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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.

Audi's diesel-electric supercar is codenamed 'Scorpion'

Speculation continues as to the final nature of the diesel-hybrid Audi supercar said to arrive in 2016 or 2017. A previous report in Automobile had the halo coupe, based closely on the R18 etron quattro endurance racer, codenamed R20 and pegged to look like a Le Mans winner for the street with around 700 horsepower and 737 pound-feet of torque from a twin-turbo V6. Now Car and Driver has updated the gossip with a report that the car is internally called "Scorpion," and it will be even closer to the R18 than supposed.
CD says the heart of the car will use the R18 etron quattro's carbon fiber tub and its engine will be "taken directly" from the race car. That means a 3.7-liter V6 with a single turbo that, in ACO-spec restricted form, outputs 500 hp and 625 lb-ft - CD suspects production output could get to 600 hp - and drives the rear wheels, aided by hybrid motors driving the front wheels. And remember, at Le Mans the R18's hybrid motors can't kick in until they're above a certain speed in order to prevent Audi from getting an advantage coming out of slow corners. A street car wouldn't face that restriction.
The Scorpion would be a fulsome and undiluted example of the technologies Audi has created during its return to sports car racing. Its exterior design hasn't been finalized, with CD citing either the convoluted concept of "a retro take on the future of racing" or packaging that would adhere to the R18's looks. To make sure it is properly appreciated and sells well, production could be limited to the same 333 units as the R8 GT and A1 Quattro.

Audi bringing new TT Roadster to Paris

The TT may be first and foremost a coupe, but in presenting the third-generation model, Audi has toyed with all sorts of body-styles. There's been the prototypical coupe, of course, but also shooting brake and crossover concepts. The one thing it hasn't shown us is the convertible model, but that ends today as Audi takes the wraps off the new TT Roadster and TTS Roadster.
Set to be unveiled at the Paris Motor Show next month, the new TT Roadster naturally follows its fixed-roof counterpart's lead closely, but with the addition of a folding fabric roof mechanism. Made of magnesium, aluminum, steel and plastic, the mechanism weighs 6.6 pounds less than its predecessor's, helping keep the center of gravity lower. It also folds flatter to allow for more luggage space, and can deploy or retract in ten seconds at speeds up to 31 miles per hour. With the roof up it's also quieter, and with a drag coefficient of 0.30, Audi claims it's the slipperiest in the segment.
Of course, Audi's also worked to keep the weight down and rigidity up. As a result, the 0-62 sprint only takes an extra 0.2 seconds, quoted in the TTS Roadster at 4.9 seconds instead of 4.7 in the TTS coupe. Top speed remains pegged at 155 miles per hour. That, of course, is with the top-spec, 310-horsepower 2.0-liter turbo four, but Audi will also offer the less potent 184-hp version as well as a 2.0-liter TDI, mated to either a six-speed manual or six-speed DCT, though specific performance figures for each version were not disclosed in the press release below.