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More intensive use of simulation technologies than ever before

³The Audi Q7 represented uncharted territory for Audi ± both in its own product range and on
the competitive scene. The market had no similarly sporty and dynamic, but also spacious,
multifunctional vehicle with off-road capability to offer. To achieve this position was the special
challenge our development teams had to face.´

Almost 5,000 people work in Technical Development at AUDI AG. Since 2002, many of them
will have been engaged to a greater or lesser degree on the project bearing the internal Audi
number AU 716: the development of the Audi Q7. But in addition to the many technical
departments, experts from Production, Toolmaking, Quality Assurance and Marketing were
brought in from the first concept and design sketches onwards. There can be no doubt that
creating a vehicle such as the Audi Q7 is one of the most complex tasks encountered anywhere
in industry. So many of the tasks it involves can only be hinted at or described in brief here.

At Audi, the engineers, designers, mathematicians, physicists, industrial chemists, mechanics,

shop-floor personnel, electronics and IT experts work in virtual computer worlds, on crash
circuits, test rigs and other test equipment, in wind tunnels ± or in worlds of the senses. But they
have all contributed to a fine result: a third-generation sports utility vehicle (SUV)




One of the most important reasons for buying a car has always been its appearance ± in other
words, its design. The designers are the first people to concern themselves with a new vehicle
project: they give the idea its actual shape. Even for the Audi Q7, the process starts in a µclassic¶
way, with pencil and sketch pad. Audi Q7 design project manager is Canadian Dany Garand,
who recalls: ³The Audi Q7 design process was a special challenge for our team. We had to create
a product that was totally new for Audi, and bring the normally rather crude design of an SUV
into harmony with Audi¶s formal idiom. The kind of SUV on the market today would not have
suited us.´
The varied demands that this vehicle segment has to satisfy in the European, American and
Asian markets also had to be taken into account. Garand comments: ³Consumer profiles in
Europe and overseas are distinctly different, and during the design process we had to bear these
regional patterns of life in mind. This included the Audi Q7¶s overall size, its maximum capacity
of seven seats, specific storage facilities and even new colour concepts both inside and out.´

Audi¶s large SUV project acquired concrete form midway through 2002. Garand explains: ³After
the concept had been largely finalized, we succeeded in developing and building the fully
functional Audi Pikes Peak Quattro show car in only six months, so that it could be shown to an
international public at the Detroit Motor Show. We wanted to establish how the public would
react to our vision for this vehicle segment.´

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1.? To understand the car manufacturing process, you have to understand the underlying
supply chain that drives domestic vehicle assembly. Today's cars are primarily "sourced
out" to produce various sub-assemblies in over 4,000 disparate locations as far away as
China. This means a car's "production" plant is an active assembly point, where skilled
workers and robotic systems bring together all of the necessary loose components to create
a final product on a "just-in-time" basis.



2.? The chassis of the car is the baseline component. All other parts are integrated on, or
within the chassis. This is typically a welded frame that's initially attached to a conveyor
that moves along a production line. As the frame progresses, the car is literally "built from
the frame up" to create a final product. Parts that are sequentially applied to the chassis
include the engine, front and rear suspension, gas tank, rear-end and half-shafts,
transmission, drive shaft, gear box, steering box, wheel drums and the brake system.

À 

.? Once the "running gear" is integrated within the frame, the body is constructed as a
secondary process. First, the floor pan is positioned properly, then the left and right
quarter panels are positioned and welded to floor structure. This step is followed by
adding the front/rear door pillars, the body side panels, rear deck, hood and roof. The
entire process is typically executed by robotic machines.



4.? Before painting the vehicle, a quality control team inspects the body as it sits. Skilled
workers look for dents, abrasives or other deformations that could create a finishing issue
when undergoing the painting process. Once this step is completed, the car is
automatically "dipped" with primer, followed by a layer of undercoat and dried in a heated
 paint bay. Once the primer/undercoat process is finished, the car is again "dipped" with the
base coat and again dried before moving the assembly to the next stage.




5.? After the structure is entirely painted, the body is moved to the interior department in the
plant. There, all of the internal components are integrated with the body. These
components include: instrumentation, wiring systems, dash panels, interior lights, seats,
door/trim panels, headliner, radio, speakers, glass, steering column, all weather-striping,
brake and gas pedals, carpeting and front/rear fascias.


À  


6.? The two central major assemblies are next mated for final setup and roll-out. Again, this
process is executed via computer and control machines (C&C) to ensure speed, and
perfect the fit between the body assembly and the chassis. Once the car is rolling on its
own, it's driven to the final quality control point, inspected and placed in a waiting line for
transportation to its final dealer destination.









 

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Below are just a few of the models that we offer Audi auto parts for:

