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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.

The Audi RS5 takes aim at the BMW M4 and Mercedes-AMG C63

The current generation of the Audi A5 has soldiered on for the past 10 years, an eon when it comes to automobiles. Though we've seen and driven its replacement, the new car hasn't quite made it to market. As with most of Audi's lineup, the car is expected to come in three versions. While the full reveal and first drive reviews of the A5 and S5 took place late year, until now we haven't had a peek at the range topper Audi RS5. It sits on Audi's B9 platform shared with the Audi A4 sedan. Essentially, it's Audi's equivalent to the BMW 4 Series or the Mercedes-Benz C-Class coupe. In the case of the RS5, compare it to the BMW M4 and the Mercedes-AMG C63. Like its rivals, the RS5 sits longer, lower, and wider than its sedan stablemate. The RS features aggressive front and rear fascias and a set of unique wheels. While the styling of the new model may look evolutionary, it is indeed all-new inside and out. The two cars in these photos are wrapped in camouflage that covers everything below the beltline. The general shape of the bodywork looks the same, but the front and rear are slightly restyled. The front now has larger air intakes in the corners and a lower chin spoiler. Out back, the dual single-exit exhaust pipes give the RS model away. The S5, like all S models, features quad exhaust tips. The rear bumper is slightly modified, but all in all it's not far off from the A5 and S5 models. Audi's styling is always conservative, so this should come as no surprise. There's no word as to what's resting under the hood, but look for forced induction and six cylinders, possibly pulling something from the Porsche Panamera. As with every other Audi performance car, power will be sent to all four wheels through the latest generation of the Quattro all-wheel drive system. Look for a full reveal in the next few months, possibly as soon as March at the Geneva Motor Show. Related Video:

Autoblog Podcast #390

Episode #390 of the Autoblog Podcast is here, and this week, Dan Roth, Steven Ewing and Sebastian Blanco from Autoblog Green talk about the 2015 Ford Mustang specs, the 2016 Smart models, a proposal to add real-world numbers to EPA economy tests and the potential downside of autonomous cars. We start with what's in the garage and finish up with some of your questions, and for those of you who hung with us live on our UStream channel, thanks for taking the time. Check out the new rundown below with times for topics, and you can follow along down below with our Q&A. Thanks for listening! Autoblog Podcast #390: The video meant to be presented here is no longer available. Sorry for the inconvenience. Topics: 2015 Ford Mustang specs 2016 Smart FourTwo and FourFour EPA wants road tests The downside of autonomous cars In the Autoblog Garage: 2014 Nissan Leaf 2015 Audi A3 Sportback E-Tron 2014 Scion tC Hosts: Dan Roth, Steven Ewing, Sebastian Blanco Runtime: 01:33:35 Rundown: Intro and Garage - 00:00 Mustang Specs - 34:40 2016 Smart Models - 51:14 EPA Tests - 01:02:57 Autonomous Cars - 01:11:19 Q&A - 01:21:22 Get the podcast: [UStream] Listen live on Mondays at 10 PM Eastern at UStream [iTunes] Subscribe to the Autoblog Podcast in iTunes [RSS] Add the Autoblog Podcast feed to your RSS aggregator [MP3] Download the MP3 directly Feedback: Email: Podcast at Autoblog dot com Review the show in iTunes Podcasts Audi Ford Nissan Scion smart Electric Hybrid