Communications
March 2017
B A S I C P R E S S I N F O R M AT I O N
Insights 2
Site highlights 3
*The fuel consumption and emissions values of all models available on the German market and named in this text are
listed in the last section of this basic information document.
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Insights
The largest production site of the Audi Group and the second largest car factory in Europe.
More than half-a-million cars leave the AUDI AG plant at the Ingolstadt site each year. A
record-setting 592,337 entirely built Audi models were produced in Ingolstadt last year. An
automobile drives off the assembly lines every 30 seconds, or more than 2,500 a day. The new
Audi Q2 and the Audi A5 are the highlights at Audi Ingolstadt, which also produces the Audi A3
and Audi A4 model series. The product portfolio is continuing to grow with hybrid and electric
vehicles. For two years now, the Audi A3 Sportback e-tron and the Audi A3 Sportback g-tron have
been built with the same cycle times and on the same line as the conventional A3 models. Audi
will continue to hybridize and electrify. For example, the Audi A4 Avant g-tron and
Audi A5 Sportback g-tron will expand the repertoire of climate-friendly models built in
Ingolstadt in 2017.
As the headquarters, lead plant and a high-tech site, the Ingolstadt plant plays a key role
within the Audi Group. With nearly 44,000 employees, Audi is the regions largest employer and
is also among the most attractive. Five important sites are merged into a common idea foundry
in Ingolstadt:
Audi plant headquarters with Technical Development and e-competence
High-tech production in Mnchsmnster
Audi Neuburg with the Audi driving experience and
Competence Center Motorsport/Audi Sport
Proving grounds in Neustadt
Future IN-Campus technology park
Fit for the future: Audi is preparing its German sites for electric mobility and key technologies.
Over the past years, there has been an increase in investment at the Ingolstadt site in structure
projects, production flexibilization and company-wide digitalization. A prime example of a
sustainable, digital factory of the future is being created in Ingolstadt, where developments are
consistently aimed in the direction of the smart factory. Topics such as modular assembly,
sophisticated automated guided vehicles and metal 3D printing are being expedited. Startup
initiatives serve as a bridgehead. Thinking outside the box enables creative solutions for the
future. The long-term goal of clean cars from clean factories is being implemented sustainably
at the site in Ingolstadt. Audi has been building cars exclusively with green electricity for five
years now, and the new paint shop is among the most environmentally friendly worldwide.
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Site highlights
Fit for the future the regions economic engine: With state-of-the-art manufacturing
facilities, innovative production technologies and flexible logistics concepts, the Audi Ingolstadt
site is ideally prepared for the future. The key is further flexibilization, and this is being
systematically implemented with respect to models, utilization, production lines and market
requirements. The objective is complete structural flexibilization at the site in order to realize
the vision of the intelligently networked smart factory. Continuously updating this high-tech
location and ongoing construction measures energize the region and contribute to its prosperity.
Construction projects at the Ingolstadt site: The many construction sites on the site show that
Audi has its finger on the pulse of the times and continues to evolve. New future-oriented
projects are ambitiously implemented, including:
The new topcoat paint shop with dry separation is among the worlds cleanest.
o Up to 900 bodies are painted on the shops three floors each day.
o Modern application systems conserve resources
o Ergonomically configured workplaces
The Area Sd/H6 office complex offers space for creativity and networking, and enables
modern forms of collaboration.
o Phase 1: Completed in fall 2016, 1,000 office workspaces, includes new company
cafeteria
o Phase 2: Completion in late 2017, an additional 1,500 office workspaces
Hall B in the Logistics Center: The new production and logistics hall is a pre-assembly center
for rear axles and cockpit modules with the associated logistics processes.
o Inauguration January 2017
o Usable floor space: 30,000 square meters (322,917.3 sq ft)
o Currently 530 employees (later max. 800 employees working three shifts)
Technical Developments new Design Center will offer space for 700 employees.
o Completion in summer 2017
A new body shop is being erected for a future Audi model.
o Start of construction 2016, scheduled completion 2019
o 157,000 square meters (1,689,933.9 sq ft)
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Expansions in the vicinity of Ingolstadt: The Audi site in Ingolstadt has been growing steadily
for years and expanding its footprint in the region.