100 5000CS QUATTRO A4 Quattro V6 0V A6 Quattro V8 4.2L General Purpose

80 5000S A4 Quattro V6 0V A6 V6 2.7L Turbo QUATTRO

90 5000S QUATTRO A4 Quattro V6 0V A6 V6 2.8L-12V S4

200 80 QUATTRO A4 Turbo 4 CYL 20V A6 V6 2.8L-0V S4 AVANT

4000 90 QUATTRO A4 Turbo 4 CYL 20V A6 V8 4.2L S4 Q Twin Turbo V

5000 90 QUATTRO SPORT A4 Turbo 4 CYL 20V A8 S6

100 QUATTRO 90 SPORT A4 Turbo 4 CYL 20V A8 QUATTRO S6 AVANT

100 S4 A4 A4 V6 2.8L-12V A8 Quattro V8 4.2L S8

100LS A4 AVANT A4 V6 2.8L-0V A8 Quattro V8 4.2L TT

200 QUATTRO A4 QUATTRO A6 A8 V8 .7L TT

4000CS QUATTRO A4 QUATTRO AVANT A6 QUATTRO ALLROAD QUATTRO TT QUATTRO

4000S QUATTRO A4 Quattro Turbo 4CY A6 QUATTRO AVANT CABRIOLET TT Quattro

5000 QUATTRO A4 Quattro Turbo 4CY A6 Quattro Turbo V6 Cabriolet V6 V8 QUATTRO

5000 TURBO A4 Quattro Turbo 4CY A6 Quattro V6 12V COUPE

5000CS A4 Quattro Turbo 4CY A6 Quattro V6 0V COUPE QUATTRO

A4 Quattro V6 12V A6 Quattro V8 4.2L FOX

Some of our categories are:

Air Intake Body Electrical Body Mechanical & Trim Body Sheet Metal Brake Climate Control Clutch Cooling System
Diesel Injection Drive Belts Driveshaft & Axle Engine Electrical Engine Mechanical Exhaust Fuel Delivery Fuel Injection
Steering Suspension Tools and Hardware Transmission

Some of our popular parts are:

2 door (2d), 4 door Ceramic Brake Engine Controls Hydraulic Power Break Stem
(4d) Pads Engines ICU Units Strut
4 door coupe Clamps & Evaporator, Idler bearring Power Steering Stub Axle
4x4 Front Axle Parts Hardware Evaporators Ignition Control Pump Suspension
A/C Blower Motor Clutch Assembly Exhaust Gasket Unit Pressure Suspension
A/C Compressors Clutch Hydraulic Exhaust Ignition Modules Pressure Plate Bushings
A/C Condensors Clutch Master Manifold Injection Sensor Primary Wire Suspension Kit
A/C Evaporator Cylinder Exhaust System Instrument Pump & Motor Switches
ABS Clutch Slave Pipes Instrument, Radio Assemblies Tail Lamp
Accessory Cylinder Expansion Intake Push Rod Cover Tail Light
Accumulator/Filter Coil Packs Receiver Intake & Exhaust Racing air filters Tail Light
Drier Coil Springs Exterior Manifold Rack and Gear Assembly
Accumulators Compressor w/ Exterior Trim Interior Radiator Tank
Actuator Clutch Assembly Fan Clutches Leveling Radiator Fan T-Belt Tensioner
Air Conditioning Compressor with Fender, Bumper, Suspension Radiator Hose Spring
Air Hose Clutch Valances Light Radiator Temperature
Air Meter and Valve Compressor Final Drive Lighting Pressure Cap Terminals,
Alternator without Clutch Flange Line and Hose Radiators Connectors
Anti-Drainback Computer (BCM) Flywheel Lock Braking Rear Main Seal Thermostat
Valve Condenser, Front Lights System Rearview Throttle
Assembly Condensers Front Panel Lubrication mirrors Tie Rod End
AT Clutch Controlers Fuel Cap Main Bearing Set Refill Timing Belt
AT Filter Control Arm Fuel Distributor Master Cylinders Relays Timing Cover
AT Shift Control Cooling Fan Fuel Injector Metallic Pad Release Tools,
Automatic Core Fuel Pump Mirrors Retrofit Accessories
Transmission Corner Lamp Full Gasket Sets Modulator Rocker Panel Torque Struts
Ball Joints Corner Light Fusebox and Modulators Rod Bearing Transmission
Battery Cables Crankcase Relay Mount Rotors Mount
Blower Motors Crankshaft Fusible Link Muffler,Mufflers RWD Turbocharger
Body Cruise Control FWD Nut Driveshafts Turn Signal
Booster CV Joints Components Offset Shaft Kits Safety By Universal Joints
Boot CV Shafts Gas Oil Coolers Seals Import (Foreign)
Bottom Cylinder Head Gasket Oil Filler Seat, Door Domestic (USA)
Bumper Cylinder Head glass Oil filters Locks Valve, Valves
C.V. Joint Gasket Guide Oil Pan Senders & Valve and
Cable, Lock and Differential Halfshafts Oil Pressure Sender Solenoids Regulator
Lever DIS Control Hanger Oil Pump Sensors Valve Blocks
Cables Modules Head Gaskets Orifice Tubes Shock Absorber Valve Cover
Caliper Disc Head Lamp O-Ring Side Rear Left Voltage
Caliper (Calipers) Disc Pads Head Sets O-ring kits Right Regulators
Cam & Bolt Distributor Caps Header Pipe Overdrive Silicone Wire Water Outlet
Cam Plug Distributor Rotor Headlight Oxygen Sensor Solenoid Water Pump
Camshaft Door and Window Assembly P/S Spark Plug Water Temp
Carburetion Part Heater Parking Brake Spindle and Weatherstrip
Carburetor & Fuel Door Handle, Heater Cores Pass Valve Housing Wheel
Injected Armrest Heavy Duty PCV Valve Spring Wheel Bearing
Carburetor Parts Drain Plug Caps Grommet Starter Wheel Cylinders
Catalyst Drier High Pedal Steel Spring Windshield
Catalytic converter Driers Performance Piston Ring Set seals filter Wipers
Central Lock System Drive Belts Hood and Trunk Steering, Wiper and
Drum Shoes Horn Suspension Washer
EGR System Hose Steering Wiper Blade
Electric pump Hub Column Insert
assembly Steering Wiring Harness
Electronic Module Damper
Engine & Steering
Emission Control Linkage
Engine Control Steering Rack
Computers Steering Wheel