Start of production in Ingolstadt
Audi integrates A2 e-tron into existing production
For the new electric model, the manufacturer is relying on existing facilities, joint body production with the A3 and fewer parts variants. More than 1,200 production components are being reused or further used.
Rather than setting up an entirely new production line, Audi has focused on integrating the A2 e-tron as efficiently as possible into existing manufacturing structures at its Ingolstadt plant. A significant share of the production equipment is being reused. More than 1,200 components, including robot welding guns and around 250 robots previously used for other Audi models, have been repurposed for the new EV.
The approach reflects a growing challenge for established automotive plants: bringing new vehicles and powertrains into existing factories without building dedicated production facilities for every new model.
A2 e-tron and A3 share body production
This is particularly evident in the body shop, where Audi builds A2 e-tron bodies alongside those of the A3. The flexible layout of the existing production equipment enables the two models to share manufacturing capacity. This kind of flexible mixed production on existing lines is becoming increasingly important as OEMs adapt plants to different powertrains and changing volumes.
Audi has not yet detailed the extent of the modifications required or the proportion of newly installed equipment. However, the extensive reuse of existing production assets is a key element of the manufacturing concept.
At the same time, Audi is increasing automation levels. The A2 e-tron introduces fully automated wheel assembly to Ingolstadt for the first time. Robot stations in front- and rear-axle pre-assembly replace the semi-automated bolting stations previously used in this area.
Further automation has also been introduced in the body shop. Audi is using bin-picking technology, with camera-guided robots identifying and picking components directly from unsorted containers. According to the carmaker, the system can now also handle small sheet-metal parts and feed them directly into the production process. This also reduces the need for ergonomically demanding manual handling.
Lower complexity simplifies logistics
A second focus is reducing product and process complexity. Audi says the A2 e-tron requires fewer production-related part numbers than previous vehicle projects, although it has not disclosed a precise comparison.
The reduction also affects in-plant logistics. Fewer part variants mean fewer material supermarkets and therefore less space required for material provision.
Audi is also introducing the so-called pearl-chain production principle in Ingolstadt for the first time, following its use at the Neckarsulm plant. Under this system, the sequence of customer orders is fixed six days before assembly begins and then maintained throughout the production process.
This allows suppliers to manufacture and pack components in the exact sequence required on the assembly line. As a result, Audi says it can reduce the need for additional storage and sequencing areas inside the plant. The system reflects the growing importance of smart sequencing in modern vehicle assembly, particularly as model and variant complexity increases.
Edge Cloud replaces more than 450 industrial PCs
The IT architecture supporting production is changing as well. For the A2 e-tron, Audi is using its Edge Cloud 4 Production to provide production applications centrally.
The universal testing system used to commission vehicle control units, as well as digital operator guidance for vehicle-specific assembly tasks, are both managed through the cloud. According to Audi, this eliminates the need for more than 450 industrial PCs in assembly.
Moving these applications away from individual shopfloor computers towards a central infrastructure is intended to simplify software updates, maintenance and the rollout of new functions. For Audi, the A2 e-tron is therefore also another step towards a more software-driven and connected production system.
The company is complementing this with AI-based knowledge tools. A supply chain chatbot gives employees access to information on processes and documentation, while the so-called mAIntenance Chat supports maintenance teams with fault analysis and troubleshooting.
Development time cut by 21 months
Audi has also shortened the product development process for the A2 e-tron. From the start of development to series production readiness, the programme took 21 months less than previous vehicle projects.
The carmaker attributes the shorter timeframe to experience gained from earlier launches, streamlined coordination processes and a higher level of vehicle maturity at an earlier stage of pre-series production.
For Gerd Walker, Audi board member for production and logistics, the project goes beyond the launch of a single model. “With the A2 e-tron, we are also showing that it is possible to build cars economically in Germany,” he said. Flexible production systems, AI applications and workforce expertise are central elements of the approach.
For Ingolstadt, the A2 e-tron is therefore also a test of how effectively a new EV can be integrated into an established plant using existing equipment, lower complexity and a leaner logistics setup. The next question will be how far these measures translate into measurable savings in investment, space requirements and production costs as the model ramps up.
