Smart factory: Audi is on the way to the factory of the future
Audi is making its production fit for the future with the smart factory. In this factory of the future, big data – the creation and intelligent connection of large volumes of data – will facilitate data-driven and thus highly flexible and highly efficient manufacturing. A method of production in which Audi might no longer build its cars on an assembly line but according to a radically new, disruptive concept is modular assembly. In addition to this major project, Audi is pursuing many other exciting projects for the production of the future – from the application of virtual-reality glasses to metal 3D printing.
Modular assembly
The complexity of automobile production is increasing. New market needs, customer expectations and the legislative framework are increasingly requiring innovative technologies and differing vehicle versions. This means that the fixed timing of the assembly line is becoming less efficient. The more the number of derivatives and variants grows, the more difficult it becomes to master high complexity and integrate new routines into the rigid, sequential process.
Audi intends to meet this challenge and to develop a completely new principle for it: modular assembly. With this method, small, separate workstations allow highly flexible working routines – in terms of both time and space. Between those workstations, driverless transport systems take over the transport of the car bodies as well as the parts required for production. A central computer precisely controls the driverless transport systems – it recognizes the needs of each individual station, thus ensuring a smooth workflow.
Audi assumes that modular assembly will result in 20 percent better productivity than the assembly lines of today. It is now being applied for test purposes at the engine plant in Gy?r, Hungary, and application is planned in two further projects.
At present, the key principles of this innovative production system are being worked out and tested by “arculus” – a startup company established a few months ago.
The new driverless transport systems required for modular assembly are being created in Audi’s “Technology Development Production Assistance Systems” department. This small department has developed two types of driverless vehicle: One of them moves under control by a computer, the other moves autonomously on a defined route. Three onboard laser scanners allow the driverless transport systems to orient themselves and to recognize and avoid potentially critical situations. Audi developed the navigation software itself. It is based on automotive software and automotive-software development processes.
The main task of the Technical Center for Production Assistance Systems is to work on new production technologies in early stages of their development. In addition to driverless transport systems, it is also working on four other projects. They comprise safe cooperation between humans and machines when working in the same space, assembly tables with assistance functions and two innovative robots: a flexible gripper arm and a special lightweight robot.
Audi’s answer to this challenge is a completely new concept: modular assembly. The idea behind it is production without assembly lines, broken down into the individual work stages. The new assembly stations are occupied by one or two workers. Unlike today, they work steadily at a continuous pace, because they no longer have to adapt their activities to the speed of the line. And they do not have to move with the car on a conveyor; they can work in one place.
The transport of the car bodies and components between the stations in modular assembly is taken over by driverless transport systems. Audi is currently developing new systems of this kind that can navigate themselves and thus move with great flexibility (see separate chapter). Their movement is exact to the nearest centimeter and is controlled by radio; a central computer guides them as required.
The heart of motionEAP is an infrared depth camera – a standard “Kinect 2” from Microsoft. This is an example of how production technology can benefit from the latest developments in the gaming industry.
Another system with the name “Clever Klaus” is already in use. It helps the workers on the preassembly of Audi A4 doors with the complex cabling.
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