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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.

The mood at this year’s Paris Motor Show: Quiet

The Paris Motor Show, held every other year in the early fall, typically kicks off the annual cavalcade of automotive conclaves, one that traverses the globe between autumn and spring, introducing projective, conceptual and production-ready vehicle models to the international automotive press, automotive aficionados and a public hungry for news of our increasingly futuristic mobility enterprise. But this year, at the press preview days for the show, the grounds of the Porte de Versailles convention center felt a bit more sparsely populated than usual. This was not simply a subjective sensation, or one influenced by the center's atypically dispersed assemblage of seven discrete buildings, which tends to spread out the cars and the crowds. There were not only fewer new vehicles being premiered in Paris this year, there were fewer manufacturers there to display them. Major mainstream European OEM stalwarts such as Alfa Romeo, Fiat, Nissan and Volkswagen chose to sit out Paris this year, as did boutique manufacturers like Bentley, Aston Martin and Lamborghini. This is not simply based in some antipathy on the part of the German, British and Italian manufacturers toward the French market — though for a variety of historical and societal reasons that market may be more dominated by vehicles produced domestically than others. Rather, it is part of a larger trend in the industry. Last year, Mercedes-Benz announced that it would not be participating in the flagship North American International Auto Show in 2019 — and that it might not return. Other brands including Jaguar/Land Rover, Audi, Porsche, Mazda and nearly every exotic carmaker have also departed the Detroit show. Some of these brands will still appear in the city in which the show is taking place, and host an event offsite, to capitalize on the presence of a large number of reporters in attendance. And even brands that do have a presence at the show have shifted their vehicle introductions to the days before the official press opening in an attempt to stand out from the crowd. In many ways, this makes sense. With an expanding number of automakers, with diversification and niche-ification of models and with wholesale shifts that necessitate the introduction of EV or autonomous sub-brands, there is a growing sense that, with everyone shouting at the same time, no one can be heard.

VW Group exploring F1 options, would likely wait until Ecclestone is out

The real hurdle is that Volkswagen overlord Ferdinand Piech doesn't like Bernie Ecclestone on a personal or professional level. Superbugs. They are antiobiotic-resistant bacteria and viruses, fiends that defy eradication no matter how much counteracting agent you throw at them. Reports that Audi is going to join Formula One? They are the superbugs of rumors; for five years they've been coursing through the blood of motorsport, and no amount of denials or Audi's continued non-presence in F1 has been able to make them go away. Not even a month ago we contracted another bout of it, courtesy of Auto Express, citing sources who said Audi would leave endurance racing and DTM - handing Le Mans over to Porsche, instead of the other way around - and buy either Red Bull or Toro Rosso for an entry in 2016 with an in-house powerplant. Within 24 hours of that story, Audi Sport sent the tweet, "Audi in F1? There rumors keep appearing with regularity since years. It's pure speculation again this time and without any foundation." Now, few things are impossible in F1, but lining up on the grid in 2016 is not far away from needing to be ready tomorrow, in F1 terms, which is why these announcements come long in advance. Honda, you'll recall, gave us almost two years' notice of its F1 reunion and Porsche gave us three years notice about Le Mans. A brand-new report in the BBC says that Audi is using new hire and ex-Ferrari technical director Stefano Domenicali to lead a feasibility study into an F1 program. According to that story, the real hurdle to the foray, however, is that Volkswagen Group overlord Ferdinand Piech doesn't like F1 boss Bernie Ecclestone on a personal or professional level, so one of them would need to leave his position before Audi could say yes, feasibility be damned. Since we're talking about two men who define professional longevity, that day might not come soon. The BBC story goes on to say that Martin Winterkorn, head of the VW Group management board, would like to see the group in F1, and that if it happened it would be with a "car designed and made in Germany." Ladies and gentlemen, you know where to file this one...