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Production 4.0: Audi plans for the smart factory

Automotive production is becoming more integrated and at the same time has to be more intelligent and more efficient. Flexible production of customized vehicles is one of the big challenges for the future, especially for a premium carmaker like Audi. How will the "Vorsprung durch Technik" brand meet its aim of offering premium quality with added custom flexibility? The company sees the "smart factory" as the key. Whether it's body-color moldings or light-alloy wheels in a special size, almost every car is ordered with some kind of customization, and the demands are increasing. This requires of course already a lot of flexibility. While the variety of models and quality demands are increasing, automotive manufacturers such as Audi are eager to make production sustainable. In an Audi interview, innovation management members Alois Brandt and Henning Loser talk about "production 4.0" and the upcoming "smart factory." How will Audi manage the production site with its very high standards of quality, efficiency, and environmental acceptability? Will the so-called "smart factory," which should be the intelligent factory of the future, only employ robots? Alois Brandt: "With a deep look into the production, I am convinced that our employees and not machines are the relevant working forces behind the Audi brand. Machines can be bought anywhere." Increasing digitalization is paving the way for the smart factory – the intelligent, digitally connected production facility. New high-tech solutions in manufacturing should further increase the high level of quality, while at the same time the assembly work should be easier and result in better ergonomics. Can you give us a clearer imagination of the "smart factory"? Alois Brandt: "There are a lot of ideas. But the big question at the moment is: Which one is really needed and leads into the right direction?" Can you tell us a little bit more about "production 4.0"? Alois Brandt: "The assembly line as we know it in the present will no longer play the same role. If it makes sense, it will be terminated and replaced by – let's call it – a virtual assembly line. The production will be more modular than before and the car will be directed to a production point – a so-called 'island of competence' – where it is needed." Henning Loser: "If the vehicle is to be assembled to the customer's wishes, it is obvious that efficient programming of robots and coordinating with the human workers is needed.

Suspended VW exec Hackenberg resigns in wake of scandal

Ulrich Hackenberg, father of the innovative modular architecture that underpins many modern Volkswagen and Audi products and a 30 year veteran of the giant company, has resigned his position as the lead engineer for the entire Volkswagen Group as well as his seat on Audi's management board, reports Automotive News. The resignation closes out a two-month suspension while the investigation into VW's deceptive emissions practices continues.The resignation follows the admission by Audi that the 3.0-liter TDI V6 engine was also fitted with emissions-control defeating software, like some of its four-cylinder TDI counterparts. In turn, this lead to changes in Audi's management structure. AN reports that Matthias Muller, who has already taken over Martin Winterkorn's position as VW Group CEO, will also be named chairman of the Audi brand.Hackenberg's successor was named as part of this announcement. Stephan Knirsch, who has lead engine development at the Audi division, will assume Hackenberg's roles as both board member for Audi in charge of technical development, and as the head for technical development across the whole group.Related Video:

IIHS gives 90 models its Top Safety Pick award in one fell swoop

Although the Audi A7 and the Toyota Sienna are positioned on completely different ends of the automotive spectrum, they overlap in one important area: both earned a Top Safety Pick+ award from the Insurance Institute for Highway Safety (IIHS). They're among the 49 cars that received the distinction for 2021, while 41 additional models scored a Top Safety Pick (without the plus) award from the institute, bringing the number of winners to 90. Earning a coveted Top Safety Pick award from the IIHS is easier said than done. Recipients need to score a good rating in the institute's six crash tests, be available with a front crash prevention system that scores a superior or advanced rating in vehicle-to-vehicle and vehicle-to-pedestrian evaluations, and be offered with (but, crucially, not necessarily fitted standard with) headlights that are either good or acceptable. Vehicles that have good or acceptable headlights across the full range, regardless of trim level, are eligible for the Top Safety Pick+ award. The Hyundai Group (which includes Hyundai, Kia, and Genesis) earned more awards than any other carmaker, with 12 standard Top Safety Pick distinctions and five earning a Pick+. Volvo led the Pick+ chart with its entire lineup of nine vehicles. At the other end of the spectrum, Mitsubishi still hasn't earned a single award, and General Motors only nabbed one of each. Safety is spreading across market segments, according to the IIHS. It pointed out that, in 2020, there were no minivans or pickup trucks on the list of Top Safety Pick recipients. Fast forward to 2021, and the list includes the Honda Odyssey, the Toyota Sienna, and the Ram 1500 crew cab; the first two earned a Pick+. The full list of 2021 award winners is on the IIHS website. Note that, for some models, only units built after a certain date earned an award. This distinction reflects a change (usually in headlights) during the production run. Cars sold in the United States are safer than ever, but automakers still sell vehicles with a zero-star crash test rating in many global markets. Suzuki's 2020 S-Presso flunked a reasonably basic round of tests in 2020. Featured Gallery 2021 Hyundai Palisade View 12 Photos Audi Hyundai Volvo