AI Integration in Production
Audi is advancing the use of artificial intelligence (AI) across its production and logistics operations. The company is expanding its cloud platform to facilitate large-scale series production, harnessing the expertise of established partners. This initiative merges decades of manufacturing experience with innovative digital solutions.
Gerd Walker, Member of the Board of Management for Production and Logistics, states, “Artificial intelligence is a quantum leap for efficiency in our production. With our AI and digitalization roadmap, we are transforming our plants into smart factories where AI acts as a partner, providing our employees with tailored support.”
Foundation of Edge Cloud 4 Production
Audi is implementing the Edge Cloud 4 Production (EC4P) across its manufacturing sites. This initiative establishes a benchmark in factory automation while laying the groundwork for widespread AI application. EC4P integrates traditional automation with cloud-based flexibility and computing power, streamlining processes, reducing hardware needs, and enhancing IT security.
In German assembly plants, centralised cloud control is guiding workers by providing real-time information on vehicle specifications. This shift has already resulted in the removal of over 1,000 industrial PCs.
At the body shop for the A5 and A6 series in Neckarsulm, Germany, EC4P is now operational within a highly automated environment for mass production. Virtual programmable logic controllers (vPLC) are replacing local hardware controllers, enabling over 100 robots to operate with millisecond precision. This system supports the manufacture of several hundred vehicle bodies daily across three shifts, setting an industry standard.
AI Enhancements for Quality and Employee Support
The Weld Splatter Detection (WSD) system will operate on the EC4P to enhance flexibility and scalability. At Audi’s Neckarsulm site, WSD identifies weld splatter on vehicle underbodies and marks it for removal. A robot arm has been introduced to grind down the splatter, alleviating physically demanding work. This AI-supported system is set for series production across six plants in Ingolstadt.
Audi is also developing ProcessGuardAIn, an in-house AI solution for monitoring manufacturing processes. This development is backed by a team that has created the “P-Data Engine” platform, which harmonises data from multiple systems. ProcessGuardAIn monitors production in real time, detects anomalies early, and alerts experts. Current pilot cases in the Neckarsulm paint shop focus on dosage optimisation in pretreatment and anomaly detection in cathodic dip coating (CDC), with full production integration expected by the second quarter of 2026.
Innovative Wiring Loom Project
Audi’s Next2OEM project aims to digitise and automate the entire wiring loom production process in collaboration with ten partners at its Ingolstadt headquarters. Currently, less than ten per cent of wiring loom assembly is automated industry-wide. The project features a demonstrator funded by the Federal Ministry for Economic Affairs and Energy that maps the entire process chain from production to installation, significantly reducing logistical efforts and lead times.
AI-Driven Dryer Operation in Paint Shop
Audi is piloting an AI-supported dryer operation at its Neckarsulm site, marking the first application from its collaboration with IPAI. This AI model, adapted from another industry, optimises temperature and air volume control in the dryer, promising enhanced resource efficiency. Testing will continue until summer 2026 to measure energy savings.
Collaboration and Expertise in AI Development
Audi’s pursuit of data-driven production leverages internal expertise alongside partnerships with industry leaders. Approximately 60 specialists within the Audi Production Lab (P-Lab) are advancing new technologies from concept to production.
Collaborations with companies like Broadcom, Cisco, and Siemens are essential for integrating virtualisation platforms with automation technology as part of EC4P. Since 2023, Audi has been an active participant in the IPAI in Heilbronn, utilising these partnerships to accelerate innovation implementation in production.
Commitment to Responsible AI Use
Audi’s Code of Conduct outlines a commitment to the responsible application of AI, guided by principles of respect, security, and transparency. These principles aim to harness AI’s potential while safeguarding company and employee interests.
Cross-Plant Collaboration on Digitalisation
The Audi production network focuses on scaling various AI applications:
- The News/media-releases/focus-on-digitalisation-and-artificial-intelligence-at-audi-hung.html” target=”_blank”>Audi Hungaria team evaluates its value chain to identify digitalisation opportunities, enhancing transparency and efficiency in production.
- At Audi México, management employs the AI-supported “Production Reports” tool for real-time data analysis and decision-making based on operational metrics from the San José Chiapa plant.