Audi Manufacturing Mnchsmnster: The 48-hectare (118 acre) site is located approximately
30 kilometers east of Ingolstadt. This competence center for high-tech suspension components,
aluminum structural components and pressed parts is really hitting its stride:
In 2016, more than 20.1 million vehicle components were manufactured, and growth is
expected to continue in 2017.
Over 800 employees work here in three shifts.
Smart Factory in Mnchsmnster: Wheel hubs are built in just eight seconds thanks to a
combination of robots, 3D image recognition software and control system.
Audi Neuburg: The high-tech Audi Neuburg site is an integral element of the Neuburg an der
Donau region as well as a magnet for visitors. Nearly 20,000 visitors attended the more than
750 events held at the site in 2016.
Audi driving experience: A wide range of driver training courses has been offered here since
2014. Around 10,000 visitors from 23 countries took part in driving exercises during 2016.
Motorsport Competence Center/Audi Sport: Audi Neuburg remains the competence center
for the motorsport activities of AUDI AG. Audi Sport develops and builds racing cars, rolls out
the cars and organizes all of the races worldwide.
Audi Sport customer racing: Neuburg has been the worldwide control center for Audi
customer racing for more than one year. In addition to the Audi R8 LMS, the
Audi Sport TT Cup is also organized here.
IN-Campus site: Audi set the course for the future of the site in 2015: Through a joint venture
with the city of Ingolstadt, the company acquired the former site of the company Bayernoil in
the east of the city. The 75 hectare (185 acre) industrial wasteland will be remediated and
developed over the long term into a modern technology center. The IN Campus is a key project
for the future of Audi and the region, and is an answer to the future challenges facing the
automotive industry.
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High employment: The Audi Group further increased the number of employees at all sites in
2016 and now employs some 88,000 people worldwide, over 61,000 of whom work in Germany.
Nearly 44,000 employees work at the Ingolstadt site, of whom roughly 1,800 are apprentices or
enrolled in the dual education program.
Top vocational training: Audi increased the number of apprenticeships by around 10 percent in
2016. Roughly 550 young people started their vocational training or a course of dual
apprenticeship and higher education in Ingolstadt. The budding skilled workers will support the
company on its growth path, in particular with the current model and technology initiative. In
2016, the magazine Focus Money named Audi Germanys best training organization in the
categories Automobile and Companies with more than 10,000 employees.
Time for career and family: Audi takes account of the various life phases of its employees and
helps them to balance career and family life. There are more than 200 different working-time
models. Employees can work remotely or take a sabbatical. The company is continually
expanding the Audi Play Space child-care concept, which combines all activities relating to
child care. This includes for example reserved places in kindergartens near the plant and child-
care offers for school holidays or flexible short-term child care.
Lifelong learning: The issue of further education has high priority at Audi. Imparting and
transferring knowledge are more important than ever, as the complexity of requirements is
constantly rising. The Audi Academy is available to the employees of the Audi Group in all
matters of competence development and practice-oriented training and education. The
spectrum of subjects ranges from personnel development to personality and behavioral training,
as well as courses for technical qualifications and language skills.
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The Technical Development division of AUDI AG has its headquarters in Ingolstadt. True to the
brand claim Vorsprung durch Technik, 8,998 employees work here on innovations for the
automobiles of tomorrow. Technical Developments tasks include everything from the
development of new bodies, transmissions, engines, suspensions or vehicle concepts to design
and electrical and electronics development.
Enhancing connected collaboration: 450 employees from Development, Model Series and
Procurement are working at the SE Forum with the task of shaping the automotive future. SE
stands for simultaneous engineering the integrated and concurrent development of products
and processes. This further shortens the development cycles of new models. The tallest building
on the site is also home to a state-of-the-art test laboratory and testing equipment as well as an
innovative IT center.
Lighting the way: The Lighting Assistance Center is located in the basement of the SE Forum.
At 120 meters (393.7 ft), it is the largest drive-in light tunnel in Europe. From Xenon plus
headlights to Matrix LED-headlights and laser lights, Audi has been putting pioneering
innovations into series production for 20 years.
