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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.

Don't hold your breath for an Audi RS8

There was a time not so long ago when Quattro GmbH produced essentially one model at a time. But that time is behind us. These days it's expanding into a full-fledged performance division to rival Mercedes-AMG and BMW's M department. Quattro GmbH is currently building the Audi RS4 Avant, RS5 coupe and cabrio, RS6 Avant, RS7, RS Q3 and the TT RS coupe and roadster - not to mention the R8. And while it's showing no signs of slowing down, but the latest intel from across the pond suggests we shouldn't count on an RS version of Audi's flagship sedan.
This according to Car and Driver, which spoke to Stephan Reil, the chief engineer at Quattro GmbH. Reil says Audi works on a teutonically rigid performance formula: an RS model has to have 20 to 25 percent more power than the existing S version. Considering that the existing S8 makes 512 horsepower and the RS7 a solid 553, we're not sure Audi really needs anything more powerful. But by Reil's calculations, the RS8 would need to pack between 630 and 655 hp, which would put it well ahead of rivals like the 550-hp Jaguar XJR, the 540-hp BMW Alpina B7, the 523-hp Maserati Quattroporte and even the new 577-hp Mercedes-Benz S63 AMG - and in league only with the even more powerful S65 AMG, which in its outgoing form produced 630 hp.
The question then comes down to whether there are enough customers lining up for the S65 that Audi would want to poach away from Mercedes. Or perhaps more pertinently, whether it might end up just taking customers from the new Bentley Flying Spur, which is already offering 616 horsepower in an even more prestigious, if less performance-focused package. Either way you look at it, Audi is apparently steering clear.

Audi R8, Lamborghini Huracan could get twin-charged five-cylinder

Engine downsizing and forced induction are some of the biggest trends in automotive powertrains today because. They offer the chance to reduce emissions and boost fuel economy, while possibly maintaining power. The shift is already happening to performance cars with turbocharged four-cylinders finding their way into the Ford Mustang, Chevrolet Camaro, and future Porsches. Now, there are rumblings of a tiny chance for a similar change coming for the Lamborghini Huracan and Audi R8. Why the new powertrain? China. While the market there might have slowing growth, it's still a major country for auto sales. The annual taxes on cars there also happen to be based on engine displacement, and there's a 40 percent rate on those over 4.0-liters, according to Car and Driver. The obvious answer to this conundrum is to build a smaller displacement, forced induction engine for the R8 and Huracan. Car and Driver points to the new turbocharged and electrically supercharged, 2.5-liter inline five-cylinder from the recent Audi TT Clubsport Turbo concept as a possible solution. Audi's e-turbo technology runs off a 48-volt electrical system and lithium-ion battery to produce a total of 600 horsepower and 479 pound-feet of torque in the prototype. With this mill, horsepower would barely shrink compared to the R8 V10 Plus and Lambo, but it actually makes more peak torque than their 5.2-liter V10s. While this is all theoretically feasible, take the possibility with a big grain of salt for now. According to Car and Driver, Quattro GmbH's Stephan Reil says that there's no work currently underway to fit the twin-charged five-cylinder, "but it has been talked about." That means such a vehicle is likely years away, if ever. In the meantime, a diesel version of the e-turbo setup is on the way the in the SQ7. Related Video: