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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 Audi A3 Sedan makes its world debut in NYC

Audi is bringing some excitement to this year's New York Auto Show, showing off a 2014 A3 Sedan that will shortly be vying for attention in the luxury market's newly hot compact segment. The newly minted A3 faces immediate challenge from box-fresh small premium sedans like the Mercedes-Benz CLA and the Acura ILX, as well as players like the Buick Verano and the Lexus CT200h.
Of course, the German automaker will be the first to tell you that this new A3 is more than up to the challenge. Audi's typically high-level of design is in effect here, with sheet metal that is attractive without looking like a clone of the larger A4. The A3 will have the option of full LED headlamps, of course, carrying on Audi's now famous positioning in the world of recognizable lighting. Wheels will range from 16-inches to 18-inches, we're told, which will also help to cement the sporty look and premium placement of the small sedan.
The A3 Sedan will be vying for attention in the luxury market's newly hot compact segment.

Recharge Wrap-up: BMW i3 carshare, Audi e-gas plant

Elix Wireless has announced its E10K Wireless Charging System. The system is designed for harsh conditions, delivers up to 10 kilowatts and features automatic detection and removal of foreign objects. Its low frequency makes it safe to operate near oil and gas, and in other hazardous environments. The system can charge personal vehicles, as well as electric buses, trucks, mining equipment and heavy duty machinery. Elix has "created an entirely new technology that meets customer demand for fast, safe and reliable charging," says, CEO David Smith. The E10K system uses Elix's Magneto-Dynamic Coupling technology, with rotating permanent magnets in the transmitter and receiver. Read more at Green Car Congress, or in the press release from Elix Wireless. FreeWire Technologies and Siemens are working together on a pilot program for the Mobi Charger. The mobile charging station, which uses second-life EV batteries to charge electric vehicles, will be deployed for a trial at LinkedIn's campus in Mountain View, CA. The Mobi is more flexible than stationary chargers in that it brings the charging to the car, regardless of where it is parked, rather than having to park the EV in a specific spot. It can charge up to five cars per day without putting stress on the grid during peak hours. Read more from Siemens. Audi's e-gas plant in Werlte, Germany helps stabilize the power grid. The plant, which produces synthetic methane using CO2, water and electricity, is able to draw six megawatts of power within five minutes, allowing it to become certified in the electricity balancing market. This helps the grid adapt to the larger load fluctuations that go hand-in-hand with generating renewable energy. It also allows the plant to achieve higher operating times and produce more e-gas each year. Read more in the press release from Audi. The BMW i3 is now available through the DriveNow carsharing service in Germany. DriveNow, which is a joint venture between BMW and car rental company Sixt, has put 100 i3s into service in Berlin, Hamburg and Munich. BMW also says that it supports a shift away from private car ownership in order to improve urban living and mobility, and sees electric carsharing as an important part of that. "We are witnessing the changes our customers and society as a whole are making and we are taking them on board," says BMW's Dr. Bernhard Blattel.