SHERIDAN, WYOMING – April 7, 2025 - New in-house innovation sharpens precision and speeds up production for the Audi e-tron GT
Audi is redefining production precision with the introduction of a cutting-edge innovation called “Agile Shimming.” Developed and implemented entirely in-house by Audi teams in Neckarsulm and Ingolstadt, the new technology is now in use at the Audi Sport plant at Böllinger Höfe—bringing a new level of automation and accuracy to body shop operations.
Agile Shimming enhances precision in real time
“The measurements clearly show that agile shimming has made us even more precise,” says Wolfgang Shanz, Head of Audi Sport Production at Böllinger Höfe. “It is also noteworthy that the project was developed and implemented entirely in-house. ‘Agile’ describes not only the technology, but how we work.”
Previously, shimming—fine-tuning parts by tenths of a millimeter—relied solely on the experience of skilled employees. This process involved adding or removing ultra-thin metal shims at strategic clamping points to ensure components were perfectly aligned. While effective, the manual approach depended heavily on craftsmanship and could be time-consuming.
Now, Audi has connected this process to an automated control circuit in its two-way framer. Thanks to a smart algorithm and real-time measurement feedback, the system can automatically adjust positioning with unmatched precision. A linear motor makes micro-adjustments based on the data from the in-line measurement station, ensuring optimal fit without manual input.
Innovation born at Böllinger Höfe
Böllinger Höfe, home of the Audi e-tron GT, plays a key role in Audi’s journey toward a smart, digitalized production environment. Known for its small-series production capabilities, the site serves as a testing ground for forward-thinking technologies and agile processes.
The deployment of agile shimming at Böllinger Höfe reflects Audi’s commitment to continuous innovation and digital transformation. The body shop there operates as a real-world laboratory, where technologies are not just developed but applied in live production scenarios—accelerating learning and implementation across the brand.
“Agile” defines both the tech and the teamwork
The term “agile” in agile shimming represents more than just the mechanics. It reflects a broader mindset shift within Audi’s production philosophy. The close collaboration between teams in Neckarsulm and Ingolstadt showcases how Audi employees are driving change through teamwork, adaptability, and innovation.
The success of agile shimming underscores Audi’s ability to lead with internally developed, high-tech solutions that meet the growing demands for production efficiency and dimensional precision—especially critical in electric vehicle manufacturing where body design and aerodynamics are crucial.
A step forward for smart factory ambitions
This advancement also ties into Audi’s long-term vision of a fully connected smart factory, where machines, data, and people work in perfect sync. Agile shimming contributes directly to this goal by reducing manual intervention, minimizing tolerances, and enhancing product consistency.
By integrating agile technology into its manufacturing processes, Audi not only ensures top-tier craftsmanship for the e-tron GT but also lays the groundwork for broader application across its future electric and hybrid vehicle lineup.
Innovation consumers can feel in every drive
While agile shimming happens behind the scenes, its benefits are tangible for consumers. Tighter tolerances mean better build quality, enhanced driving dynamics, and a noticeable improvement in vehicle finish—hallmarks of the Audi experience.
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To learn more about Audi’s latest production technologies and the future of electric mobility, visit www.audi.com or follow Audi on social media.