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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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Is this the Audi C-BEV Concept?

The head of R&D at Audi, Ulrich Hackenberg, used part of his comments at the company's annual conference to broach the subject of an all-electric SUV. He didn't give many details, but he said it would be based on the same MLB 2 platform as the Q7, would have a range of more than 311 miles, and perhaps use a battery rated at 90 kWh. German publication Auto Motor und Sport has just published sketches of what that SUV, supposedly codenamed C-BEV internally, will look like when we see it in concept form at the Frankfurt Motor Show. Autocar's sources say this is a five-seat, "production-relevant zero-emissions concept" that offers hints about the coming Q6 and how Audi plans to battle the BMW X6 and Tesla Model X. Autocar says the lithium-ion battery, placed inside the platform, could hit that 90 kWh number, and power three electric motors. One of the motors is mounted in the transmission, two more at the rear axle, and combined output is reportedly 500 horsepower and 516 pound-feet of torque. Styling will aim for something coupe-ish, the company expecting it to be so sleek that it will have a coefficient of drag under .30. For comparison, the Audi A6 has a Cd of .28. All-out luxury is the word here, with interior architecture shared with the next A8, and "Range Rover rivaling ride quality." We're not sure if this has anything to do with Audi's announcement that it will show a concept with OLED matrix lighting at Frankfurt, but the production vehicle that the Frankfurt concept leads to will go on sale in late 2018.