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At its Ingolstadt facility, Audi assembles and stores wheels before they are being shipped to its car production plant. The automated material handling system was built by Vanderlande Industries.


Each wheel consists of a tyre and a rim. Depending on the required combination, wheels and rims are selected from storage and sent to the assembly process. On 3 assembly lines the tires are placed on the rims,  inflated and tested. The assembly belt system is based on batches to optimise its utilisation rate. The finished wheels are temporarily stored in a four-crane miniload system, sufficient for 3 days of production (10,000 positions).

Based on the production sequence, wheels required for a particular car are automatically retrieved from the miniload system and sorted according to their final position on the car (1st: front left wheel, 2nd: front right wheel, 3rd: back left wheel, 4th: back right wheel, 5th: spare).

The wheels per car (4 or 5) are combined and stacked before they are shipped to the car production facility,  located 2km away. The stacks of wheels are pre-positioned in front of the truck based on the required production sequence. On two levels inside the truck there are 3 conveyors that hold 3x18 stacks. A similar setup on two levels is created inside the factory, to minimise loading time. During the automated loading process all data for each shipment are transmitted to the truck's PLC.