TL;DR:
- Audi is introducing an artificial intelligence (AI) system for quality control of spot welds in car body construction.
- The AI technology will be deployed at multiple Volkswagen Group locations.
- By utilizing AI, Audi can analyze 1.5 million spot welds per shift, significantly enhancing quality control.
- This approach allows employees to focus on identifying anomalies and improves efficiency.
- The technical infrastructure for AI use is being installed at Audi Brussels, the Volkswagen plant in Emden, and Audi’s headquarters in Ingolstadt.
- The data generated through AI usage has the potential to optimize other processes, such as predictive maintenance.
- Audi has collaborated with reputable organizations to ensure the process aligns with quality and certification standards.
- The project serves as a use case for the Automotive Initiative 2025 (AI25) launched by Audi, promoting digital factory transformation and innovation.
Main AI News:
In a bid to revolutionize its production processes, Audi has taken a significant step towards digitalization. The renowned automotive brand, recognized by its four iconic rings, has commenced the implementation of an artificial intelligence (AI) system for quality control of spot welds in car body construction. Following a successful pilot project at the Neckarsulm site, Audi plans to deploy this cutting-edge AI technology across three additional Volkswagen Group locations by the year’s end. This strategic move aligns with the Automotive Initiative 2025 (AI25) launched by Audi, positioning the company at the forefront of automotive innovation.
Leveraging the power of artificial intelligence, Audi now possesses the capability to analyze approximately 1.5 million spot welds across 300 vehicles during each shift at the Neckarsulm facility. By comparison, the previous method involved manual quality inspections conducted by production staff using ultrasound technology, focusing on resistance spot welding processes (known as Widerstandspunktschweißen or WPS in German) through random analyses. This labor-intensive approach involved checking around 5,000 spot welds per vehicle. However, with the integration of AI, employees can now dedicate their attention to identifying potential anomalies, significantly enhancing quality control. This pioneering approach enables Audi to streamline and optimize its quality assurance processes efficiently and effectively.
Preparations for introducing this groundbreaking technology to other Volkswagen Group plants are already underway. For instance, the installation of technical infrastructure to support AI applications is presently taking place at the Audi Brussels plant. Additionally, the Volkswagen plant in Emden, as well as Audi’s headquarters in Ingolstadt, are scheduled to implement the necessary infrastructure later this year. To facilitate a seamless transition, the team of experts is meticulously identifying differences in weld settings, ensuring the AI model is adequately retrained.
Moreover, the data generated through the utilization of AI holds immense potential for optimizing various processes in the future. The Audi team is currently exploring the application of this data for predictive maintenance, which can significantly enhance the overall efficiency of assembly lines. Gerd Walker, Audi’s Board Member for Production and Logistics, envisions the integration of artificial intelligence as a key driver in their 360factory production strategy, which aims to maximize efficiency across Audi locations worldwide. Walker believes that the utilization of AI in series production holds tremendous promise.
To ensure the process adheres to the highest standards of quality and certification, Audi’s development efforts at the Neckarsulm location have been closely coordinated with reputable organizations such as the German Association for Quality (DGQ), the Fraunhofer Institute for Industrial Engineering (IAO), and the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA). Given the absence of established standards or certifications for AI applications, this collaborative approach ensures transparency and accountability. Mathias Mayer and Andreas Rieker, project managers of WPS-Analytics, emphasize the significance of this coordinated effort in clearly demonstrating the origin and reliability of AI-based test results. Furthermore, Audi has partnered with the Fraunhofer Institutes IAO and IPA to develop an AI guide for production, underscoring their commitment to driving innovation in the automotive industry.
The “WPS-Analytics” project not only demonstrates Audi’s dedication to harnessing the potential of AI but also serves as a remarkable use case for the Automotive Initiative 2025 (AI25). This initiative aims to foster a network of expertise dedicated to digital factory transformation and innovation. As Audi advances toward becoming a smart factory, it collaborates with renowned scientific institutions and IT industry partners to test and refine digital solutions within a real manufacturing environment at the Neckarsulm facility, with the ultimate goal of integrating these advancements into series production. With their unwavering commitment to innovation and digitalization, Audi is undoubtedly shaping the future of automotive manufacturing.
Conclusion:
Audi’s implementation of artificial intelligence for quality control of spot welds is a significant development in the automotive market. By harnessing the power of AI, Audi can streamline their production processes, enhance quality assurance, and optimize efficiency. This move not only demonstrates Audi’s commitment to technological advancement but also sets a precedent for other manufacturers to explore the potential of AI in their production activities. As the automotive industry continues to embrace digitalization, AI-based solutions have the potential to revolutionize manufacturing processes and drive the market toward a more efficient and innovative future.
