Audi boosts Ingolstadt production of A3 Sportback e-tron

Article by Christian A., on November 21, 2014

Audi is increasing the production of A3 Sportback e-tron at its main plant in Ingolstadt. The plant is expected to come out with 50 cars on a daily basis. Audi AG Board of Management Member for Production Dr. Hubert Waltl revealed that the production of the A3 started last summer and with the integration of the assembly work to the line, there is no more need to separate the manufacture of the different parts.

Waltl adds that this shows not just the flexibility but also the efficiency of those who plan the production as well as its employees. Audi hopes that the A3 Sportback will change how people will view mobility.

The A3 Sportback is a five-door vehicle with a 1.4-liter engine and 75-kW electric motor. This combination allows the car to have a 204 horsepower output with a fuel consumption of 1.5 liters for every 100 kilometers.

The A3 can go as far as 50 kilometers on the electric motor alone and when coupled with the engine, can go an additional 890 kilometers. Waltl disclosed that the plant had initially increased its output to 30 cars per day before going up to 50 cars per day.

Audi hopes to increase the output in the near future. Ingolstadt plant head Peter Kössler shares that while the production of the new model was initially seen as a new challenge, the plant has adapted to this and even mastered it.

Sporty, adaptable, and practical -- Audi introduced the all-new A3 Sportback. The five-door compact model with the roomy luggage area is innovatively lightweight thanks to ultra-light technology. The engines are forceful and highly effective. The infotainment has intuitive connection tech, and along with the available driver assistance systems, it has the all-new Audi A3 Sportback setting new standards in the premium compact group. The total design ethos focuses on the fundamentals, with every single element of design making an assured aesthetic point.

Being lightweight is a prerequisite for a car to be sporty and efficient. Audi’s ultra-lightweight technology reduces the new Audi A3 Sportback’s weight by almost 90 kilograms (198.42 lb) over the prior version. With the 1.4 TFSI engine, the five-door model’s curb weight (with no driver) is only 1,205 kg (2,656.57 lb).

Hot-shaped steel for the occupant cell of the all-new A3 Sportback reduces the weight also. The full occupant cell is 37 kg (81.57 lb) lighter in total compared to the prior model. Considerable reductions in weight also came from changes inside and with the engine. Audi is a global pioneer in lightweight constructions and has significantly reversed the weight curve and again set a new benchmark.

All-new Audi A3 Sportback’s body is lengthy and slender. While the 4,310-mm length (14.14 ft), 1,780-mm width (5.84 ft), and 1,425-mm height (4.68 ft) of this new vehicle are only a little more than on the prior model, the wheelbase is considerably longer at 2,636 mm (8.65 ft), increased by 58 mm (2.28 in).

The front end is lowered; the roof arch reaches across a dome extending beyond the slight roof spoiler to the brawny tail. The three side windows’ design is tight, with all the details accurate and dramatic. The big wheel wells emphasise the athletic aspirations of the new A3 Sportback.

Press Release

On the line and on time: Production of the Audi A3 Sportback e-tron

Production of the Audi A3 Sportback e-tron: Assembly – On the engine and component assembly line, the electric motor and transmission are fitted to the engine.

Approximately 50 cars every day, with the same timing and on the same assembly line as the other models: Audi is now ramping up production of the Audi A3 Sportback e-tron*.

The premium manufacturer is producing its first plug-in hybrid model at the brand's main plant in Ingolstadt."We started series production of the Audi A3 Sportback e‑tron in the summer," said Dr. Hubert Waltl, Board of Management Member for Production at AUDI AG.

"Most of the assembly work is integrated into the A3 line; no separate manufacturing is necessary. That demonstrates the flexibility and efficiency of our production planners and employees."With the Audi A3 Sportback e‑tron, Audi is launching the mobility of the future. The compact five‑door combines a 1.4 TFSI combustion engine with a 75 kW electric motor, resulting in a total system output of 150 kW (204 horsepower).

Despite the sporty driving performance, fuel consumption in the NEDC is just 1.5 liters per 100 kilometers (35 grams of CO2 per kilometer). The A3 Sportback e‑tron can travel up to 50 kilometers in purely electric mode and up to 890 kilometers more with the gasoline engine."We first of all ramped up production of the A3 Sportback e‑tron to about 30 cars a day in September," explained Board of Management member for Production Waltl.

"Our peak is approximately 50 units each day now. In any case, we are keeping additional capacity available."Peter Kössler, head of the Ingolstadt plant, stated: "Working with high‑voltage systems in series production was a new challenge for us, but we mastered it well. At all stages of assembly, we achieve maximum levels of safety for our employees and quality for our customers."

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