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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.

2014-15 Audi SQ5 recalled for steering issue

Audi is recalling 5,625 SQ5 crossovers from model years 2014 and 2015 due to a fault in the electric power-assisted steering system. The affected vehicles were built between May 22, 2013 and April 14, 2015. The vehicles in question may experience power-steering shutdowns in cold conditions. Good thing the US' average July temperature sits in the mid 70s. The actual root of the problem is a fault in the steering motor sensor, according to the bulletin from the National Highway Traffic Safety Administration. While manual steering would still be available, the sudden loss of power could catch drivers off guard, increasing the chances of a crash. Owners of the affected vehicles will be notified by Audi USA, and will need to report into dealers for a software update to the power steering control module. Scroll on down for the official notification from Audi. Report Receipt Date: JUL 20, 2015 NHTSA Campaign Number: 15V452000 Component(s): STEERING Potential Number of Units Affected: 5,625 Manufacturer: Volkswagen Group of America, Inc. SUMMARY: Volkswagen Group of America, Inc. (Volkswagen) is recalling certain model year 2014-2015 Audi SQ5 vehicles manufactured May 22, 2013, to April 14, 2015. The affected vehicles have an electric power steering assist system that may shut down in cold temperatures due to a steering motor sensor fault. CONSEQUENCE: If the vehicle experiences a loss of power steering assist, extra steering effort will be required at lower speeds, increasing the risk of a vehicle crash. REMEDY: Volkswagen will notify owners, and dealers will update the power steering control module software, free of charge. The recall is expected to begin July 28, 2015. Owners may contact Audi customer service at 1-800-253-2834. Volkswagen's number for this recall is 48M1. NOTES: Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

With increased range, Audi R8 E-Tron revving up for production. Maybe

As Tesla Motors proved mightily in 2013, an expensive EV with a long range can sell quite nicely, thank you very much. Perhaps Audi was taking notes, since its all-electric R8 E-Tron's on-again/off-again odyssey appears to be on again, according to UK's Autocar, citing Audi's Urlich Hackenburg. The model is near the approval stage for production, and the key to the green-light is the fact that its single-charge range has been almost doubled to 250 miles. The R8 E-Tron gained kudos in these parts last June by turning in a rather brisk 8:09 time around Germany's Nurburgring track, a record for a production electric vehicle (check out the really quiet video here). Still, plans for the 376-horsepower model, which has two electric motors and was first shown off at the Frankfurt Auto Show in 2009, had been put on the proverbial blocks largely because of a relatively short single-charge range of about 150 miles. Then word came out last spring that Audi would produce maybe 10 units before reports from Australia's Drive late last year indicated that plans for potentially broader production were being resuscitated.