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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 getting ready for an entire line-up of PHEV models

Despite years of researching any number of standard ICE alternatives, it's becoming clear that different automakers are starting to throw their weight behind their advanced-powertrain technologies of choice. For instance, Toyota is gearing up for its first production hydrogen fuel-cell vehicle next year. Nissan continues to preach the gospel of the battery-electric engine. For Audi, plug-in hybrids appear to be the way to go. The German automaker plans to have a plug-in hybrid version of every one of its models by the end of the decade, UK's Autocar reports, citing comments Audi research and development head Ulrich Hackenberg made at a recent launch event for the A3 Sportback E-Tron. Hackenberg spelled out two variants of the powertrain, including one front-wheel drive version that pairs an electric motor with a 1.4-liter gas engine (this is the version used in the A3), and another to be used for four-wheel-drive vehicles in which an electric motor drives the rear wheels. We couldn't get more information from Audi representatives here on the A3 Sportback E-Tron launch ourselves, and an Audi spokesperson said in an e-mail to AutoblogGreen that the company wasn't commenting further on its plans for plug-in hybrid powertrains in more models. Audi has started pre-sales of the A3 Sportback E-Tron in Germany, pricing the car at about $51,000 with deliveries to start sometime this winter. The vehicle puts out 204 horsepower and can go as far as 31 miles on electric power alone. An exact date has not been set for importing that plug-in to the US, but it will happen some time next year.

2015 Audi Q3 headed for Detroit before hitting US showrooms this fall

The market for small premium crossover vehicles continues to grow in popularity here in the US, and Audi is finally ready to get in on the action. Going up against competitors like the BMW X1, Land Rover Range Rover Evoque and soon-to-arrive Mercedes GLA-Class, Audi will unveil a US-spec version of the 2015 Q3 at the Detroit Auto Show next week. And in what we can only assume is an amusing coincidence, the Q3 will go on sale during Q3 of this year.
As we reported back in October, it appears that our Q3 will boast a slightly taller ride height than its European counterpart, but Audi isn't releasing too much information about the crossover just yet. What we know for sure is that it will be powered by Audi's well-liked 2.0-liter turbocharged TFSI inline-four producing 200 horsepower and 207 pound-feet of torque. A six-speed automatic transmission and front-wheel drive will come standard, while Audi's Quattro all-wheel-drive system will be optional.
Visually, the 2015 Q3 shown here has a different front fascia design than its European counterpart, but it's not immediately clear if this is exclusive to the US model or if it will be a new element for Q3 in all markets. We don't expect pricing to be announced until closer to its on-sale date, but the Q3 will definitely be stuffed with content, even in base form. Audi has already confirmed such niceties as a panoramic moonroof, Xenon headlights and heated leather seats. Delivering a good amount of practicality for its size, the Q3 will provide a maximum cargo capacity of up to 48.2 cubic feet and 16.2 cu-ft with the rear seats in place.