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At the group headquarters of AUDI AG and its largest production site, 551,889 vehicles were built in 2011, including the Audi A3, Audi A4, Audi A5 and Audi Q5 car lines. The body shop and paint shop also process the Audi TT Coupé, Audi TT Roadster and Audi A3 Cabriolet. Big draw for members of the public: the Audi Forum, which attracts more than 400,000 visitors each year.
The origins of the Ingolstadt site as one of the most modern production locations in the automotive industry stretch back to 1949. The newly established Auto Union GmbH started out by producing motorcycles, rapid delivery vans and parts on the site of the former Ingolstadt fortress. In 1969 the company merged with NSU to form NSU AUTO UNION AG, and the resulting entity changed its name to AUDI AG in 1985. The headquarters of the group were moved from Neckarsulm to Ingolstadt.
The task areas covered in Technical Development range from design, engines and transmissions to vehicle concepts, electrics/electronics, body and suspension.
Latest innovation at the Ingolstadt site: the SE Forum. Here 450 employees are involved in simultaneous engineering – integrated and simultaneous product and process design. Other highlights of Technical Development include the Neustadt an der Donau proving ground extended in 2012, with its focus on driver assistance systems, the Wind Tunnel Centre, the Audi Pre-Series Centre and the Transmissions and Emissions Centre.
The toolmaking shop, which has won multiple awards, also supplies car manufacturers outside the group. In addition to the production line, which has its own press shop, the plant includes a body shop, a paint shop and an assembly line. Cycle, flow, pull and perfection are the key principles of the Audi Production System (APS) – one of the most flexible and efficient production systems in the automotive industry. The production and assembly lines have already received the “Automotive Lean Production Award” on several occasions. The new logistics concept is designed to optimise the materials flow even further in future.
Extremely high number of variants, worldwide production and procurement networks: these days, automotive manufacturers’ logistics networks are hugely complicated. To simplify matters, the Logistics Centre (GVZ) consolidates the many different flows of materials into industry parks. Audi is meeting the requirements for efficient logistics management on an area measuring 118 hectares at the site. The 15th production facility is already under construction. Audi has been locating key suppliers in the immediate vicinity of the plant since 1995. Subassemblies thus reach the final assembly line at just the right moment. This just-in-sequence principle makes the production process more economical and reduces the burden on the environment. Single transhipment point for assembly parts: The second consolidation centre that was built in 2010.
Consummate workmanship, outstanding design and uncompromising reliability: attributes associated with the Audi brand worldwide. The ADAC has also recognised these characteristics and selected the Audi A3 built in Ingolstadt as the winner of the “Yellow Angel” award in the “Quality” category in 2013. The vehicle beat off a field of 52 models.
Quality is not an abstract maxim at Audi, but an end-to-end principle that stems from the corporate culture. At the Ingolstadt headquarters, over 2,000 employees are responsible for quality assurance at all Audi plants worldwide. From development, vehicle manufacturing to dealership support, the hallmark high standard of quality is ensured across the board.
Environmental protection in practice, at every level: the Audi Production System (APS) dissects the group’s environmental policy as far down as the individual production lines. The Ingolstadt site has already been revalidated several times under the EU Eco-Management and Audit Scheme (EMAS) by DEKRA Certification GmbH and accredited to ISO 14001 in 2004. The new European standard DIN EN 16001 on energy efficiency has likewise formed part of the environmental management system since 2010. The site thus fulfils particularly stringent requirements for the steady and systematic reduction of energy consumption. The new data centre in Ingolstadt, which was inaugurated at the end of 2012, also contributes to this aim: thanks to the use of cutting-edge technology, more than 9,000 tons of CO2 can be saved every year. The TÜV Rheinland (Rhineland Inspection Authority) singled out the company’s efforts by awarding it premium certification in the most energy-efficient category. Other evidence of Audi’s environmental commitment: the charitable environmental foundation Audi Stiftung für Umwelt, the use of district heating to reduce CO2 emissions, and the use of renewable electricity. Since August 2010, the latter has been used to power all freight trains transporting cars from the group headquarters Ingolstadt to Emden, the port of loading on the North Sea coast.
Modern world of discovery and communication platform: the Audi Forum Ingolstadt attracts more than 400,000 visitors each year. Award-winning restaurants, concerts, an in-house cinema and the “Market and Customer” service centre offer an interesting and varied range of amenities. The Audi museum mobile brings the philosophy and history of the premium manufacturer to life. At the strikingly designed Customer Centre, customers receive personalised advice and can take receipt of their new vehicle in attractive surroundings. Numerous discovery tours give visitors an exciting glimpse behind the scenes.