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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 R8, Lamborghini Huracan could get twin-charged five-cylinder

Engine downsizing and forced induction are some of the biggest trends in automotive powertrains today because. They offer the chance to reduce emissions and boost fuel economy, while possibly maintaining power. The shift is already happening to performance cars with turbocharged four-cylinders finding their way into the Ford Mustang, Chevrolet Camaro, and future Porsches. Now, there are rumblings of a tiny chance for a similar change coming for the Lamborghini Huracan and Audi R8. Why the new powertrain? China. While the market there might have slowing growth, it's still a major country for auto sales. The annual taxes on cars there also happen to be based on engine displacement, and there's a 40 percent rate on those over 4.0-liters, according to Car and Driver. The obvious answer to this conundrum is to build a smaller displacement, forced induction engine for the R8 and Huracan. Car and Driver points to the new turbocharged and electrically supercharged, 2.5-liter inline five-cylinder from the recent Audi TT Clubsport Turbo concept as a possible solution. Audi's e-turbo technology runs off a 48-volt electrical system and lithium-ion battery to produce a total of 600 horsepower and 479 pound-feet of torque in the prototype. With this mill, horsepower would barely shrink compared to the R8 V10 Plus and Lambo, but it actually makes more peak torque than their 5.2-liter V10s. While this is all theoretically feasible, take the possibility with a big grain of salt for now. According to Car and Driver, Quattro GmbH's Stephan Reil says that there's no work currently underway to fit the twin-charged five-cylinder, "but it has been talked about." That means such a vehicle is likely years away, if ever. In the meantime, a diesel version of the e-turbo setup is on the way the in the SQ7. Related Video:

Autoblog Podcast #394

Episode #394 of the Autoblog Podcast is here, and this week, Dan Roth, Steven Ewing, and Michael Harley talk about the possibility of a supercharged Dodge Viper, the Chevrolet Silverado Rally Edition, the newly released supercharger kit for the Honda CR-Z, and rumblings of an Alfa Romeo 6C. 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 rundown below with times for topics, and you can follow along down below with our Q&A. Thanks for listening! Autoblog Podcast #394: The video meant to be presented here is no longer available. Sorry for the inconvenience. Topics: Supercharged Viper Chevrolet Silverado Rally Edition Honda CR-Z Supercharged Alfa Romeo 6C In The Autoblog Garage: 2014 Ford Fiesta SE 2015 Cadillac Escalade 2015 Toyota Tundra TRD Pro 2015 Audi A8 L TDI Hosts: Dan Roth, Steven Ewing, Michael Harley Runtime: 01:32:30 Rundown: Intro and Garage - 00:00 Supercharged Viper - 44:25 Chevrolet Silverado Rally Edition - 55:19 Supercharged Honda CR-Z - 01:00:52 Alfa Romeo 6C - 01:07:29 Q&A - 01:13:41 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