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The New Audi A5: A Leap Towards Sustainable and Efficient Production
The introduction of the new Audi A5 family marks a significant milestone for Audi as it rolls out the first models based on the Premium Platform Combustion (PPC). This platform integrates partially electrified drive systems and a new electronic architecture, underscoring Audi's commitment to sustainability and advanced manufacturing. As part of Audi's ambitious "360factory" production strategy, the goal is to achieve net carbon-neutral production at the Neckarsulm plant by 2025. This transformation is set to redefine automotive manufacturing with enhanced efficiency and sustainability.
A Pioneering Production Approach
The Neckarsulm plant is undergoing its largest start-up phase in history with the production of the new Audi A5. Gerd Walker, Audi's Board Member for Production, emphasizes the plant's extensive experience in vehicle production and complex ramp-ups. This expertise positions the Neckarsulm team well to manage the transition to a more sustainable production model. Plant Manager Fred Schulze highlights that the workforce has undergone additional training to handle new systems and automotive technologies, ensuring a robust infrastructure for future production.
Cutting-Edge Paint Shop and Reduced Energy Consumption
Audi's dedication to sustainability is evident in the modernization of its paint shop at Neckarsulm, which will be among the most advanced in the industry upon completion in 2025. The new paint shop introduces significant improvements, including a shift to water-based paints and a new wet-on-wet painting process that eliminates the need for separate drying of filler. This innovation reduces energy consumption by up to 140 kWh per vehicle.
The plant also employs advanced corrosion prevention methods such as cathodic dip painting and a more energy-efficient transverse drying process. These techniques ensure thorough application and drying while reducing energy usage. Additionally, the new dry separation process for paint mist captures over 90% of filtered air, minimizing the need for fresh air conditioning and reducing water and chemical usage.
Sustainable Water Use and Automation
Audi is committed to responsible water management, aiming to halve its ecologically weighted water consumption by 2035. At the Neckarsulm site, a closed water cycle system and treatment plant will cut fresh water use by up to 70% starting in 2025. This approach aligns with Audi's membership in the Alliance for Water Stewardship (AWS), reinforcing its dedication to water conservation.
The Neckarsulm plant also leads in automation with the fully automatic installation of add-on parts in the body shop. Over 80% of material volumes are now supplied automatically, thanks to smart transport systems introduced in 2014. Innovations such as virtually smokeless fixing and augmented reality (AR) for quality control further enhance efficiency and precision in production.
The Future of Audi Production
The new Audi A5 is more than just a vehicle; it represents Audi's vision for a sustainable and technologically advanced future in automotive manufacturing. With significant advancements in production technology, energy efficiency, and environmental stewardship, Audi is setting new standards for the industry. The Neckarsulm plant's transformation reflects the brand's commitment to achieving CO2-neutral production and delivering high-quality vehicles with minimal environmental impact.
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