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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.

Audi Sport sets up new shop in Neuburg

Racing fans may know Audi best for its Le Mans team that's positively dominated the endurance racing scene. But as formidable as its Le Mans program is, that's only one of the racing disciplines in which Audi competes. It also competes in the full FIA World Endurance Championship, as well as Germany's popular DTM touring car series and supports customer teams in GT racing series around the world. And now the competition division is getting a new headquarters.
Audi Sport has until now been based in an old supermarket near to the company's head offices in Ingolstadt, but is now moving into a brand new, state-of-the-art facility 12 miles to the west in nearby Neuburg. The result of some 20 years of planning and two years of construction, the complex covers 116 acres of land in Neuburg-Heinrichsheim and will house engineers, technicians and other staff who deal with the R18 E-Tron Quattro, the RS5 DTM and R8 LMS Ultra that compete the world over.
The facility was officially opened this past Saturday with participation from top Audi brass and local government officials and included demonstrations from all three of those racecars around the on-site test track. The works team has begun moving in and the customer racing department will move into its new Motorsport Competence Center in the first half of 2015.

Next Audi TT glimpsed, same as it ever was?

Audi has teased the new TT coupe ahead of its Geneva Motor Show reveal with renderings and video, but now, what appears to be a photo of the new two-door has leaked onto the web, courtesy of Autofans.be. And if you're thinking, "Well, jeez, that looks familiar," you definitely aren't alone. Aside from the new lighting character in the taillamps, everything you see here looks pretty much unchanged from the old car. Of course, the front should get a nice freshening, and that interior should be super-high-tech. We'll reserve final judgments until we see the new TT live in Geneva next week.