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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.

Meet the first of four Audi A4s coming to our long-term fleet

Yes, you read that right, this is the first of a quartet of A4s we'll be looking at over the course of the year. We're kicking things off with an Audi A4 Premium Plus sedan, and we'll be looking at other iterations of the A4 line later on: the A4 Prestige, Allroad, and S4. What we hope to do is provide you with a thorough examination of each variation, and hopefully give you some guidance on what's worthwhile and what isn't. But first, let's introduce you to the A4 Premium Plus. What we got The A4 Premium Plus is the middle child of the standard A4 line, fitting between the entry-level Premium and the top level Prestige. Stepping up to the Premium Plus adds 18-inch alloy wheels, LED headlights, an S Line body kit, Bang & Olufsen sound system, parking sensors, aluminum window trim, and heated power seats with memory. The model we received from Audi has a number of upgrades that bring it quite close to the Prestige trim level. Most notable is the Technology package, which adds the Audi Virtual Cockpit instrument panel, which replaces the physical gauges with a big LCD screen. It also comes with rear cross traffic alert. A First Edition package was added, too, which adds cooled sport seats, a three-spoke steering wheel, and unique wheels and aluminum interior trim. Our favorite part, is the sport package, which adds sportier suspension, a black headliner, and the aforementioned sport seats. What we skipped Really, we didn't skip much here – this particular A4 Premium Plus is pretty loaded. The only packages not included were the Cold Weather package, which includes heated rear seats and steering wheel, and wheel and tire options. The heated steering wheel isn't necessary since winter is almost over (at least we hope). The cost of these packages added up fast, too. Moving up to the Premium Plus trim over the standard Premium added $3,800. The Technology package was $3,250, the First Edition package was $1,100, and the Sport package tacked on $750. Along with the white paint at $575, our Audi has over $9,000 in options. That brought our tester up to $49,825 from a base MSRP of $40,350. We like everything that's been added. If we were to pick packages we could live without, though, we'd probably pick the Technology and the First Edition packages. As slick as the LCD instrument panel is, there's nothing wrong with physical needles and dials.

Recharge Wrap-up: Smart metals, OTA updates, Rolls-Royce LNG ship

"Smart" metals could help engines reduce emissions and invigorate US business. Metallurgist and University of Wisconsin – Milwaukee professor Pradeep Rohatgi combines known metal alloys with materials like ceramics, nanoparticles, and recycled waste to produce strong, lightweight composites with self-lubricating properties that help internal combustion engines run more efficiently. Rohatgi hopes his startup, Intelligent Composites, and its products can help US foundries compete with production outsourced overseas. See the video above, and read more at Phys.org. Almost 203 million cars will be capable of over-the-air (OTA) updates by 2022, according to ABI research. While Tesla has the OTA firmware updates nailed down, other automakers will focus on software update capability. This will take the place of dealer-installed updates and - like Chrysler did after the Jeep hacking incident - updates sent to owners via USB drives. OTA updates will enhance vehicle security and reduce recall rates. Read more at Green Car Congress. European bus manufacturers have agreed upon a standardized charging interface for their electric buses. Irizar, Solaris, VDL and Volvo will use pantograph charging for "opportunity charging" and CCS plugs as the base for overnight charging and network communication. The manufacturers hope other bus makers and charging providers to join them in cooperation over standardized charging. Read more at Green Car Congress. The second Audi Autonomous Driving Cup will take place from March 22 to 24, 2016 at the automaker's Museum Mobile in Ingolstadt, Germany. The competition involves eight university teams implementing basic Audi software in 1:8 scale electric Audi Q5 models, and putting them through the paces of simulated real-world driving situations. The teams develop software architecture to use the suite of sensor to have the cars drive, park, maneuver in traffic and perform emergency braking autonomously. Teams also perform a freestyle event where they put the car through an additional task of their choosing. The winning team gets ˆ10,000, with smaller prizes for second and third place. The competition also gives the students the opportunity to showcase their skills in front of a potential employer. Read more at Green Car Congress. Rolls-Royce will provide the Liquefied Natural Gas (LNG) propulsion for an NSK cargo ship carrying fish food. The ship will deliver 2,700 metric tons of fish food to fish farms along the Norwegian coast.