Perfect testing: The Acoustics, Performance, Mechanical Engineering, Material Strength and
Corrosion departments work at the Physics Center. Individual components and complete
vehicles are tested using a wide variety of measuring and testing devices. All models undergo a
realistic test program that includes everything from an exterior noise test rig to a road simulator
and level-track test rig. Suspension Development inaugurated the new Tank Technical Center in
2015. All tank systems of the Audi model range are developed and tested at this roughly
2,750-square meter (29,600 sq ft) testing and workshop facility. A new department
Automated Driving Development will be established in 2017 to pool the competences and
resources relevant to this topic of the future.
Electronics? Check! The Electronics Center is outfitted with a wide range of measuring and
testing equipment, such as board layouts of the entire vehicle electronics for testing complex
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components and a climatic roller dynamometer for simulating different weather and road
surface conditions. Audio concepts are developed in an MMI laboratory (Multi Media Interface)
and a sound laboratory. This is also the place for all aspects of in-car digitalization and
connectivity.
Windproof: The plant in Ingolstadt has its own Wind Tunnel-Center with three test units: the
aero-acoustic wind tunnel, the thermal wind tunnel and a climatic wind tunnel. Optimal
aerodynamics are honed at wind speeds up to 300 kilometers per hour (186.4 mph). The cars
interior climate control and thermal management are developed here, and the engineers work
incessantly to reduce wind noise.
Typically Audi: The number one reason for buying given by Audi customers is the progressive
and creative design. A new Design Center is being built at the Technical Development site in
Ingolstadt and will be completed in mid-2017. This is where designers, project managers and
modeling technicians will work together on the latest production models and show cars. The
focus is always on close collaboration with the engineers from the other Technical Development
departments. More than 300 designers work in Ingolstadt altogether. The Concept Design
Studio in Munich is also a key cornerstone for the development of innovative design and product
concepts.
Get in a virtual Audi: In the Design Check department, vehicle models can be viewed
realistically and with accurate details before they are ever built. The virtual reality studios make
this possible. The various materials appear tangible and life-like, giving the impression of a car
they can get into.
Weatherproof drive system: In the Engine Center, emissions and fuel consumption
measurements are carried out on roller dynamometers under climatic conditions. Driving
performance with all-wheel drive is tested in a simulation chamber at altitudes up to
4,200 meters (13,780 feet). In the adjacent workshops and modern transmission test rigs,
engines are set up and tested before they go into use. Established in 2010, the Development
and Test Center for Electrified Drive Systems features cutting-edge test rigs for testing
electrified drive concepts.
Smart production from the outset: The Audi Pre-Series Center (VSC) groups the tasks of
Technical Development and Production together in a single area of responsibility. This ensures
the economic production of the automobiles from the early development phase.
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A tradition of testing quality: For over 20 years, Technical Development has been testing new
developments in various driving situations at its own proving grounds in Neustadt an der Donau.
High-speed tests are conducted on the 4.7-kilometer (2.9 mi), three-lane oval track with two
banked corners, and performance, fuel consumption, noise, temperature and braking are also
measured.
At Audi, premium quality in automobiles means maximum body quality through efficient
production systems and new high-tech solutions. The vision is the Smart Factory the
intelligent, digitally connected factory.
AUDI AG has one of the most flexible and efficient production systems in the automotive
industry: The Audi Production System (APS) is based on the fundamental principles of cycle,
flow, pull and perfection. Audi systematically implements these principles in Production and
throughout the company, resulting in short cycle times, low inventories and a large increase
in productivity up to ten percent per year. The primary focus is the continuous improvement
process (CIP), because without sustained improvements, the companys long-term success
would be at risk.
Increasing digitalization is blazing the way for the Smart Factory the intelligent, digitally
connected factory. New high-tech solutions in production enhance the very high quality level
even further, while facilitating work on the assembly lines and ensuring better ergonomics.
Perfectly planned from A to Z: Production and Plant Planning is responsible for the planning of
all vehicle projects of the Audi brand, designing the product, the manufacturing process and the
production locations worldwide.
In close cooperation with Technical Development, Production and Plant Planning make
automobile production possible. The focus is on the customers and their requirements.
Photo-realistic models help with the visualization, analysis and assessment of customer-
relevant vehicle surfaces.
The Pre-Series Center and Toolmaking are involved in all aspects of new-vehicle development
during the prototype phase.
Production and Plant Planning and its approximately 1,600 employees establish all the
conditions for manufacturing the Audi models in maximum quality.
Leading the way in metal 3D printing: Audi stands for the high quality of car bodies by means
of small radii, homogeneous surfaces and exact dimensions. What is physically possible, and
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what can be reliably manufactured? These are the questions answered by Audi Toolmaking. The
division cooperates closely with designers, development engineers and planners. As a general
contractor, Audi Toolmaking supplies both Audi and other brands of the Volkswagen Group with
forming tools and body-manufacturing equipment.
The newly established Metal 3D Printing Center at Toolmaking produces steel and aluminum
parts from metal powder using the laser melting process. This process is now being used in
series production tools. Components for limited production vehicles could also be produced
using this method in the years ahead.
Audis Toolmaking division currently employs more than 2,300 people at five locations in
Ingolstadt, Neckarsulm, Barcelona (Spain), Gyr (Hungary) and Beijing (China);
approximately 1,100 of them work in Ingolstadt.
To meet the growing challenges with respect to quality, design aspirations and economic
feasibility, Toolmaking and press shop collaborate very closely and are organized together as
the Competence Center Equipment and Metal Forming Technology.
From sheet to complex geometries: In the Ingolstadt press shops, steel and aluminum sheets
are formed into extremely precise body parts highly efficiently and with a recycling ratio of one
hundred percent.
The modern large-capacity presses lead the field internationally in productivity.
The forming tools and tremendous press forces convert steel or aluminum rolls, called
coils, into the complex geometries of the individual parts in as many as six process steps.
Particular attention is paid to surface quality,
Approximately 1,300 people work in the press shop in Ingolstadt. Each day, they process
roughly 1,675 tons of sheet metal, including 88 tons of aluminum, into 569,000 individual
body parts.
Like magic: The Ingolstadt body shops for the Audi Q2, Audi A3, Audi A4 and Audi A5 model
series are cutting-edge production facilities featuring innovative manufacturing technologies
and maximum flexibility. Reflecting the focus on efficiency and sustainability during their
planning, they feature automatic matrix lighting control system, photovoltaic systems for
renewable power generation on the roof and energy consumption analyses.
Direct collaboration between humans and machines is already reality here: A robot helps with
the application of bonded seams in the body shop. In this man-robot collaboration (MRC), the
employee lays out the body parts and starts application of the adhesive.
The Energy Productivity at Production employee-training program, intelligent shutoff
strategies and energy-efficient system components help to conserve energy.
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3,450 employees and over 3,200 robots build bodies with maximum precision in the
Ingolstadt body shop.
For a beautiful skin: At the Ingolstadt sites paint shop, it takes several coordinated stages of
manufacturing to make a vehicle body shine in one of 30 standard colors. Quality is always top
priority, from cathodic electrocoating through basecoats to clearcoats.
Every day, the roughly 2,500 paint shop employees make sure that innovative Audi designs of
the Audi Q2, Audi A3, Audi A4, and Audi A5 models gleam in all the right colors.
The employees painting experience and intuition as well as a keen eye for detail are
essential. Highly skilled young workers are trained on the spot in the paint shops.
Audi inaugurated a new topcoat paint shop at the Ingolstadt site in 2016. The paint shop is
one of the most environmentally friendly in the world. This is thanks to the use of the latest
technologies such as air recirculation, dry separation and cleaning of exhaust air.
Modern application systems conserve resources:
o Air recirculation conserves energy and reduces organic solvents.
o Paint separation with stone dust rather than water conserves water.
The ergonomically design workplaces in the paint shop are also exemplary.
Modular assembly on the rise: In the assembly shop, roughly 8,000 people working in three
shifts assemble more than 2,500 Audi models each day, with no two cars alike each Audi is
individual. The vision is to have the worlds most efficient and sustainable premium assembly
shop.
A good example in the assembly shop is the electronic quality inspection (eQP), which serves
to ensure that the high quality requirements are fulfilled.
The electronic vehicle job card (eWBK) is also in successful operation. It displays on monitors
exactly which component the employee needs for each car.
Human-robot collaboration is also integrated into the assembly process: The robot Adam
works hand in hand with the employees without any protective fence and adjusted to their
working speed.
Assembly processes are continually being further developed with the prime objective of
minimizing complexity. The start of production of the new Audi Q2 will also involve some
innovations. The A3/Q2 assembly line is equipped with a brand new module hopper. Its
increased storage capacity is a reflection of the increasing number of different models and
variants.
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Audi seeks to master these challenges more flexibly and efficiently with a new concept,
modular assembly. Driverless transport systems such as the Paula AGV (Automated Guided
Vehicle) are a core technology of the Smart Factory and revolutionize conventional production
processes.
Logistics has become much more important in the automobile industry. The growing variety of
models is increasing process complexity along the entire value chain. Logistics at Audi ensures
that vehicle production and market supply are punctual and flexible, with minimal throughput
times and the smallest possible inventories. Because the variety of models in the plants requires
mastering complexity, Smart Factory principles are already anchored in the logistics.
Like at the airport: Audi Logistics at the Ingolstadt site introduced Truck Quick Check In. This
system directs the trucks delivering vendor parts and admits them to the plant according to
priority. The truck control point functions like an airport control tower. The self-controlled
delivery process is based on innovative geofencing technology.
Smart logistics: Another new development is automated transport of parts and vehicles. Audi
is the worlds first automobile manufacturer to combine traditional storage in a parts
supermarket with the automated guided vehicles (AGV). With this new way of commissioning
according to the goods-to-person principle, the parts are automatically retrieved and
transported to a fixed picking station. Loading of vehicles has also been automated. Ray is a
parking robot that picks up the new cars at a transfer station, sorts them by destination and
marshals them for loading onto railcars.
Just in sequence Delivery to the Logistics Center: Modern logistics is characterized by short
information and transport paths as well as by environmental awareness. The location of the
Logistics Center directly at the gate of the Audi site in Ingolstadt is the result of traffic studies
and serves to attract important logistics functions and JIS systems suppliers. The advantages of
the Logistics Center for Audi are supply reliability, the ability to master complexity and the
reduction of logistics costs.
Clever material delivery: Module suppliers fabricate their products just in sequence in assembly
centers and are responsible for delivering them to the assembly lines. Materials are delivered
directly to the assembly lines by electric tractor. The new Hall B with 30,000 square meters
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(322,917.3 sq ft) of usable floor space was inaugurated in early 2017. In this production and
logistics hall, Audi employees fabricate cockpit and rear axle modules in the pre-assembly
center, which are then delivered just in sequence to the production lines. In addition,
13 external suppliers and service providers currently supply Audi via the Logistics Center. The
Logistics Center also includes a Consolidation Center housing the CKD (completely knocked-
down) packaging plant. With short paths between Logistics and Production, conditions are ideal.
History and facts: The Logistics Center, which opened in 1995, has two investors and owners:
IFG Ingolstadt, a company fully owned by the city of Ingolstadt, and LGI GmbH, a joint
subsidiary of IFG Ingolstadt and AUDI AG. The 122-hectare (301.5 acre) site is home to 17 halls
with 486,000 square meters (5,231,260.6 sq ft). The Logistics Center strengthens Ingolstadt as
a business location, creates new jobs and reduces environmental pollution by reducing truck
traffic.
Audi vehicles have earned a reputation worldwide for peerless workmanship, premium
appearance and excellent reliability. At Audi, quality is anchored throughout the company.
Headquartered at the Ingolstadt plant, Quality Assurance coordinates and oversees matters of
quality at every Audi plant in the world. It is involved in every product process.
Impressive all down the line: Quality Assurance is already responsible for numerous monitoring
and advisory functions during the vehicle development process. It thus specifies product
requirements at an early stage during the vehicle concept phase. During the actual development
phase, the components are qualified together with the collaboration with the suppliers.
