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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.

Next-gen Audi RS4 coming, might make it to America

Let us be frank: The second-generation Audi RS4 was one of the best, most exciting cars of the past decade. A four-door sedan with a 4.2-liter V8, all-wheel drive, and a six-speed manual transmission? What wasn't to like? While you can still get a taste of the B7 RS4's character with the current RS5, it isn't quite the same. That's why we're giddy about a new report from Car and Driver, which claims that not only is a new RS4 on the way, but that it could, maybe, possibly return to the United States. As previously reported, the fourth-generation RS4 will go back to a twin-turbocharged V6, after two generations of unassisted V8s under the hood. As per RS4 tradition, it will also be limited to a five-door Avant body style, because "that is what people expect from the RS4," Quattro GmbH boss Heinz Hollerweger told Car and Driver. An RS5 Sportback could also be in the offing, which might remain more true to the character of the first US-market RS4. The US question, though, remains an iffy one, largely because of the Avant shape. Audi has reduced the number of wagons it's offered in the US over the years, dropping the A4 and A6 Avant, although the former is sort of still offered in the form of the Allroad. But that position might be enough to keep the next-gen RS4 off our shores, although as the Quattro boss told CD the US market is changing and "there is more demand there [for wagons], so maybe that will change." Well, Herr Hollerweger, we're here to tell you that America loves wagons, and that you should put the next-gen RS4 on sale over here post haste. Danke.

BMW considering building 3 Series in North America

There might be even more BMWs coming from North America soon. The company recently announced plans to build a flagship crossover called the X7 at its Spartanburg, SC, factory. Now, rumors are emerging that the Bavarians might be thinking about building a second North American factory that could build its quick-selling 3 Series.
According to Bloomberg, the German luxury giant is considering several possible locations for a North American factory, including two in Mexico, that may build the 3. "We will decide this in the next months. On the North American continent, there's still potential," said BMW production boss, Harald Krueger, in an interview meant for company staff obtained by Bloomberg.
If BMW decides to open a plant in Mexico, it would be following its rival Audi, which already announced construction of a factory there. Mercedes-Benz has been rumored to be working on a deal with Nissan to build its cars South of the Border as well. Rumors of Bimmer considering Mexican production have also cropped up in the past, so it wouldn't come as a total surprise to hear it made official.