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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 Audi Q7 to debut with electric turbocharger?

For years, the concept of an electric turbocharger was essentially a joke sold on eBay to boost power in your slammed Civic, but in the last five years it has moved from an idea on a piece of paper to a feasible reality. Audi has already toyed with a showcase of the cutting-edge tech in road cars with the RS5 TDI concept. Now, reports suggest an electric turbo may make it to the streets as soon as next year in the next-gen Q7 (spy shot pictured above).
"I can confirm we are working on the development of the e-boost definitely," said Ulrich Weiss, Audi's diesel engine boss, to Australia-based Drive. He didn't give an exact timeframe but hinted at sometime next year, possibly in the Q7. He also suggested the chance of an RS-branded diesel model in the vein of the RS5 TDI concept on the horizon, as well.
This tech isn't entirely new for the folks in Ingolstadt. Audi's R18 endurance racer already uses such a system to capture waste heat from the engine, converting it to electric power to further power the hybrid car. The RS5 TDI concept employs a similar idea with a 3.0-liter, twin-turbocharged V6 with an electric supercharger to make up for the turbo lag. It's able to pump out 385 horsepower and 553 pound-feet of torque and allegedly sprint to 62 miles per hour in four seconds.

Recharge Wrap-up: Audi R18 e-tron Quattro wins WEC opener, Toyota Mirai goes to DC

The Audi R18 e-tron Quattro has won the World Endurance Championship season opener at Silverstone. Drivers Marcel Fassler, Andre Lotterer and Benoit Treluyer piloted the number 7 hybrid racecar to a hard-fought win in the six-hour UK race. "This victory is a dream start of the season and a great reward for the whole squad for the hard work last winter," says Audi Motorsport boss Dr. Wolfgang Ullrich, congratulating the team. Audi's second R18 took fifth place in the race after a couple of unscheduled pit stops ate up precious time. Read more in the press release from Audi, below. Mini and Spanish designer Jaime Hayon are presenting new versions of the Mini Citysurfer electric scooter concept at Salone del Mobile in Milan, Italy. The installation, called "Urban Perspectives" depicts an idea of the future of urban mobility. The imaginary living space houses two examples of the Citysurfer concept designed by Hayon. The first is painted to resemble blue and while porcelain, with dots and stripes to give it an upbeat look. The second uses more upscale materials like anodized metal, copper and leather to blend modern and classical elements. The foldable Citysurfer scooter can travel 10 to 15 miles on a charge, and is designed fit and charge inside the trunk of a Mini Cooper. Read more from Mini. Tesla has announced the locations of its first Superchargers in Australia. It will install eight charging booths at the Goulburn Visitor's Centre, about 120 miles southwest of Sydney. The Goulburn superchargers will be powered by renewable energy. Tesla plans to install a network of Superchargers in cities along the route connecting the Sunshine Coast north of Brisbane south to Melbourne. Read more at Clean Technica. The Toyota Mirai will be on display at the National Mall in Washington DC to celebrate the 45th anniversary of Earth Day. Toyota is a sponsor of Global Citizen 2015 Earth Day from April 17 to 19, which will include speakers, musical performances and, of course, Toyota's new hydrogen fuel cell car. "Earth Day 2015 is a great platform to educate the public about hydrogen fuel cell technology and the potential of hydrogen as a future fuel," says Toyota's Bob Carter. Also in April, Toyota will continue to enlighten the public about the Mirai and hydrogen technology in Union Square Park in New York on April 19, and at Waterkeeper Alliance's "Keep it Clean" comedy event in Los Angeles on April 22. Read more from Toyota.