Last week, we reported that the Audi A3 assembly line has earned the Automotive Lean Production Award for streamed line production processes and exemplary excellence; as promised today we’ll look into detail at this highly efficient assembly process.

The Audi A3 assembly line established an industry benchmark thanks to Audi’s philosophy of focusing on continuous improvement.

At the Ingolstadt site, 1,800 employees work in a three-shift schedule to assemble approximately 800 units of Audi A3 and Audi A3 Sportback every day. In total the assembly sector encompasses 28,000 square meters incorporating more than 150 distinct processes via a streamlined chain of operations and seamless workflow which are the product of continuous improvements.

The A3 assembly process is firmly focused on the employees with an emphasis on ergonomics, cushioned floor coverings, perfectly organized material magazines and an ergonomically designed assembly seat facilitates the installation of head airbags.

What is more fascinating is that simple ideas often have the greatest impact and nearly all improvements are suggested by the employees themselves.

Peter Kessler Plant Manager at the Audi Ingolstadt site, said:

“Our employees drive our progress, and their expertise is our primary asset. Their supply of suggestions is inexhaustible and we implement every good idea as speedily as possible. An improvement in ergonomics automatically boosts quality and enhances efficiency.”

One of the principles that most impressed the Automotive Lean Production Award Judges about the Audi A3 assembly line, was the One-Touch-One-Motion principle, which denotes the possibility of completing a task with a single hand motion thanks to intelligently positioned materials and equipment.

Adjacent areas to the Audi A3 assembly line also play an important role in the overall workflow. Arrangement and pre-assembled parts organized in a fishbone configuration near the line guarantee the smooth flow of the process.

Audi knows that a happy employee is a motivated employee that is why Audi has an employee suggestions scheme where employees can suggest improvements and modifications to help make the assembly line more efficient, if a suggestion is approved and it saves Audi money a considerable share of this is paid in gratitude to the contributing employee.

Last year alone Audi received 33,460 suggestions worldwide which consequently saved Audi 50 million Euros.