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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.

Hackenberg says next Audi A4 set for Frankfurt debut

The current Audi A4 is among the oldest vehicles in the brand's lineup. Having debuted back in 2008, it's long overdue for an update, and according to our friends at Indian Autos Blog, that'll happen in roughly six months. IAB spoke to Audi research and design chief Ulrich Hackenberg, who indicated that the fifth-generation A4 will be shown at the 2015 Frankfurt Motor Show in September. The new sedan will be unveiled in "a pre-presentation" before the auto show itself, Hackenberg told IAB, adding that "you'll be happy to see it." Information beyond that, though, remains sparse. Based on our previous spy photos, we expect the new A4 to ride on the Volkswagen Group's modular MLB Evo platform that's been stretched to accommodate a larger wheelbase. The styling, meanwhile, will be more evolutionary, inspired in part by the new TT. Expect more on the next-generation A4 as September approaches. Related Video:

Next-gen Audi A5 shows its heavily camouflaged face

The new Audi A4 is set to launch at the Frankfurt Motor Show in September, so it shouldn't come as too big of a surprise that an updated A5 is on the way, as well. Our spies just caught the coupe testing for the first time while wearing heavy camouflage from nose to tail. Despite the concealment, some details are possible to make out, especially when comparing the two-door design to the previously spied A4. Audi is further differentiating the designs, and the A5's front end is significantly changed based on these photos. The headlights appear larger and more acutely angled than the narrower units on the sedan. Also, the lower bumper gets square intakes at each corner and the shape creates an additional opening in the center for the coupe. In profile, it's easy to notice the quicker sloping roof and smaller side windows. Only the rear end of the two models seem to share many significant cues. The new A5 reportedly rides on the same MLB Evo platform as the upcoming A4 to shed around 200 pounds. The two models might not launch at the same time, though, and the coupe could join the lineup somewhat later. S5 and RS5 variants are expected to join the range further down the line, too.