TechDay Smart Production
From modular assembly as a response to increasing product variety, to virtual assembly planning for the resource-efficient design of infrastructure or the local server solution Edge Cloud 4 Production that is a paradigm shift in factory automation: Audi is building a fully networked, highly efficient, and sustainable way of production that uses new technologies and concepts to successfully meet the demands of the future. In doing so, Audi is looking at manufacturing as a whole - from the individual employee to the fully automated production cycle.
Smart Production: How Audi Is Designing the Production of the Future
Audi is setting up fully networked, highly efficient, and sustainable production. The goal is to design a resilient, agile, and flexible value chain to meet future challenges successfully. These include a growing diversity of variants, the transition to electromobility, the increasingly volatile supply situation, and political uncertainties. “We’re using synergies and looking at production as a whole – from the worker to the fully automated cycle,” says Gerd Walker, Member of the Board of Management for Production and Logistics. “We’re digitizing specifically within the framework of an open innovation culture. We’re ensuring efficient value creation and making it possible to utilize resources and capacities flexibly and efficiently.”
Modular Assembly: Innovative assembly and logistics concept is about to be ready for serial production
For more than a century, the conveyor belt has set the pace in automotive production. Now it is increasingly reaching its limits. Numerous derivatives and individualized possibilities are making vehicles more and more varied. Processes and components in assembly systems are increasingly variable. In a rigid, sequential process, that complexity is more and more difficult to master. That is why Audi is introducing the world’s first modular assembly system in the automotive industry as a new and supplementary form of organization. Workers assemble components at “production islands” independently of cycle time. In addition, due to high component variability automated guided vehicles (AGVs) supply the stations with the necessary materials in accordance with the goods-to-person principle.
Modular Assembly: “We're making the assembly line more flexible and enhancing it.”
Numerous derivatives and possibilities for individualization are increasing the variability of components and processes along the assembly line. In this interview, project manager Wolfgang Kern and Josef Weinzierl, head of assembly planning for the PPE, SSP, MQB, HV battery, and module platforms, explain why modular assembly at many stations is more flexible and efficient for customer-individualized series production than the assembly line.
Edge Cloud 4 Production: How Audi is revolutionizing factory automation
Centralized, not decentralized; local servers, not hundreds of industrial PCs; software, not hardware: with the local server solution Edge Cloud 4 Production, Audi is initiating a paradigm shift in automation technology. After successful testing in the Audi Production Lab (P-Lab), three local servers will take over directing workers in the Böllinger Höfe. If the server infrastructure continues to operate reliably, Audi wants to roll out this automation technology – the only one of its kind in the world – for serial production throughout the entire Volkswagen Group.
Audi Production Lab: The link between an idea and high-volume production
Audi uses its Production Lab, or P-Lab for short, to identify new and innovative technologies and reliably integrate them into production sequences. In Gaimersheim, just a few minutes drive from the Ingolstadt plant, experts under P-Lab director Henning Löser test the suitability of trailblazing new solutions for series production. That means finding and testing innovations that reliably help optimize efficiency, ergonomics, flexibility, and quality in Audi plants.