Electromobility: assembly on a new level

With the Q6 e-tron series, Audi is starting series production of the new Premium Platform Electric (PPE) in Ingolstadt. The new technology platform, the latest E³ electronics architecture, and in-house battery assembly will open up new fields of activity.

04/25/2024 Reading Time: 2 min

Audi Q6 e-tron: Power consumption (combined) in kWh/100 km: 19.6–16.5CO₂ emissions (combined) in g/km: 0CO₂ emission class: A

Audi Q6 e-tron: Power consumption (combined) in kWh/100 km: 19.6–16.5CO₂ emissions (combined) in g/km: 0CO₂ emission class: A

employee during the production of a Q6 e-tron

The Q6 e-tron1 marks a significant milestone for Audi. The SUV is the first battery electric model (BEV) on the Premium Platform Electric (PPE) and the first electric car to be produced at the Ingolstadt site. Audi boss Gernot Döllner believes this is just the beginning: "The PPE and, therefore, the Q6 e-tron series are the basis for further electric Audi models." Audi wants to achieve this with a holistic, sustainable approach: the 360factory production strategy. The Four Rings is, therefore, modernizing, digitalizing, and transforming its existing plants from the inside out. Since 2024 Audi Ingolstadt has been CO2 neutral2 in production. The synergetic production concept significantly contributes to this.

 

Q6 e-tron body shells are lifted by robot arms

360factory: Production steps using existing structures and processes

“Most of the conversion measures are not visible at first glance, as many of the production processes for the all-electric models on the new PPE have not changed fundamentally compared to the combustion engine,” says Ulrich Polz, who manages the assembly line. “And yet we have made the assembly line fit for the future in recent years with numerous conversion measures.” In line with its 360factory production strategy, Audi focuses on integrating individual production steps into its existing structures and processes.

 

The assembly starts with the perfect body

the production of Premium Platform Electric car bodies

The assembly starts with the perfect body

To use resources sustainably and synergistically, Audi uses 680 robots to produce the PPE bodies, which are already used to manufacture other Audi models. 

the production of Premium Platform Electric car bodies

The supply chain is becoming more digital and automated

Automated guided vehicle system for material supply in the production hall

The supply chain is becoming more digital and automated

Audi has established a fleet of more than 40 driverless transport systems for the Q6 e-tron series. These take over the provision of materials in the building and automatically supply the body shop's systems with the necessary parts. 

Automated guided vehicle system for material supply in the production hall

A fresh coat of paint in the paint shop

A car is sprayed by application robots in the paint shop

A fresh coat of paint in the paint shop

"One highlight is the automatic hole sealing," says Carsten Mohr, head of the paint shop. "After priming, application robots automatically seal around 70 holes in the bodywork with adhesive pads." Employees previously had to carry out this process step manually overhead.

A car is sprayed by application robots in the paint shop

Audi also manufactures the high-voltage batteries at its main plant

Automated production line for high-voltage batteries at the Audi main plant in Ingolstadt

Audi also manufactures the high-voltage batteries at its main plant

In the new battery assembly facility at the freight transport center in Ingolstadt, around 300 employees work daily in three shifts across an area of around 30,000 square meters to assemble up to 1,000 high-voltage batteries for the new PPE models. The facility has an automation rate of almost 90 percent.

Automated production line for high-voltage batteries at the Audi main plant in Ingolstadt

On the road to e-mobility: new personnel for the assembly

Audi Q6 e-tron assembly

On the road to e-mobility: new personnel for the assembly

The Four Rings need new skills to master the transition to electric mobility. To date, Audi has trained 8,300 Production, Technical Development, and Sales employees for the launch of the Audi Q6 e-tron model series in Ingolstadt.

 

Audi Q6 e-tron assembly

Audi is getting ready for more e-models

The production of the Q6 e-tron1 in Ingolstadt marks a milestone on Audi's path to a fully electric future: "By the end of the decade, we will have made all Audi sites fit for the production of electric models," says Gerd Walker, Board Member for Production. “We are using electrification to transform our existing plants comprehensively. With the production of the Q6 e-tron series, the Ingolstadt plant is taking the next step towards the 360factory.”

 

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