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Launch of a synchronized production system at Audi Toolmaking

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Khatir Soltani
The new workshop is home to Plant and Equipment Construction, in which important parts of the body shop plants are developed and built. Immediately adjacent to this is a learning station for mechatronics trainees. Also located here are the Laser Team, which cuts the required shapes from the metal blanks, and a storage area for the raw castings.

Photo: Audi

Among the technical highlights of the extension building is an automatic storage facility for tailored blanks, which offers space for 500 metric tons of material in a high-bay warehouse. Two new gantry cranes that run 35 meters (115 ft) along the roof can carry loads of up to 50 metric tons.

The Ingolstadt toolmaking expansion project was completed in three construction phases. Groundbreaking took place in September 2008, and employees moved into the new space at the end of last year. A total of 630 metric tons of steel, 6,100 m3 (215,419 cu ft) of concrete and 810 metric tons of reinforcing steel went into the project.

Audi Toolmaking enjoys an excellent reputation within the industry and plays a leading role, as numerous awards and prizes attest. Roughly 900 people are employed in toolmaking at the Ingolstadt plant alone, with roughly 1,700 employed in toolmaking throughout the company.

Audi Toolmaking is best known for its innovative power. Among the most recent developments are particularly lightweight items of equipment for the body shop in which large components are made of carbon fiber composites. Their low weight drastically reduces electricity consumption – by more than 40 percent.

Another novel technology used at Audi Toolmaking is shaping tools with highly sensitive sensors that detect possible deviations from the ideal when shaping panels. The “intelligent tools” of the future, which are already at the prototype stage at Audi, will even be self-regulating in the interest of maximum precision.

Khatir Soltani
Khatir Soltani
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