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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.

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Audi readying diesel PHEV models for US and Europe

With the racing pedigree provided by the Audi R18 E-Tron Quattro, you'd be forgiven for thinking that the German king of Le Mans is capitalizing on the connection between its road cars and race cars at every opportunity. Maybe there's an entire range of Le Mans Editions for the automakers diesel-hybrid offerings, with perhaps Tom Kristensen acting as the brand's spokesperson for the technology in Europe. You'd be wrong, though, because despite the R18's overwhelming successes in endurance racing, Audi the road-car manufacturer doesn't offer a single diesel-hybrid production car.
This factoid will hopefully be as short lived as it is disappointing, though, as a diesel-electric is around the corner, according to the brand's tech boss, Ulrich Hackenberg. In fact, it gets better than a mere diesel-hybrid; it will be a plug-in diesel-hybrid, only the second to hit the market, alongside the European-market Volvo V60.
According to Hackenberg, the new tech will be the result of a marriage between the brand's well-received 3.0-liter, TDI V6 with an electric motor. The next-generation Audi Q7 (shown above) will be the initial recipient, confirming previous reports that claimed a PHEV TDI could come to the next-gen CUV. Its MLB architecture, meanwhile, would allow the plug-in-hybrid-diesel powertrain to be fitted easily enough to the A8 luxury sedan. While the new Q7 should hit the market at some point in 2015, it's unclear when the PHEV TDI model could see the light of day.