Vehicle production is one of the pillars of Audi Hungaria. Audi models have been produced in Győr since 1998 under a cooperative production system with the Ingolstadt plant. Thanks to the expansion of the plant, the vehicle factory was commissioned in autumn 2013. As a result, Audi Hungaria now covers the entire manufacturing process: from the pressing and lacquering of body parts to the final assembly.
Cars have been manufactured in Győr for more than 20 years. Vehicle manufacturing started in 1998 with the series production of Audi TT models at Audi Hungaria. Production of the second generation of the Audi TT Coupé and Audi TT Roadster in Győr started in 2006. Series production of the Audi A3 Limousine started in June 2013, followed by the Audi A3 Cabriolet in October at the vehicle factory covering the entire manufacturing process. Production of the third generation of the Audi TT Coupé and Roadster started in 2014. The one millionth car rolled off the production line in 2016. In October 2017, the 500,000th car rolled off the production line at the new vehicle factory. In 2018, the series production of the first SUV from Győr started: the second-generation Audi Q3. For the production of the new, sporty, second-generation Audi Q3, a new 150,000-square-meter body shop has been built, where 700 new robots have been installed.
In addition to the Audi RS Q3 and RS Q3 Sportback, the sporty Q models in the Győr-based product portfolio, Audi Hungaria has started series production of the Q3 and Q3 Sportback models with mild hybrid drivetrains (MHEV, Mild Hybrid Electric Vehicles). Both models are powered by a 1.5-liter TFSI engine from Győr together with a 48-volt on-board network and a belt-driven starter-generator (Riemen-Starter-Generator, RSG). Audi Hungaria's first plug-in hybrid model, an Audi Q3 Sportback in turbo blue, rolled off the production line in December 2020. Plug-in hybrid technology is based on a classic combustion engine and an electric engine powered by a lithium-ion battery.
The company has integrated the production of plug-in hybrid models into its existing vehicle manufacturing infrastructure. In the body shop, new equipment and robots have been installed for the production of modified and new body parts. A PHEV-specific workstation has been set up in the vehicle assembly shop, where, among other things, charging connectors are installed. As always, the focus in workplace design is on ergonomics. For example, when installing the high-voltage battery and the tank, a special lifting device is used to help the employees.
Audi Hungaria has prepared and trained 1,500 employees in theoretical and practical training sessions for the production of PHEV models. In addition, several Hungarian employees supported the production of the Audi e-tron in Brussels, the Volkswagen ID.3 in Zwickau and the ramp-up of the SEAT Leon PHEV in Martorell, where they gained valuable experience.
The Experimental Powertrain Manufacturing Center has been supporting Volkswagen Group powertrain projects from inception to series production for ten years. These projects involve close collaboration between production, production planning and design from an early stage of development. The Experimental Powertrain Manufacturing Center ensures a smooth transition between the development phase and series production by producing experimental and pre-series powertrains and testing new power units and production technologies.
Audi Hungaria's Experimental Powertrain Manufacturing Center was opened in 2010 with the aim of integrating the experience gained in series production into the development process of powertrains. Since then, new competences have been added to the Center's activities: the experts of the Experimental Powertrain Manufacturing Centre support powertrain projects across the Group. In doing so, they coordinate entire projects, from the receipt of the order to the delivery of the powertrains to the customers.
Future-oriented technologies such as 3D printing, virtual testing and virtual powertrain assembly are available in the workshops of the Experimental Powertrain Manufacturing Center. The use of virtual technologies is becoming more and more important to achieve significant time and cost optimization, as well as to increase production efficiency.
Ten years ago, the Experimental Powertrain Manufacturing Center started with just 20 employees, and today we have 200 highly skilled employees. In the meantime, our competence center has also become responsible for electric drives. The area supports high-level training for the next generation through scientific cooperation. The External Department of the Audi Hungaria Faculty of Automotive Engineering at the Experimental Powertrain Manufacturing Center has supported the theoretical training of more than 200 students with practice-oriented education.
One building houses all the fields of specialization related to experimental powertrain production and the functions that cover the whole process of ramping up series production. This includes project coordination, product and process optimization, cutting, assembly, quality management and logistics related activities.
Our activities form a bridge between the development and series production process. Powertrains of the future arrive in our area in an experimental phase, before series production. Through our optimization and development activities, we ensure that powertrains arrive on the production line in perfect condition with perfect parameters ready for series production.
Audi Hungaria has been producing power units for the Audi and Volkswagen Groups since 1994. Since then, the company has grown to become one of the world's largest powertrain factories, with employees having produced more than 37 million power units in Győr.
Production is divided into two parts: mechanical production and powertrain assembly. Currently, more than 3,500 machines and equipment are used for the mechanical production of the 5 main components (crankcase, cylinder head, crankshaft, camshaft, crank) and the assembly of powertrains. Final assembly is carried out in 8 powertrain assembly shops on 28 different mechanical production lines using state-of-the-art production techniques.
- The company's more than 5,500 employees produce vehicle powertrains for the Volkswagen Group's 37 vehicle manufacturing sites.
- Of the 1,661,599 powertrains produced in 2020, 1,211,769 were three- and four-cylinder petrol and diesel engines.
- Our employees produced 11,007 five-cylinder petrol engines, 241,295 six-cylinder petrol engines and 95,438 six-cylinder diesel engines, as well as 14,747 eight- and ten-cylinder engines. 87,343 electric drives were produced in Győr.
In 2020, Audi Hungaria produced five different Otto engine and three different diesel engine variants, as well as an electric drive range with a power output of 63 kW (86 hp) and 470 kW (639 hp).
- Series production of the electric drive range at Audi Hungaria started in June 2020. The new electric drives are built into the Audi e-tron S models. The Audi e-tron and Audi e-tron Sportback S models feature three electric drives from Győr, two of which provide 370 kW of boost power and 973 Nm of torque at the rear axle.
- Audi Hungaria employees produced the 38 millionth powertrain in July 2020: the four‑cylinder, 2.0-liter, TFSI Global Engine was built into an Audi Q3. The engine is part of the third generation of the engine range, which has been in production since 2019, with a power output of 170 kW (231 hp) being the most powerful engine in its category.
- A new generation of the 2.0-liter TFSI power unit has been introduced. In 2019, this engine type was named “International Engine of the Year” in the 150-250 hp category. The four‑cylinder engine is one of the most flexible and versatile engines ever developed.
- The new generation “Evo 3” V6 TDI engine has also been produced in Győr since 2020.
Since 2018, electric drives have also been produced in Győr, and their share is growing strongly. In 2020, our daily production capacity increased to 720 electric drives/day. The innovative equipment and production islands needed to manufacture the e-motors have been installed within a year. In Győr, E-Motor Development, Production Planning and the Experimental Powertrain Manufacturing Center have worked closely together to build up the necessary competences. Employees of the E‑Competence Center have become practical experts in e-motor manufacturing.
Since 2005, Győr has been home to one of the largest tool shops in Central Europe, which has grown from 18,000 square meters to 52,000 square meters, and where 700 employees now develop press tools and bodywork production equipment. In addition, bonnets, doors, tailgates, fenders and side panels for the exclusive and supersport models of the Audi and Volkswagen Groups are also produced, including the brand new Audi e-tron GT, various Audi RS models, the Audi R8 and Lamborghini, as well as the Bentley Bentayga models, all of which are the result of the professional work at the Győr-based tool shop.
More than 700 employees at the tool shop in Győr produce body parts for the exclusive and supersport models of the Audi and Volkswagen Groups on an area of more than 50,000 square meters. In 2016, the next phase of the expansion of the Tool Shop began, with 15,000 square meters of additional space added in 2017, increasing capacity for future projects. In 2017, four new presses with a capacity of up to 2,500 tons were installed. In 2018, Audi Hungaria increased its exclusive series production capacity in the tool shop. Thanks to the capacity increase, in the future the tool shop will supply body parts for 120 individual models every day. Tool and device manufacturing and exclusive series production are at the cutting edge of technology. The product portfolio consists of production equipment for exterior body parts, mainly made of aluminum.
Here you'll find large presses that can apply up to 25,000 kilonewtons of clamping force to workpieces with 50-ton tools. Translated into everyday language, imagine 1,278 Audi A8 cars on top of each other pressing down on the plates with their combined weight to get the desired shape.
Since 2020, the body parts for the Audi e-tron GT, the top-of-the-range electric model, have also been produced here. Almost all body parts of the Audi e-tron GT are manufactured exclusively by Audi Hungaria. The Gran Turismo's doors, fenders, bonnets and tailgates are also made by the tool shop employees.
As part of the Audi Group's international production network, Audi Hungaria is making a major contribution to the project: the highly complex aluminum body parts of the electrically powered Gran Turismo are produced in the Győr-based tool shop. The highly complex exterior body parts, such as bonnets, doors, tailgates, fenders and side panels, produced in Győr, are used in Audi sports models such as the Audi RS, Audi R8, Lamborghini and Bentley Bentayga.