Zwickau produces models as diverse as the compact ID.3 from Volkswagen and the Q4 e-tron, an SUV from Audi. However, when it comes to what’s inside, the cars have a lot of similarities. The bumper, for example: the design is different, but the screws, tools and grips are the same. Robert Pahlow can count more than 120 instances of “identical concepts”. And the models from Zwickau are also closely related when it comes to the software. This is facilitated by the shared technical basis – the Modular Electric Drive Matrix (MEB). Volkswagen’s vehicle architecture developed specifically for electric drive gives long ranges, plenty of space inside and strong performance.
Efficient production 1 plant – 6 models: How VW builds electric cars in Zwickau
Since a few months, the all-electric ID.5 is coming off the production line at Volkswagen’s Zwickau site – this is the sixth electric model to come from the car plant in Saxony. One factory – six cars: an extraordinary challenge. Experts Robert Pahlow (Head of Product Management) and Frank Schemmel (vehicle production) explain how it works.
1. Identical assembly concepts
The models from Zwickau are closely related when it comes to the software. This is facilitated by the shared technical basis – the Modular Electric Drive Matrix (MEB).
2. Flexible change
Production is extremely versatile: various measures, such as a special indicator (“PR number”), guide the different models to the respective production line with so much precision that employees always know which parts they need to install. To keep up with the high demand for electric cars, two production lines are in operation – one for the ID.3 and CUPRA Born, and the other for the ID.5, Q4 e-tron and Q4 Sportback e-tron. The ID.4 can be built on either line – as needed. Overall, the Volkswagen plant has completed six model start-ups for three of the Group’s brands in the space of two years.
The production pros at Zwickau can schedule the electric SUV ID.4 on either of their two production lines – allowing the plant to adapt flexibly to demand.
3. Fewer variations
Volkswagen is doing away with superfluous differences while maintaining a wide variety for customers. One example of this is body construction. While the Zwickau plant built more than 100 body versions for previous Golf models, often there are only two variations for the latest electric models. The advantage being more efficient production and reduced costs.
4. Fresh knowledge
Volkswagen invested 1.2 billion euros in converting Zwickau, to make it the first major vehicle production plant to only build electric cars. Training all 9,000 of the employees was a key factor. The Zwickau workforce completed more than 20,000 days of electric mobility training – 1,500 employees alone have obtained the high-voltage driving licence.
5. Even greater pride
Zwickau has produced powerful cars such as the Golf and Passat in the past – but electric mobility has made the site a pioneer. “Zwickau has been in the Champions League of automotive engineering since the start-up of the electric models. This is something many people can identify with,” said Frank Schemmel. The additional pride is reflected in high quality and high levels of commitment.
The Zwickau workforce started preparing for their new tasks well before the first electric models entered production – trainer Frank Schönfelder teaches two employees.
Start of a new era: in the presence of the then Chancellor Angela Merkel, the first of a new generation of electric vehicles rolled off the production line at the end of 2019 – a white ID.3.
6. Strong team
It’s not just the core workforce working at the multi-brand plant in Zwickau – they are supported by teams from Volkswagen, Audi and CUPRA. More than 100 specialists from each brand help with the model start-ups, including experts in production, development, procurement and quality assurance. Even after the vehicle start-ups, Volkswagen experts from other plants, as well as Audi and CUPRA specialists remain at the Zwickau site. Robert Pahlow: “This is hugely beneficial because it allows us to clarify many questions quickly.”
Teams from three brands work on the various models at Volkswagen’s Zwickau site.
Six electric cars from Zwickau
Volkswagen ID.3 – the pioneer
The ID.3 was the first Volkswagen based on the modular electric drive matrix (MEB).In its very first year on the European market, the compact model with the likeable face attracted more than 144,000 customers.
Volkswagen ID.4 – the global car
100% SUV – 100% electric: the ID.4 is the first all-electric SUV from Volkswagen, and the brand’s first electric global car. A car for Europe, China and the US. It’s part of the biggest market segment in the world, the compact SUV class.
Volkswagen ID.5 – the top-of-the-range model
The ID.5 is the first electric SUV coupé from Volkswagen classed as premium. The ID.5 and the sporty ID.5 GTX with twin engine four-wheel drive captivate with expressive design, long-distance capability and the latest software.
CUPRA Born – the passionate one
Beautiful. Powerful. 100% electric: the CUPRA Born. The brand’s first all-electric model is built for passionate driving. The CUPRA Born is the perfect match between electrification and performance.
Audi Q4 e-tron – the all-rounder
Diverse all-rounder with a progressive design: the Audi Q4 e-tron. Like the sportback model, it combines new spatial dimensions inside with pioneering solutions when it comes to operation, display and assistance systems.
Audi Q4 Sportback e-tron – the sustainable one
Everyday electric mobility for every situation – this is what the Audi Q4 Sportback e-tron offers. Like the Q4 e-tron, Audi’s production of the Q4 Sportback e-tron is also net-zero climate neutral. Around 26 recycled 1.5-litre plastic bottles are used to make each seat.
