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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.

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

Audi reveals R8 E-Tron Piloted Driving concept at CES Asia

Designed as they are to take the driver out of the equation, you might think that the idea of an autonomous vehicle would seem diametrically opposed to that of a supercar. But Audi disagrees. The German automaker has cooked up a series of "piloted driving" concepts that are increasingly focused on performance, and this could be the ultimate iteration yet. Audi's latest Piloted Driving demonstrator is based on the R8 E-Tron. It's altogether almost identical to the one we saw in Geneva, packing an electric powertrain to deliver 456 horsepower, 679 pound-feet of torque and a 0-62 time of 3.9 seconds. Only in this case, it can do it all on its own, without any driver intervention. To pull that off, Ingolstadt has fitted this show car with an array of sensors, including a new laser scanner, multiple video cameras, ultrasonic sensors and radar transmitters at both ends – all handled by a central "driver assistance control unit." It's the latest in a series of concept cars that has already included a version of the RS7 Sportback designed to lap the racetrack, and the Prologue concept that drove itself to CES. This concept was similarly unveiled at CES Asia, the Eastern counterpart to the tech expo we usually catch in Las Vegas. Just what the point is in engineering (or buying) one of the best-driving cars on the market and then handing over its operation to a computer, we don't quite get. But at least we can rest easy knowing that Audi is not giving up on performance as autonomous tech turns the driver into just another passenger. Related Video: Audi R8 e-tron piloted driving technical concept car 340 kW of power, 0 to 100 km/h (62.1 mph) in 3.9 seconds and a driving range of 450 km (279.6 mi) – Audi has extensively developed its all-electrically powered high-performance R8 e-tron sports car further. The technology study is one of the highlights of CES Asia, and it brings together future technologies – which relate to lightweight design, high-performance drive systems and functions for piloted driving. The Audi R8 e-tron piloted driving concept car is based on the multimaterial Space Frame of the new production R8. A rear car body module made of carbon fiber reinforced polymer (CFRP) integrates the luggage compartment, which extends the frame structure. The walls of the luggage compartment shell are corrugated, so that they can absorb extreme amounts of energy with little material weight in case of a rear-end collision.