How Audi shortened development time for the A2 e-tron
Audi has revealed key details about the development and production of the A2 e-tron at its Ingolstadt plant. According to the Volkswagen subsidiary, the development timeline for the electric A2 was reduced by nearly two years compared to previous vehicle projects.
Image: Audi
Audi has launched production of the A2 e-tron at its Ingolstadt plant. First unveiled just a few days ago, the new compact-class battery-electric vehicle is based on the updated Modular E-Drive Toolkit (MEB+) from the Volkswagen Group and will be delivered starting in December. The price: from €38,200. All the details about the electric A2 can be read here.
With the production of the A2 e-tron, Audi demonstrates how the company itself is becoming more efficient: “Development time has been shortened by 21 months, the range of variants and complexity have been significantly reduced, and the degree of automation has been increased. Existing equipment and production facilities continue to be used,” states a company announcement.
Audi explains that the faster development of the A2 e-tron stems from experience gained in previous vehicle projects and streamlined processes that reduce coordination effort. According to the company, both factors have enabled “the vehicle to reach maturity earlier during pre-series production.”
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In producing the compact electric car in Ingolstadt, Audi now incorporates more than 1,200 manufacturing components (including robot welding tongs and around 250 robots) that have already been used in the production of other Audi models. These are either reused or repurposed. For example, Audi manufactures the bodies of the A2 e-tron alongside those of the Audi A3. Additionally, the A2 e-tron has a relatively low number of part numbers, which reduces complexity. “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,” Audi explains.
Audi is also applying the so-called “string of pearls” production principle in Ingolstadt for the first time, a method already practised at the company’s Neckarsulm plant. The sequence of customer orders is determined six days before the start of assembly and processed across all trades. According to Audi, this type of factory control offers 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 is further increasing the degree of automation in production at its main plant. With the A2 e-tron, fully automatic robot stations are being introduced in Ingolstadt, replacing the previously semi-automated screw stations in the pre-assembly of the front and rear axles. New technologies are also assisting in body construction: with the so-called “bin picking”, automation technology now identifies and grips components using image processing and camera-guided robot control. This allows robots to remove small sheet metal parts directly from unordered containers and feed them into the production process for the first time.
For the digital networking of assembly, Audi relies on the ‘Edge Cloud 4 Production’ industrial cloud. This centrally controls, for example, the universal test system for commissioning vehicle control units and any individual customisations of a vehicle. “This saves more than 450 industrial PCs in assembly,” Audi states. In addition, IT specialists from the brand are developing a series of AI-supported knowledge assistants across locations. “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.”
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On this basis, Audi executives conclude that the A2 e-tron “is an example the transformation of Audi production”. CEO Gernot Döllner puts it in his own words: “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.”
Gerd Walker, Audi Board Member for Production and Logistics, adds: “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.”