moment for Audi, as it is one of the biggest start-up phases for the plant to commence the production of Audi A5 at Neckarsulm. Audi’s Neckarsulm capitalizes the teams extensive experience in combustion engine vehicle production and complex ramp-ups stated Gerd Walker, Audi’s Board Member for Production.
Further, plant manager at Audi Neckarsulm Fred Schulze stated the team has undergone multiple trainings in new systems and automotive production technologies. Further, emphasizes the preparedness of the team with a future-proof production infrastructure. Rainer Schirmer, Chairman of the Works Council, expressed confidence in the team’s ability to manage complexity and remain flexible, ensuring the success of the Audi A5 at the site.
Vision for Sustainable Production
This vision of future production is unfolding as Audi transforms, digitalises and remanufactures its plants for green production. At the moment, Audi’s goals include making all of the company’s sites CO2-neutral by 2025, which of course, includes Neckarsulm.
Innovations in the Paint Shop at Audi Neckarsulm
Energy-Efficient Processes
The Neckarsulm paint shop is currently upgrading its facilities, with completion set for 2025. Additionally, the shop will implement many upgraded processes and sustainable methods. The new painting process, which replaces the filler with pre-zone paint, allows for wet-on-wet painting, reducing energy consumption per vehicle by up to 140 kWh.
Corrosion Prevention and Drying Techniques
Audi employs advanced methods to prevent corrosion, including cathodic dip painting, which uses a rotation process to dip and rotate the body, preventing air bubble formation and dirt deposits. A new energy-efficient transverse drying process is also utilized, blowing air into the interior and heating the body from the inside. This process is not only energy-efficient but also better suited for future electric and hybrid vehicles.
Paint Separation and Air Recycling
A new paint separation process at the Neckarsulm site saves around 50 kWh per vehicle by capturing paint mist with state-of-the-art filters. This dry separation process allows over 90% of the filtered air to be reused. Further, reducing the need for energy-intensive fresh air conditioning and eliminating the use of fresh water and chemicals.
Sustainable Water Use in Production at Audi Neckarsulm
Water Resource Management
Across site usage of water responsibly shall be the focus for Audi. Especially, aiming to halve its ecologically weighted water consumption in production by 2035. At Neckarsulm, the Audi relies on a closed water cycle using the nearby wastewater treatment plant. New pipes and plant technology will ensure that no more process water is drawn from the Neckar canal. Further, saving up to 70% of freshwater from 2025 onwards. Audi will further treat the water purified by the plant for reuse in production. Further, reinforcing the commitment towards water conservation is Audi’s membership in the Alliance for Water Stewardship (AWS).
High Automation for Premium Quality
Automated Add-On Parts Installation
Neckarsulm is the first site within the Audi Group to fully automate the installation of all add-on parts in the body shop. This automation improves the fitting accuracy of the parts and minimizes external influences. Seven robots are used simultaneously for the complex task of fender attachment.
Smart and Automated Material Provision
Audi’s “360factory” production strategy includes a supply chain that relies on automated material provision. Neckarsulm shall be the role model of automation with plans to transform other Audi sites being in place. The site was the first worldwide to implement driverless transport systems (DTS), with over 80% of material volumes in the body shop now provided automatically.
Virtually Smokeless Fixing
Audi has introduced a world-first in car body construction: virtually smokeless fixing. This process involves attaching glued components, such as doors, with small soldering points to prevent slipping, significantly reducing residue build-up and increasing efficiency.
State-of-the-Art Quality Monitoring
Inline Quality Control at Audi Neckarsulm
Quality control measurements in the body shop are now carried out inline. Further, eliminating the removing vehicles from the production line. New measuring technology at two stations uses sensors to determine the dimensional accuracy of components. Further, ensuring real-time quality control, as the increased number of measurements by Audi lets them respond quickly to any deviations.
Augmented Reality (AR) for Inspection
Audi uses innovative technologies like augmented reality (AR) for inspecting car bodies. An AR app on tablets with integrated cameras shows connection points in real time, allowing for immediate documentation of weld seams and other components. This digitalization significantly increases inspection efficiency, reducing the time required to determine specifications for bonded seams from hours to just seconds.
