Audi begins production of the A2 e-tron: greater speed, efficiency, and competitiveness

Audi has significantly shortened its product development process for the A2 e-tron. The period from development to production readiness was 21 months shorter than for previous vehicle projects. Experience from earlier vehicle projects and streamlined processes reduce the time and effort required for coordination and enable the vehicle to reach maturity earlier during pre-series production.

Audi has significantly reduced complexity in the A2 e-tron. The model combines a high level of customer benefit with significantly fewer production-relevant part numbers. This also significantly reduces the number of logistics supermarkets. As a result, less space is required for logistics, and material supply within the plant is simplified.

For the first time, Audi is applying the so-called string-of-pearls production principle in Ingolstadt, a principle already successfully used at the Neckarsulm plant. The sequence of customer orders is determined six days before assembly starts and then processed across all production areas. This type of factory control has several key advantages: among other things, it reduces process complexity because a fixed sequence allows parts to be produced directly at the supplier in the correct order and packed in the designated container. In addition, Audi is increasing the cost-effectiveness of the production process because storage and sequencing areas are eliminated.

Audi manufactures the bodies of the A2 e-tron together with those of the Audi A3. This is made possible by the flexible layout of the facilities.

More than 1,200 production components, including robot welding guns and around 250 robots that have already been used to manufacture other Audi models, are being reused or put to further use.

Audi is bringing fully automated wheel installation to the Ingolstadt site with the A2 e-tron: fully automated robot stations are replacing the previous semi-automated bolting stations in the chassis preassembly area for the front and rear axles.

Audi is optimizing processes in the A2 e-tron body shop with so-called “bin picking”. Using image processing and camera-guided robot control, the intelligent technology recognizes and picks up components. This can reduce ergonomically demanding tasks. For the first time, the robots can also remove small sheet-metal components directly from disordered containers and feed them into the next stage of the production process.

The industrial cloud “Edge Cloud 4 Production” supports the digital networking of assembly. The Universal Test System for commissioning the A2 e-tron control units and the so-called “operator guidance,” which provides information on vehicle customizations, are centrally controlled from the cloud. This saves more than 450 industrial PCs in assembly.

Audi is also establishing a range of AI-supported (artificial intelligence) knowledge assistants across production sites. For example, the Supply Chain Chatbot helps employees search for expert knowledge, processes, and documentation. The maintenance Chat supports maintenance teams with fault analysis and finding solutions.

In addition to technological innovation, the successful production launch of the A2 e-tron is the result of the targeted and early development of skills within the workforce. With a multistage concept combining hands-on training and virtual qualifications, Audi prepared employees for the requirements of manufacturing the fully electric model. This combines traditional practical modules on the assembly line with digital qualification concepts such as virtual assembly training on a screen.

The qualification program for the A2 e-tron strengthens electromobility expertise at the Ingolstadt site and sustainably anchors knowledge relevant to the future in the plant. Continuous employee qualification is a key factor in the successful ramp-up of new technologies and the continued development of production.

The A2 e-tron is an example of the transformation of Audi production. Less complexity, a high degree of automation, and extensive digital networking demonstrate how Audi is advancing the transformation of its plants and sustainably strengthening competitiveness. At the same time, people remain a central factor in success: modern technologies provide targeted support for employees in their tasks.

Further information on the Audi A2 e-tron is available in the media set.

“The Audi A2 e-tron represents the next step in our renewal. It shows how we consistently think from the market backward, because different regions need different answers. The A2 e-tron was developed for Europe and is manufactured in Ingolstadt. It is the most efficient Audi we have ever built, and it makes electric mobility suitable for everyday use. At the same time, it shows how we are implementing our transformation in concrete terms: developing faster, producing more efficiently, and thereby strengthening industrial value creation and competitiveness in Germany.”

– Gernot Döllner, CEO of AUDI AG

“The start of production of the A2 e-tron in Ingolstadt is a strong signal for our site and its future. We are particularly proud of this as the works council, because together with the workforce we have repeatedly fought with great determination since 2019 for Audi to develop an entry-level electric model and build it in Ingolstadt. The project stands for technological expertise, industrial value creation, and secure prospects for our employees. Above all, however, the successful production launch is the result of the tremendous commitment and skill of our colleagues. Once again, this shows: at Audi, Vorsprung durch Technik is not just announced, it is achieved.”

– Jörg Schlagbauer, Chairman of the Audi General Works Council

“The A2 e-tron again demonstrates that it is possible to build cars profitably in Germany. Particularly important in this regard are AI assistants developed jointly by our Neckarsulm and Ingolstadt sites, our highly flexible production facilities, and, above all, the expertise of our employees. The model demonstrates the transformation of Audi production: less complex, even more efficient, and with a high degree of digitalization and automation.”

– Gerd Walker, Board Member for Production and Logistics at AUDI AG

“The start of production of the Audi A2 e-tron is the result of extensive teamwork at the Ingolstadt plant. Drawing on their wealth of experience from numerous product launches, the team has laid the groundwork for a successful ramp-up of the model and further optimized our processes. Production of the new model strengthens core capabilities at our headquarters.”

– Siegfried Schmidtner, Plant Manager at Audi Ingolstadt