Materials Engineering then tests and validates them using cutting-edge analysis methods. All
components then receive their finishing touches on the master jig. This reference tool helps
ensure that all components interface perfectly with one another on the car body as well as in
the interior. The focus here is on a sense of premium quality by means of precise radii, seams
and clear transitions between components, but also the surface appearance and haptics of
components.
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its specifications over the long term. A model must first pass this test before it is approved for
series production.
Better safe than sorry: Quality Assurance supports the production process with numerous
consulting and monitoring functions. In Final Acceptance on the production line, the cars are
intensively inspected and tested prior to delivery. Random checks are also performed as part of
the vehicle audit or during road testing. In the case of any deviations, control loops immediately
spring into action to ensure that all automobiles that leave the plant fulfill Audis requirements.
Once a car is with the customer, service technology specialists support retailers with vehicle
servicing. The knowledge gained flows back into current series production as well as into the
development process for new Audi models.
On the road to sustainable mobility: Here it is essential that the environmental balance of an
automobiles entire lifecycle is optimized before the first kilometer is driven. AUDI AG has set
itself the target of reducing its specific CO2 emissions by 25 percent relative to 2010 by the year
2018.
There are plans to reduce carbon dioxide emissions associated with the supply of energy at
the German sites by 40 percent per reference unit by 2020. Audi is also pursuing its vision of
manufacturing all vehicles made in Ingolstadt completely CO2-neutral and with zero
wastewater.
Environmental protection also entails conserving resources. Once again with 2010 as the
baseline, the Group is striving for a 25-percent improvement in the key environmental
metrics for energy, fresh water, waste and volatile organic compounds (VOC) by 2018.
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Working together for a good cause: The Audi Volunteers initiative is celebrating its
fifth birthday in 2017. Audi bundles community service activities and supports the volunteer
efforts of its employees under this motto.
The Ingolstadt site will celebrate Audi Volunteer Day again in 2017. Audi employees will
spend the day working in the regions social institutions.
Audi also supports various social institutions in the region according to its funding guidelines.
In September 2015, the company approved one million euros for refugee assistance projects
at the production locations in Ingolstadt, Neckarsulm, Brussels and Gyr.
Currently some 50 projects are being implemented in the Ingolstadt region alone.
Focus on education and research: Audi is working in Ingolstadt and the region to make the area
even more attractive as a location for science. The company also wants to encourage young
people to study in technical and scientific fields.
Supporting Audi-endowed professorships
Scientific partnerships, such as with the TH Ingolstadt and KU Eichsttt-Ingolstadt (joint
research projects)
Science in dialogue: Lecture series with professors from Audi partner universities
Electric Mobility advanced training program for drive system developers in collaboration with
TH Ingolstadt
Procurement Management MBA program
Entry-level qualification programs to assist young people who have not been able to secure
an apprenticeship or vocational training.
Promotion of MINT: MINTmacher network, Jugend forscht science fair, Girls Day, Girls for
Technology camp
Funding of the Ingolstadt public special-profile school
In March 2017, Audi and the mentoring foundation Mentor Stiftung Deutschland are
launching a mentoring program at the Herschel School in Ingolstadt.
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Shaping mobility: Audi is working with the Ingolstadt public transit company (INVG) and
Deutsche Bahn, among others, to relieve traffic around the site.
Collaboration with Ingolstdter Verkehrsgesellschaft GmbH (INVG):
o Audi employees in Region 10 can buy the inexpensive Jobticket Bus and Jobticket
Bus/Bahn (bus/rail).
o INVG bus routes 11, S7 and S8 began servicing stops inside the Audi plant in
November 2016.
o Route X12, which has been in service since 2012, now runs through the plant more
frequently.
o New is the winter ticket (five-month pass) for employees intended to relieve rush-hour
traffic during the winter months.
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2014 Opening of Audi Neuburg: Audi driving experience and Competence Center
Motorsport/Audi Sport.
2015 Opening of Audi Academy in downtown Ingolstadt.
IN Campus: Land for future technology center in the Ingolstadt region.
2016 Inauguration of new paint shop and new office complex
Launch of new Audi Q2* SUV
2017 Inauguration of new production and logistics hall in
Logistics Center (GVZ) Ingolstadt
6 nbet
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