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| The paint shop |
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Robots at the paint shop
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| There is no limit when it comes to colours |
Including the logistics area, Audi Hungaria's 720-metre long assembly hall is one of the Győr plant's most characteristic facilities. Currently four models are made on the same assembly line (A3 Sedan, A3 Cabriolet, TT Coupé and TT Roadster).
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| We were shown around by Zoltán Les |
A new car is finished in every two minutes, which means that every day, 645 cars are assembled at Audi Hungaria's assembly line. Once finished, each car is tested on a 1.3-kilometre internal test route.
Pre-assembly stations are installed on both sides of the main assembly line, where the doors, the dashboard and the suspension are assembled. The assembly of the car body with the mechanical components is fully automatic, carried out at the third stage out of a total of six stages of assembly. With 56 bolted joints this is the most complex phase of the assembly process.
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| Employees work in three shifts, with two people at one work station at the same time |
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| The insulations are also tested during a 6-minute probe |
Nearly 1,700 people work at 51,000-square-metre the assembly line, most of whom had previously worked at the old TT line. There are work groups consisting of 12 people and the employees switch work phases in every two hours to avoid monotony.
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| Roof being fitted on a TT Roadster |
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| Inspecting paint thickness |
The frames and suspended platforms are adjustable at each stage of the assembly line. At the door pre-assembly employees work while seated in ergonomic chairs. To reduce manual labour, material conveyors are used for the assembly of batteries and seats and filling fuel.
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| We don't see too many TT Roadsters yet: two cars are made every day but production volume will increase week by week |
Assembly is supported by a complex logistics system. Components are supplied by supply stocks at each stage of the assembly line, while at the eastern side of the assembly hall we find a 40,000-square-metre logistics area.
Logisticians responsible for the sequencing cars are supported by an online system. This makes sure that the right components are loaded from the shelves. They use a pick by voice system: the logistician has to read out loud the desired part's reference number into a microphone and a beep signals whether the right component has been selected.
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| The maximum capacity of the line is 645 cars a day, annual capacity is 160,000 units |
Audi's reliable and high-quality work process is supported by a number of complementary tools and devices. For example, lights flash up when the part stock or the shelf ran out of parts or a bolting machine with electronic torque vectoring.
50 percent of the cars manufactured at the Győr plant are A3 Sedans, 25 percent are TT Coupés, 12.5 percent are TT Roadsters and 12.5 percent are A3 Cabriolets.
The last stage at the assembly line in Győr is deployment, followed by technical inspections. The cars are tested on a rolling suspension test bench, capable of testing cars at speeds as high as 120km/h. After that, the cars are submitted to a brake test. The excess heat produced during the tests are used for the heating of the assembly hall.
