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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.

Comparison test: 2019 Acura RDX vs. compact luxury SUV competitors

Truth be told, if we were to compare the all-new 2019 Acura RDX with those compact luxury crossover SUVs it would most likely be cross-shopped against, you'd be looking at a different list. Even Acura admits that Lexus and Infiniti are the most likely bogies, but with the 2019 RDX, Honda's luxury brand is attempting to attract those customers who think as much with their hearts as with their heads. And for the most part, those folks have been buying from German brands: the Audi Q5, BMW X3 and Mercedes-Benz GLC-Class. So, to show how the new RDX compares to them, Acura actually provided examples of each during the recent press drive along with a Volvo XC60. All were determined to have greater emotional appeal than the last RDX, and we would certainly agree. For, as much as the previous-generation RDX made sense on paper, it was really hard to get excited about it. And when you're paying extra for a luxury vehicle, shouldn't you get a little excited? Well, as luck would have it, Consumer Editor Jeremy Korzeniewski and I were on hand in Whistler, British Columbia, for the press launch. We didn't have an abundance of time in each RDX competitor, but in conjunction with our usual comparison chart, our impressions should provide a good first taste of how the new RDX compares. Performance and fuel economy Contributing Editor James Riswick: On paper at least, the RDX is gutsier than its comparably powered European rivals. It also weighs the same or less, which logically should mean it'll be the quickest in a straight line. During my brief drives, though, I'm not sure it really stood taller than the three Germans. It at least matches them for smoothness, which is something that can't be said about the Volvo. Fuel economy is lower than them all when you consider all but the Mercedes come standard with all-wheel drive. It's also worth noting that all the competitors are available with engine upgrades, and unless Acura's forthcoming resurrection of Type S models includes the RDX, it should stay that way. Consumer Editor Jeremy Korzeniewski: Line 'em all up in a drag race, and I have a feeling the Acura would squirt away to victory. A good bit of that, though, would be due to its 10-speed automatic transmission, which offers a huge spread of ratios and fires off extremely quick shifts. In the real world, I'd guess fuel economy will be similar across the board, so I'm willing to call that category a draw.

Are future vehicular hacks inevitable?

Before the hack of the Uconnect system in a Jeep Cherokee resulted in a 1.4-million vehicle recall, the potential software vulnerabilities in vehicles were already a hot topic with Congressional inquiries and even proposed legislation in the US. As cars' interconnected systems gain the ability to go online, they become open to a host of new threats. Automakers are trying to stop this, but it might be too late to put the genie back into the bottle. Throughout 2015, the issue of software security in vehicles has become increasingly vital. For example, the recent Jeep case wasn't even the biggest hack this year. In February, a major flaw was discovered in the BMW Connected Drive service that allowed researchers to remotely lock and unlock the doors and potentially affected 2.2 million cars. The fix was an over-the-air patch for the problem. Automakers are actively working to fix the issues. Mercedes-Benz, BMW, and Audi reportedly are using encrypted connections and firewalls in their vehicles to prevent hacking. "Absolute, 100-percent safety isn't possible," Daimler spokesperson Benjamin Oberkersch said to Automotive News Europe. "But we develop our systems, tested by internal and external experts, so they're up to date." These vulnerabilities seem to be popping up more often. A successful hack took $14 in parts from Radio Shack in one case. There was also a 60 Minutes report earlier in the year about DARPA's ability to hack into OnStar to take control of a Chevrolet Impala. Experts aren't so sure companies can contend with hackers' advancement. "The difficulty for the carmakers at the moment is the question whether they can keep pace with advances in technology, and especially hacking technology," Rainer Scholz, executive director for telematics consultant EY, said to Automotive News Europe. "We seriously doubt they can." At this point, vehicle hacks are coming more from researchers looking for holes than from those with malicious intent. Still, the vulnerabilities are definitely there. It's up to automakers to keep patching the problems before they become dangerous to drivers. Related Video: News Source: Automotive News Europe - sub. req.Image Credit: Bill O'Leary / The Washington Post via Getty Images Audi BMW Jeep Mercedes-Benz Safety Technology Emerging Technologies hacking cyber security