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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.

Why we can't have better headlights here in the U.S.

It wouldn't be a European auto show if we weren't teased with at least one mainstream vehicle we can't have here. At the Geneva Motor Show last week, the small but vocal contingent of shooting-brake buffs lamented that the Mazda6 wagon won't be coming to our shores, although they can take comfort in the fact that the vehicle won't get the torquey 250-horsepower 2.5-liter turbocharged gasoline engine we'll get here. Mercedes-Benz also announced a new headlight technology in Geneva that likely won't be available here anytime soon. It's just the latest in a long line of innovative and potentially lifesaving front-lighting solutions that the federal government doesn't allow in this country due to outdated standards — and a current lack of leadership at the U.S. Department of Transportation. Mercedes-Benz's new Digital Light system that debuted in Geneva uses a computer chip to activate more than a million micro-reflectors to better illuminate the road ahead. The Digital Light headlamps works with the vehicle's cameras, sensors and navigation mapping to adjust lighting for the given location and situation and to detect other road users. The Digital Light technology also serves as an extended head-up display of sorts by projecting symbols on the pavement ahead to alert drivers to, say, slippery conditions or pedestrians in the road. And it can even project lines on the road in a construction zone or through tight curves to show the driver the correct path. Digital Light will be available on Mercedes-Maybach vehicles later this year, although like any technology it's bound to trickle down to less expensive vehicles. That is, if we ever get it here in the U.S. Audi, a leader in automotive lighting, has repeatedly run into snags trying to bring state-of-the-art car headlights to the U.S. The German luxury automaker's recently introduced matrix laser headlight system, which performs many of the same trick as Mercedes-Benz's Digital Light, also isn't legal on U.S. roads. And five years after the introduction of its matrix-beam LED lighting, which illuminates more of the road without blinding oncoming motorists with brights by simultaneously operating high and low beams, Audi still can't bring that technology to the U.S. either.

Jon Olsson's 1,000-hp Audi RS6 Avant stolen at gunpoint, burned

Swedish professional freeskier Jon Olsson loves some insanely modified vehicles, like his Rebellion R2K, but tragedy recently struck for one of his crazier former rides. The custom Audi RS6 Avant was a wild wagon with DTM-inspired bodywork and an engine tuned to a claimed 1,000 horsepower. Unfortunately, the machine was stolen in a brazen armed robbery. Making matters even worse, the crooks torched the car at the end of their joyride. Olsson drove the tuned RS6 in this year's Gumball 3000, and later sold it to a dealer in the Netherlands, according to Auto Evolution. Recently, the wagon was taking part in a photo shoot in Amsterdam. That's when two armed men showed up to steal the Audi. Somehow in the chaos, the robbers' van caught fire, and they got away with the RS6. The criminals weren't too clever, though, because they didn't think to grab the key from the owner's pocket, Car Throttle reported. That would have made the Audi much more difficult to start again, if they shut if off. Although, that apparently never became a problem. The crooks sped off and eventually dumped the car before police were ever able to get them. In a final act of destruction, the thieves also incinerated the one-of-a-kind RS6. An investigation is ongoing. Olsson's Instagram post below shows how little is left of this once incredibly cool wagon. "But now I am more motivated than ever to follow this build up with something just as good," Olsson wrote on his website. Poor poor #RS6DTM Such a sad sight! ??? Who would do such a thing! #hurtsmyheart A photo posted by Jonolsson1 (@jonolsson1) on Oct 15, 2015 at 8:03am PDT Related Video: