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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 also calling in A8, S8 over sunroof issue

The S6 and S7 (apparently prone to potential fuel leaks) aren't the only Audis being recalled currently, as a separate recall notice has been issued for its flagship A8 luxury sedan and its high-performance counterpart, the S8.
The problem apparently revolves around the glass sunroof, which is fitted as standard and which is reportedly prone to break. The National Highway Traffic Safety Administration determined that not only could the falling shards themselves end up injuring the vehicle's occupants, but could also distract the driver enough to cause a crash. As a result, Audi's American wing is bringing in all 2013 and 2014 model year A8s and S8s - 1,120 units in all - to have their glass sunroofs replaced free of charge.

2016 Audi TT Second Drive [w/video]

The original Audi TT is a modern style icon. But having a one-time design hit isn't a recipe for longevity. In order to succeed, you have to bolster style with substance. Thankfully, that's exactly what Audi did with its third-generation TT. Now more than ever, the TT is a proper sports car, and it debuts with a host of new technology. The car still looks good, but it's no longer a one-off masterpiece. Instead, it takes many of the original TT's elements and incorporates new bits of modern detailing. The shape is all TT – the roofline, the wheel arches – even smaller details like the fuel filler cap and exhaust outlets moved closer to the center of the vehicle pay homage to the original car's design. But the new car's face is more angular, more robotic. Park the new R8 next to this TT and the family resemblance is clear. "It's fair to say that the new car hasn't been comprehensively reconceived; it's been comprehensively re-detailed," says associate editor Jonathon Ramsey, who first drove a Euro-spec TT back in September. It's a good move, a way to "keep the icon alive," according to Audi AG exterior designer Dany Garand. But the better news is that the rest of the car is more than just a comprehensively re-detailed machine. Launch a TT coupe from a stop and you'll hit 60 miles per hour in 5.3 seconds. The TT rides on the same modular MQB architecture as the Volkswagen Golf. The whole package is the same length as before, but the wheelbase is stretched by 1.5 inches. At 3,186 pounds, the TT is only 11 pounds heavier than its predecessor, but thanks to new body components, it's 25-percent stiffer than the second generation. We sampled the base TT on the roads of northwest Oregon – that means there's a 2.0-liter turbocharged inline-four good for 220 horsepower and 258 pound-feet of torque. It's the same output as a GTI with the Performance Package in a two-door coupe that's 155 pounds heavier. But stay with us – the magic of Quattro all-wheel drive seriously comes into play here. Launch a TT coupe from a stop and you'll hit 60 miles per hour in 5.3 seconds. Even the TT Roadster is a firecracker, able to do that same 0-60 run in 5.6 seconds. That 220-hp, front-wheel-drive GTI, by comparison, hits 60 in about six seconds flat. We didn't get to drive the TTS, but based on numbers alone, it ought to be a real honey. The S uses the more powerful version of the 2.0T engine from the Golf R, with 292 hp and 280 lb-ft of torque. Zero-60: 4.6 seconds.