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TheAudiEnvironmentMagazine Issue 2012TheAudiEnvironmentMagazine2012TheAudiEnvironmentMagazine2012 Download the junaio app from the App Store or Android Marketplace to your phone or mobile device. Start up the junaio app and search for Audi. Encounter Augmented Reality Experience video footage with your iPhone, iPad or Android smartphone. Open the channel Audi Encounter. Scan this magazine’s images tagged with theAudi Augmented Reality Logo. AudiAudi Encounter 2 3Encounter Environment Encounter Environment 14 26 42 Friends of nature: Audi employees taking a personal interest in nature. CO₂-neutrality Within the foreseeable future, theAudi Ingolstadt site will be CO₂-neutral. Building and producing sustainably: Architect Thomas Rau and Frank Dreves, Audi Board Member for Production, in discussion. Loss turns to gain: Recuperation technology in Audi production. N 60: The new bodyshell production facility for the new Audi A3. 110 30 Saving water: Audi uses service water in a closed circuit. 90 14 Mission Possible Audi’s steps along the way to CO₂-neutral vehicle production. 22 Team Players Employee commitment is the guarantee for maximum production efficiency. 26 Passion! Passionate about the environment. Audi employees and their very personal commitment to nature. 30 N 60 A new, highly efficient facility for the new, highly efficient Audi A3. 42 Energy Conservation Resource conservation in architecture and in vehicle production. 50 Magazine Creativity in the service of theenvironment – sustainability news from around the world. 54 Tail Wind Audi uses wind energy as a basis for the CO₂-neutral mobility of the future. 74 Plan A The holistic approach to planning the factory in Győr. 82 2nd life The reconditioning of used ancillaries saves resources and material. 90 A Clear Case Using service water in a closed circuit conserves the precious resource of water. 94 Densely Populated Bacteria clean water, batteries live longer – environmental protection at the Brussels plant. 98 Pushed to the Limits How the use of innovative technology helps people to break through barriers. 102 A Clean Getaway Vehicles for export take a CO₂-neutral train ride to the port of Emden. 104 Underground Preventative measures – geologists examine the ground beneath the Neckarsulm plant. 110 Recuperation Loss turns to gain – the use of recuperation in Neckarsulm. 122 Captain Future The year 2050 – a visionary glimpse into the future of car production. 130 Green IT Sustainable and efficient – the new Computer Center at the Ingolstadt factory. 132 Greenovation Audi is developing environment technologies in close cooperation with universities. 134 Think Green Tomatoes and grass in action – operational environmental protection in Ingolstadt. 136 Clean Green Brilliant ideas – foot mats for vehicles and vacuuming robots. 138 Clean Screen Always in the picture – a monitoring system replaces paper build notes in assembly. 140 AudiEnvironment Foundation Trees, bees and bioneers – AudiEnvironment Foundation projects in detail. 146 Glossary Brief explanations of the terms used in this document. 148 AudiEnvironment Policy Preamble and principles of theAudiEnvironment Policy. 166 Imprint Contents “It is the future that lays down the law for our today.” This quote by Friedrich Nietzsche can also be applied to our present time. Raw materials are finite; the price of energy is rising and, not least, climate change has to be stopped. For us as a company, this means that we have to establish today how we want to exist sustainably. At Audi, we want to ensure a future worth living for our employees and for our customers, as well as for future generations. And we believe that success cannot be measured in financial figures alone – for us, success is expressed in many ways. Among the most important is ecological responsibility. This is something that we live and breathe every day at Audi – not because we have to, but because we believe it is the right thing to do. We are not waiting for pressure from without. The best ideas at Audi come from within. We are proud of our pioneering spirit that has made our company what it is today – and that continues to drive us. “Vorsprung durch Technik” therefore also stands behind our environmental commitment. We have made a promise to the future – with the con- scious use of raw materials and energy, we are moving step-by-step toward the CO₂-neutral factory, because the mobility of the future has to be CO₂-neutral. That means not just the drives for our cars, but also their production. It will always take energy to produce cars. But we will derive this energy in an ecological way. To achieve this, we are fol- lowing new paths in many areas of our company, researching new technologies and constantly looking beyond our horizons. At our Ingolstadt plant, we were the first to implement a Combined Heat Power and Cold facility back in 1999. District heating and heat re- covery systems are further examples of ‘clean’ production. At all of our factories, people are working every day to achieve our goal of CO₂-neutral mobility – because ecological re- sponsibility is not a matter for one person. We must all take it se- riously – we must all understand, live and breathe environmental pro tection. Whether we use bacteria in Brussels to clean waste water, or recuperation in our production; whether we bring our cars to the container port with the ‘green train’ or breathe new life into used ancillary units; whether our employees restore rivers in their spare time – we are sticking resolutely to our path. With ideas that may sometimes be a little ‘different’ – but that’s how we are at Audi. Allow yourself to be surprised by all these ideas. Happy reading! We have made a promise to the future. With the conscious use of raw materials and energy, we are moving step-by-step toward the CO₂-neutral factory. Frank Dreves Frank Dreves, Member of the Board of Management of AUDI AG, Production. The efficient solar modules avoid around 250 tonnes of carbon dioxide emissions and contribute to making Ingolstadt a CO₂-neutral site. → page 14 250 CO₂-neutral The generation and use of renewable energy is one of the prerequisites of a CO₂-neutral site. The innovative photovoltaic installation on the roof of bodyshell manufacturing for the new A3 generates around 460,000 kilowatt hours of renewable electricity every year. Standby Even the most efficient production equipment needs a break. However, it shouldn’t just be on standby, but switched off completely. A3 bodyshell manufacturing is equipped with an intelligent switch-off concept that reduces energy consumption during downtimes. 80 Intelligent weekend shut-down reduces the standby electricity consumption of equipment in building N 60 by up to 80 percent. → page 30 1,300 There is a lot to do between virtual model and start-of-production – 1,300 people work in Audi Production and Works Planning. → page 74 Thought through The use of innovative, resource-conserving technologies like hot forming in Audi production is the result of carefully thought through planning. Production and Works Planning at Audi takes a holistic approach. Ergonomics, efficiency and resource conservation take front and center. 17, 20 0 The use of the Combined Heat Power and Cold plant alone reduces CO₂ emissions from the Ingolstadt plant by 17,200 tonnes per year. → page 42 Building the future Sustainability and resource conservation play just as big a role for buildings as they do for building cars. The efficient use of energy is what distinguishes CO₂-neutral buildings and the CO₂-neutral site. Mission possible 14 15Encounter Environment Encounter Environment CO₂-neutral plant At Audi, CO₂-neutral mobility starts at the factory. In the forseeable future, Audi will declare the Ingolstadt site CO₂-neutral. 16 17Encounter Environment Encounter Environment Text Patricia Piekenbrock Illustrations Büro Achter April “A car’s carbon footprint has to be wiped out before it drives its first kilometer,” says Frank Dreves with conviction. As Member of the Board of Mana ge- ment of AUDI AG responsible for Production, he is working inten- sively on the improvement of the CO₂ balance, during the “birth phase” of a new car. And he doing so with considerable success – Audi is on its way to a carbon-dioxide-neutral site in Ingolstadt. That means that electrical and thermal energy comes entirely from regenerative sources – from biogas plants to hydropower. “Cars and their production should have as little negative impact on the envi- ronment as possible,” stresses Dreves. “Audi is linking sustainable mobility with a climate-neutral site.” Peter Kössler has been working for Audi for the last 25 years. “The growth of the company during this time has been enor- mous,” relates the Works Manager for the Ingolstadt plant. In 1986, Audi put around 350,000 cars on the roads; in the record year of 2011 it was more than 1.3 million. A total of more than 580,000 of them were produced at the company’s headquarters in Ingolstadt, as were a large number of components, delivered to other locations in AUDI AG’s global network of production facilities. In spite of increasing production volumes and although the current models are considerably more complex and equipped with far more sophisticated technologies, overall energy consumption has re- mained at a stable level. The reduction in energy consumption and associated emissions has long been a central issue in the further development of the plant and production facilities. Heavy heating oil was banned as an energy source at Audi in 1983. It is made largely from resid- ual material arising from the processing of crude oil and is still used today in many power stations. Its successor was the significantly more environmentally compatible light heating oil – a very impor- tant step at the time. This contains considerably fewer impurities, a lot less sulfur and does not require additional heating prior to combustion. Back then, the transition to light heating oil avoided 5,000 tonnes of carbon dioxide per year. In 1992, however, Audi switched to natural gas, which eased the CO₂ balance to the tune of 36,000 tonnes per year. Since 1999, an efficient Combined Heat Power and Cold facility in In- golstadt has been delivering heat, electricity and cold simultane- ously – an extremely efficient plant and truly pioneering achieve- ment by Audi. This plant produces a good proportion of the required electricity, heat and cold. The very high overall efficiency of the CHPC plant of almost 80 percent avoids 17,200 tonnes of green- house gases per year compared with conventional technology. In 2004, a further, extremely forward-looking project was the district heating connection to the city’s waste incineration plant. To date, the facility has been delivering more than 60,000 environmentally protecting Megawatt hours of heat annually, avoiding a further 12,000 tonnes of CO₂ per year. Last year even saw Audi double its use of district heating to 120,000 MWh. Further steps toward 200,000 MWh of district heating are planned. Cars and their production should have as little negative impact on theenvironment as possible. Audi is linking sustainable mobility with a climate-neutral site. Frank Dreves Audi Board Member for Production 5,000 x1983x xSwitch to light heating oilx xReduction – 5,000 tonnes of carbon dioxide per yearx 36,000 x1992x xSwitch to natural gasx xReduction – 36,000 tonnes of carbon dioxide per yearx 17,200 x1999x xSwitch to CHPC plantx xReduction – 17,200 tonnes of carbon dioxide per yearx 12,000 x2004x xSwitch to district heatingx xReduction – 12,000 tonnes of carbon dioxide per yearx [...]... the bodyshell of the new Audi A3 is built with innovative technologies on state-of -the- art equipment Efficiency and sustainability were the focal point of the planning process for N 60 production hall Experience the state-of -the- art N 60 production hall and the production of the new Audi A3 on video! www.encounter .audi. com N 60 – hiding behind the unassuming acronym is the state-of -the- art bodyshell... one half of the space, while cold outside air flows through the other half Because it rotates at two revs per minute, the heat is transferred from one airstream to the other, thus warming the cold outside air The heat exchangers in the 16 ventilation units avoid a total of 207 tonnes of carbon dioxide The waste heat from the gelling oven is used in a similar way to heat the supply air in the ventilation... protective suits to shield them from the paint particles Today, we can control the airflow – and thus the paint application – so precisely that they are no longer necessary Production is more efficient, cleaner and the working environment of the individual more pleasant And the improvements that are made at the suggestion of the employees are usually also the most sustainable For me, it is therefore important... meters and the landscape has little to offer the indigenous people Vegetation is meager and wood, the traditional fuel, very hard to come by Migration is the outcome, with all its associated social problems for the cities The EcoAndina Foundation has set itself the task of offering the people of the Puna another perspective with the help of solar energy – because, if there is one thing they have in... character Their moods depend on the weather When the weather is bad, for instance, the bees are lethargic and more likely to sting And when the weather is good, they can’t wait to get going It is always exciting and varied,” says Andreas Kopp The engineers have planted the area in a bee-friendly way, with lupines, bee trees and plants like lavender, cornflowers, chamomile and mint Alongside their eight... that they themselves discover what they can improve When they then notice that their ideas have been taken on board, it is highly motivating Audi A3 bodyshell manufacturing For me, being sustainable means dealing with resources in such a way as not to lose them Everyone that comes to this earth should be able to benefit from them, in future, too Thomas Rau 46 Encounter Environment For the new Audi. .. 365 days a year.” And it works Audi shouldn’t sell cars anymore? Rau: In my concept, the car and therefore all the raw materials for the entire lifecycle remain in the possession of the manufacturer, as a rolling store of raw materials You could say that the raw materials are temporarily configured in the form of a car And sometime in the future, these raw materials can then be reused to create something... mobility Text Johannes Köbler Photo Stefan Warter The wind – the great, clean force of nature, also delivers the drive for theAudi e-gas project Through this plan, Audi is taking responsibility for the sustainable management of natural resources – a cornerstone on the path to CO₂-neutral mobility The A3 Sportback 1.4 TCNG*, which Audi presented at the2012 Geneva Motor Show as a technical model, is... areas The principle of efficient logistics applies here, too – workers take just a few steps from the factory door to the changing rooms and are then quickly in the production area The hall is automatically ventilated during the night; during the day, however, the windows remain closed for energy reasons Plenty of daylight floods the hall, thanks to more than 2,000 square meters of glass on the north... and then fed back into the main line and onward to other consumers within the plant “This idea saves one quarter of the cooling power required for the equipment and therefore 760 tonnes of carbon dioxide every year A customer could drive more than 5.6 million kilometers in an Audi A4 2.0 TDI with that!” Lasers have become a fixed feature of modern bodyshell production; since the turn of the century, they . The Audi Environment Magazine Issue 2012 The Audi Environment Magazine 2012 The Audi Environment Magazine 2012 Download the junaio app from the App Store or Android. production. 50 Magazine Creativity in the service of the environment – sustainability news from around the world. 54 Tail Wind Audi uses wind energy as a basis for the CO₂-neutral mobility of the future. . explanations of the terms used in this document. 148 Audi Environment Policy Preamble and principles of the Audi Environment Policy. 166 Imprint Contents “It is the future that lays down the law