GENERAL NEWS
New production principle for A2 e-tron
Audi has begun production of the fully electric A2 e-tron in Ingolstadt in Germany. The first units of the new electric model rolled off the assembly line in the presence of Bavarian Minister-President Markus Söder.
“ 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,” it confirmed.
Audi has significantly reduced complexity in the A2 e-tron. The model, said the company, combines a high level of customer benefit with significantly fewer production-relevant part numbers. 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.
“ For the first time, we are applying a‘ string-of-pearls’ production principle in Ingolstadt, a principle already successfully used at our Neckarsulm plant. The sequence of customer orders is determined six days before assembly starts and then processed across all production areas. This type of factory control has several key advantages: among other things, it reduces process complexity because a fixed sequence allows parts to be produced directly at the supplier’ s base in the correct order and packed in the designated container. We are increasing the cost-effectiveness of the production process because storage and sequencing areas are eliminated,” added Audi.
Audi manufactures the bodies of the A2 e-tron together with those of the Audi A3. More than 1,200 production components, including robot welding guns and around 250 robots that have already been used to manufacture other Audi models, are being reused or put to further use.
A high degree of automation
Audi is bringing fully automated wheel installation to the Ingolstadt site with the A2 e-tron. In addition, fully automated robotic stations are replacing the previous semi-automated bolting stations in the chassis preassembly area for the front and rear axles.
Audi is also optimising processes in the A2 e-tron body shop with“ bin picking”.
Images: @ Audi Group.
Above and below: Production of the electric A2 e-tron.
Using image processing and camera-guided robot control, the intelligent technology recognizes and picks up components. This can reduce ergonomically demanding tasks. For the first time, the robots can also remove small sheet-metal components directly from disordered containers and feed them into the next stage of the production process.
Audi Cloud and AI assistants
The industrial cloud“ Edge Cloud 4 Production” supports the digital networking of assembly. The Universal Test System for commissioning the A2 e-tron control units and the“ operator guidance,” which provides information on vehicle customisations, are centrally controlled from the cloud. This saves more than 450 industrial PCs in assembly, confirmed Audi.
Audi is also establishing a range of AIsupported( artificial intelligence) knowledge assistants across production sites. For example, the Supply Chain Chatbot helps employees to search for expert knowledge, processes and documentation. The
Maintenance Chat supports maintenance teams with fault analysis and finding solutions.
Skills for the future
In addition to technological innovation, the successful production launch of the A2 e-tron is the result of the targeted and early development of skills within the workforce. With a multi-stage concept combining hands-on training and virtual qualifications, Audi prepared employees for the requirements of manufacturing the fully electric model. This combines traditional practical modules on the assembly line with digital qualification concepts such as virtual assembly training on a screen.
“ The qualification program for the A2 e-tron strengthens electromobility expertise at the Ingolstadt site and sustainably anchors knowledge relevant to the future in the plant. Continuous employee qualification is a key factor in the successful ramp-up of new technologies and the continued development of production,” concluded Audi.
The Audi Group held steady in a challenging market environment during the first half of 2026. Geopolitical uncertainties, U. S. tariffs and intense competition, particularly in China, influenced the Group’ s business performance. At the same time, Audi is proceeding with the renewal of its product portfolio. n
www. audi. com
16 | ismr. net | ISMR October 2026