The Audi site in Bratislava
AUDI AG manufactures its premium Audi Q7 model in Bratislava, the capital of Slovakia. More than 2,200 employees in Volkswagen Slovakia’s most advanced factory build this sports utility vehicle (SUV) from a large number of individual components.
The manufacturing of the Audi Q7 gives evidence to genuine teamwork within the Audi production network. Audi’s German factories in Ingolstadt and Neckarsulm produce the body elements while all engines for the Audi Q7 are supplied by Audi’s engine manufacturing plant in Győr, Hungary. Production of the Audi Q7 in Bratislava began in late 2005. Total investments are in the triple-digit million euro range. A total of 54,562 of Audi Q7 were built in Bratislava in 2012.
The key production area is the body shop, set up specifically for the Audi Q7. In this building, which has an area of more than 62,000 square meters (667,400 sq ft), the bodies for this premium SUV take shape in 56 work cycles, using 220 steel and aluminum parts. The integrated aluminum process has been adopted from Audi A8 production at Neckarsulm, to ensure that this light alloy is handled expertly on the production line. The building therefore had to be completely gutted and fitted out with new machinery and equipment. 368 employees work there, in four shifts.
In total, each car body needs more than 3,400 spot welds; the conventional weld seams, for instance, measure a total length of almost 100 meters (328 ft). Laser-joined seams measuring more than six meters (20 ft) in length are also used on the body and the tailgate.
A total of 520 paint-shop employees apply the correct color to the car body. The parts are then joined together in the assembly area. The entire hall covers an area the size of 21 soccer fields. Separate assembly and testing rigs have been installed for the Audi Q7’s special equipment and electronics items. The assembly process comprises 165 steps. Around 1,309 assembly workers are supplied with components on a just-in-time basis. The 17 suppliers are located in the immediate vicinity of the plant premises.
On completion, every Audi Q7 has to pass checkpoint 8, the last one on the production line. From there, vehicles are moved to the test track about 800 meters (2,600 ft) away on the factory site, which covers 1,780,058 square meters (19,160,385 sq ft). On the 2.4-kilometer (1.5-mile) asphalt-surfaced oval track, each Audi Q7 is put through a precisely defined program before being transported by train and truck to Audi’s distribution network.
Facts and figures
Chairman of the Board of Management: Prof. Rupert Stadler
Chairman of the Supervisory Board: Prof. Dr. Martin Winterkorn
Employees (AUDI AG): 50,150 (as at: December 31, 2011)
Employees (Audi Group): 68,804 (as at: December 31, 2011)
Deliveries to customers (2012): 1,455,123 Audi brand automobiles
Production (2012): 1,469,205 automobiles (incl. Lamborghini and CKD)
The Audi site in Bratislava
Site: VOLKSWAGEN SLOVAKIA
Start of production: 2005
Employees: 2,200 (as at: December 31, 2012)
Models: Audi Q7
Production (2012): 54,562 automobiles