The new Audi A2 e-tron is already in production

Audi unveiled the new A2 e-tron just a few days ago, and today the company has already started production of the new model at its plant in Ingolstadt, Germany. The first units rolled off the assembly line in the presence of Bavarian Minister-President Markus Söder.

Audi says the development of the new A2 e-tron was shortened by a whopping 21 months compared to "previous vehicle projects". This was made possible by the use of fewer parts and measures to reduce complexity, space requirements, and "logistics effort".

For the first time, Audi is applying the "strings-of-pearls" production principle in Ingolstadt, after successfully implementing it at its plant in Neckarsulm, Germany. This enables the sequence of customer orders to be determined six days before the assembly starts.

This reduces complexity because a fixed sequence lets suppliers directly produce parts in the correct order and pack them in a designated container. Audi is increasing the cost-efficiency of the production process because storage and sequencing areas are no longer required.

The flexible layout of Audi's facilities lets it produce the A2's bodies together with those of the A3. Fully automated robot stations are installing the wheels, and robots can even remove small sheet-metal components directly from "disordered containers" and feed them into the next production step.

The company is using "a range of AI-supported knowledge assistants across production sites". There's a Supply Chain chatbot which "helps employees search for expert knowledge, processes, and documentation", while a maintenance chat "supports maintenance teams with fault analysis and finding solutions".

The production process of the new A2 represents "an example of the transformation of Audi", the company says, with production being less complex and more automated. At the same time, "people remain a central factor in success", with modern technologies providing "targeted support for employees in their tasks".