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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.

KTM X-Bow to get Audi TT-RS five-cylinder turbo

The Audi TT-RS continues to occupy a warm spot in my personal top five list of cars thanks in no small part to the lusty turbocharged 2.5-liter five cylinder under the hood. With 360 horsepower and 343 pound-feet of torque in stock configuration, the engine is a shining star of internal combustion. And now it's headed to one of our favorite vehicles. EVO reports KTM is planning to plop the turbo 2.5 from the TT-RS into the upcoming X-Bow. That ruckus you hear? It's a choir of angels singing "Halleluiah." While speaking at the Geneva Motor Show, KTM CEO Stefan Pierer said the engine is good for up to 480 horsepower.
Pierer went on to say that the company is already testing prototypes and that we may very well see the engine show up in some races next year. What's more, the company's engineers are playing with dual-clutch transmissions, too. Since KTM is already testing the turbo 2.5 on the track, it's only a matter of time before customers will be able to get their grubby mitts on a street-legal version.

2017 Audi S4 First Drive

For all its power and easy performance, the best thing about the last Audi S4 was its uncanny ability to act like a normal (but very high-spec) A4 for most of its life. Then, when you needed or wanted a bit more speed or a bit more grip, you pushed a button or opened the tap and it became something else. It became a thing with more grip, more poise, more focus, and more gristle, but the changeover between the two S4 characters was seamless. That doesn't seem to be the case with the new one. The latest, B9 A4 has been well received and is probably the best mid-sized premium car out there, so that should have left the S4 a simple job to become the best warmed-up premium mid-sizer. It hasn't quite happened like that. The spec sheet suggests the S4 should come out on top in the fight with the BMW 340i and the Mercedes-AMG C43, but the numbers aren't everything. The engine seems impressive on paper; the all-new EA838 3.0-liter turbocharged V6 was jointly developed with Porsche (and it's closely related to Porsche's next V8, with which it will share non-internal bits like the camshaft chain). The 60-degree V6 weighs 31 pounds less than the old S4's supercharged V6, and it's replete with variable valve timing and lift, centrally mounted fuel injectors, and both direct and indirect fuel injection. That gives it 354 horsepower at 5400-6400 rpm (up 6.5 percent) and 369 pound-feet of torque from 1,370 to 4,500 rpm. That gives it a peak 44 lb-ft higher than the old one, spread across a band 600 revs broader. At 2,000 rpm, where drivers live every traffic light, it has another 74 pound-feet. That's enough motivation to move to 62 mph in 4.7 seconds. There's a new all-wheel-drive system that usually shoots 60 percent of the torque to the back but can ramp that up to 85 percent when it needs to, or it can swing it around to fire more than 70 percent to the front axle. The category benchmarks suggest turbocharged 3.0-liter gasoline sixes are the thing to have, with the Mercedes-AMG C43 using one, the 340i BMW having one (though it's straight), and Maserati's Ghibli also using one. The oddball is Jaguar's XE S, which uses a supercharger. You know, like Audi just ditched. The S4 trumps all but the C43 on power (the nine-speed Benz has 362 hp). While it ties the Ghibli for torque, it again trails the Benz (by 15 lb-ft) though its torque peak hits far earlier (the Benz waits until 2,000 rpm).