The Birth of an Electric Car (A2) as Told by Audi

Audi recounts the birth of an electric car for the new A2, which has just gone into production: development time cut in half compared to before.

The birth of an electric car: 21 months less in development

The first step was to reduce complexity by using a much smaller number of parts. This significantly cuts down the number of logistics hubs, simplifying the entire process. For the first time, the string-of-perls production principle applied in Neckarsulm’s factory is now used in Ingolstadt as well. The sequence of customer orders is determined 6 days before assembly begins and then processed across all production areas. This control offers several advantages. For instance, it reduces process complexity: a fixed sequence allows parts to be produced directly at the supplier in order and packed into designated containers. Additionally, thanks to the flexible layout of the facilities, over 1,200 A2 components are produced alongside those of the A3 model. Robot welding guns and around 250 existing robots are also reused.

or for other models.

High level of automation, with Audi Cloud and AI assistants

Audi is introducing fully automated wheel installation at its Ingolstadt plant. Robots are replacing semi-automatic tightening stations in the pre-assembly of the front and rear axles. Processes in the body shop are also optimized using bin picking technology. By leveraging image processing and camera-guided robot control, this intelligent system identifies and picks up components. Robots can also remove small sheet metal parts directly from the wrong containers and feed them into the next production stage. The Edge Cloud 4 Production industrial cloud supports the plant’s digital network. The universal testing system for activating control units and guiding operators is centrally controlled by the cloud, allowing 450 industrial PCs to be saved in the assembly process.

Laggio. A range of AI-powered knowledge assistants is also being introduced. The supply chain chatbot helps employees find expert knowledge, processes, and documentation. The maintenance chat supports fault analysis and solution searching.

Employee training, both practical and digital, is at the core

But technological innovation is not enough if it is not accompanied by targeted skill development among the workforce. Through a multi-stage approach that combines hands-on training with virtual qualifications, Audi has prepared its employees for the electric vehicle era. This involves combining traditional practical modules on the assembly line with digital training concepts, such as virtual screen-based assembly training. The A2 qualification program enhances electromobility expertise in Ingolstadt, which will also be applied to future models. “This is the most efficient Audi ever built and makes electric mobility suitable for everyday use,” explains CEO Gernot Döllner. “It clearly shows how we are implementing our transformation: faster development, more efficient production. Strengthening industrial value creation and competitiveness in Germany.”

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