ABB Smart Painting Robots Enhance Safety and Sustainability at Audi Changchun NEV Factory

As the electric vehicle (EV) market continues to expand rapidly, automakers are increasingly focusing on production safety, environmental sustainability, and employee well-being alongside efficiency and quality. ABB’s recently deployed automated painting robot system at Audi’s Changchun New Energy Vehicle (NEV) factory exemplifies how advanced technology can transform manufacturing processes while creating a safer and greener workplace.

Automation for Enhanced Safety

The Changchun factory’s painting workshop features 47 ABB robots, including IRB 5500 seven-axis painting robots, IRB 5350, and IRB 6700 series units. These robots now perform tasks that were previously high-risk for human operators. Han Chen, ABB Group Senior Vice President and President of Robotics in China, stated, “By automating hazardous painting tasks, we enable workers to stay out of harmful environments, significantly improving workplace safety.”

Traditional painting operations expose employees to high concentrations of chemical solvents and paint aerosols, which can pose long-term health risks. ABB robots precisely control spray paths, angles, and paint volume, ensuring uniform coatings while dramatically reducing the presence of harmful substances in the workshop. Zhao Huan, head of the Painting Project at Audi FAW Manufacturing, commented, “Robots now handle the most dangerous aspects of the painting process. Employees focus on monitoring and managing operations, which not only improves safety but also enhances job satisfaction.”

High-Efficiency, Eco-Friendly Production

ABB’s IRB 5500 robots are equipped with the RB1000i-S high-transfer-efficiency atomizer, which increases paint utilization by approximately 15% while cutting paint waste by nearly 50%. This reduces raw material consumption and VOC emissions, supporting sustainable and environmentally friendly manufacturing practices.

The system’s compact layout, combined with the “Stop-go” operation mode, allows interior spray processes to be completed within a single station, reducing the factory’s floor space usage by approximately 25%. This design not only boosts production efficiency but also decreases energy consumption, aligning with Audi’s global “Mission: Zero” initiative for sustainable and low-emission operations.

Improving Employee Experience

Automation not only enhances safety and environmental performance but also improves employees’ working conditions. Manual painting previously required long hours of standing, repetitive high-intensity labor, and exposure to chemical agents. By shifting these tasks to robots, employees now focus on monitoring, analyzing data, and maintaining equipment, reducing physical strain and occupational risks.

The Digital Painting Suite platform provides real-time production data and a user-friendly interface, enabling staff to quickly assess workflow status and identify potential issues before they escalate. This data-driven approach improves operational transparency, reduces errors, and enhances employees’ sense of control over the production process.

End-to-End Smart and Sustainable Painting

ABB’s robotic painting system covers the entire process, from cleaning and basecoat application to clearcoat spraying and surface inspection. IRB 5350 and 6700 series robots handle automated pre-treatment for hoods, doors, and trunks, while IRB 5500 seven-axis robots perform high-precision painting. The integrated Digital Painting Suite monitors coating thickness, color consistency, and surface texture, ensuring that every vehicle meets Audi’s stringent quality standards while minimizing waste and emissions.

Predictive maintenance enabled by the digital platform ensures potential equipment issues are identified before causing downtime. This reduces maintenance costs, prolongs robot life, and enhances production reliability, further integrating safety, efficiency, and sustainability into daily operations.

A Model for Sustainable Manufacturing

The collaboration between ABB and Audi demonstrates how automation can simultaneously achieve operational excellence, environmental responsibility, and employee welfare. ABB’s robotic solutions support high-quality production while reducing material consumption, emissions, and exposure to workplace hazards, providing a model for green and human-centric manufacturing.

As the global EV industry continues to grow, industrial automation technology will play an increasingly important role in ensuring safe, efficient, and environmentally responsible production. ABB’s solutions at Audi Changchun exemplify the powerful synergy between robotics, digitalization, and sustainable practices, providing valuable insights and a benchmark for other automotive manufacturers worldwide.

Conclusion

ABB’s robotic painting solutions at Audi’s Changchun NEV factory achieve a comprehensive upgrade in safety, environmental performance, and employee experience. The IRB 5500, 5350, and 6700 series robots, equipped with the RB1000i-S atomizer and integrated with the Digital Painting Suite, create a fully automated, space-efficient, environmentally friendly, and intelligent painting workshop.

This project demonstrates the successful integration of smart manufacturing with sustainability and human-centered design. It sets a benchmark for the global EV industry, showcasing how robotic automation and digitalization can simultaneously enhance safety, efficiency, and environmental responsibility, supporting Audi’s zero-emission and green manufacturing ambitions.