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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: 20-25% of our cars will have a plug by 2025

If you like the promise of Audi's E-Tron Quattro concept, you're going to love this post. Speaking at an intimate dinner in Los Angeles the night before the start of the Los Angeles Auto Show, Audi of America president Scott Keogh had nothing but positive things to say about his brand's future plug-in vehicles, including the production version of the E-Tron Quattro. The most interesting was that he said he expects a full 20 to 25 percent of Audi's sales to be electrified by around 2025, and there was lots of detail to back up his vision. "This is the reality as we see it." - Scott Keogh Keogh wasn't making specific predictions, but it's been a long while since we've heard such a high-level Audi executive act like such a troubadour for the electric vehicle future. As long-time readers will remember, we used to hear things like this from Nissan's Carlos Ghosn, but public predictions have taken a bit of a back seat recently. It's promising to hear reasonable optimism again. "When you look at what needs to happen and you look at what we see happening in the marketplace, we're probably looking at a world where 25 percent of Audi's sales, over the next ten years, just to throw out a rough point in the future, are either going to be full electric or have some plug," Keogh said. "This is the reality as we see it." The reason Keogh is so positive is because Audi thinks the E-Tron Quattro concept is going to birth one heck of an EV. Whatever it's called when it arrives – it's unlikely to be the Q6, as some rumors have it. Internally, Audi is calling it the C-BEV, since it is a C-segment Battery Electric Vehicle – the concept previews a luxury all-electric vehicle with a range of over 300 miles. No one is talking about the price yet, but Audi of America's director of product management, Filip Brabec, did say that the sweet spot for the pricing is in the range of how mainstream luxury vehicles are priced today. "If you can put a car in the market that's priced right ... people are going to want to buy it," Keogh said. Read into all of that what you will. It's not just the price that's going to be right. Keogh said that the key point is changing hearts and minds to want electric vehicles. That means tripling down on public infrastructure (see more below) and making sure the car itself is amazing. "Everyone knows, in the history of the world, launch a defining, game-changing product, in whatever category it bloody is, and - boom - the world changes," Keogh said.

Audi will offer A3 TDI owners same goodwill package

Audi will offer a Goodwill Package, similar to the one Volkswagen has offered owners, for the German brand's emissions-cheating diesel four-cylinder engine. Participating customers will receive a $500 prepaid Visa, a $500 gift card for Audi dealers, and three years of 24-hour roadside assistance. "We are offering this Audi A3 TDI Goodwill Package as a sincere token of our appreciation for your patience," the company wrote on its customer website. This offer will only extend to the A3 TDI. A second EPA violation covers an estimated 85,000 vehicles in the US with VW's Group's 3.0-liter TDI V6 like the 2016 A6, A7, A8 and Q5, and the models are also under a stop sale. However, these owners aren't eligible for the Goodwill Package at this time. "Audi is currently investigating the allegations" against the six-cylinder engines, according to the explanation on the site's FAQ. Owners need to register their VIN on the company's website to apply for the Goodwill Package. They'll receive the items in the mail around four weeks later, but will then need to take the affected vehicle and the package to the dealer to activate the cards. Like the VW program, people have until April 30, 2016, to apply for the offer. VW Group of America CEO Michael Horn said last week around 120,000 people already registered for the brand's Goodwill Package. Related Video: