Report on the construction of the new Audi foundry in GIESSEREI (3,400 kB)

Background

AUDI is a leading manufacturer of premium vehicles with a high level of expertise in lightweight aluminum construction.

Structural components are key elements of AUDI vehicles. Die casting offers the ideal technology for meeting the complex requirements of designers: integration of various individual parts into a single casting, high strength combined with good elongation, high dimensional accuracy, low weight, weldability and bondability, process reliability, and low costs for high volumes.

AUDI wants to control the processes itself, better coordinate products and production through its proximity to design, and discuss matters with its suppliers on an equal footing. 

AUDI decided to build a completely new foundry for structural components on a greenfield site in Münchsmünster, near Ingolstadt.

AUDI commissioned PI to carry out everything from an initial feasibility study to the complete implementation of the new die-casting plant.

Results

• Factory commissioned
• Fully automated production
• End-to-end process and product data monitoring
• Implementation of the highest standards of occupational safety, environmental protection and energy efficiency

PI services

Factory planning, process planning, logistics planning

Feasibility study / Concept design
analogous to VDI 5200, phases 1 to 3

• Manufacturing segments and organization defined
  • Smelting: Smelting furnace with immersion smelting process for efficient remelting of structural parts recycling material, testing laboratory
  • Foundry: 6 fully automatic casting cells with deburring stations
  • T6 heat treatment with air quenching
  • Tool maintenance
• Logistics concept (material flow, staging areas, conveyor systems, storage systems) created
• Layout start and modular extensions created
• Resources (personnel, equipment, buildings, infrastructure) dimensioned
• Investments and unit costs determined
• Master plan for implementation created

Detailing
analogous to VDI 5200, phases 4 and 5

• Fertigungssegmente und -inseln detailliert
  • Machine layout plan created
  • R+I diagram for media supply and disposal created
  • System list created
  • System technology specified (specifications)
• Conveyor technology specified (specifications)
• Plant and conveyor technology tendered, quotations obtained and prepared for award
• Interfaces with engineering offices for construction and technical development serviced
• Budget and schedule drawn up

Implementation
analogous to VDI 5200, phases 6 and 7

• Details agreed with suppliers
• Interfaces with customers (planning, production, maintenance) and other suppliers or service providers (construction, media, crane service, etc.) coordinated, solutions developed
• Proper performance of individual services monitored and controlled
• Commissioning, rectification of defects, MFU/performance tests and acceptance coordinated
• Budget (investments) tracked
• Project progress recorded: minutes, photos, schedule

Topics

Process design: Process cost calculation, vertical integration

Factory planning: Value stream, production segments, material flow, layout, scalability, step-by-step expansion, facilities/infrastructure/buildings, cleanliness, environmental protection

Process planning: Process engineering, plant engineering, simulation of capacity requirements, automation, interlinking, energy efficiency, IT, control technology, machine and process data acquisition, Industry 4.0

Logistics planning: Simulation of movements/inventories, load carrier design, transport technology, fire protection

Trades

Charging, melting, dosing, casting, spraying, removing, cooling, deburring, burr disposal, marking, heat treatment T6, testing, straightening, WBK, mechanical processing, packaging, transport, storage; automation, interlinking; buildings, pits, foundations, ventilation technology, cranes, media, infrastructure