Digital Transformation at Audi’s Shopfloor

Audi, a leading automotive manufacturer, is at the forefront of innovation in automotive manufacturing by incorporating virtual PLC technology from Siemens into its latest production lines. This cutting-edge technology, combined with advanced data center architectures, is transforming traditional factory floors into intelligent ecosystems that prioritize efficiency, cost reduction, and innovation.

In the bustling city of Ingolstadt, Germany, Audi is striving to establish a stable and highly available production facility amidst the challenges posed by the diverse range of devices used in the manufacturing process. To meet the growing demand for their vehicles, Audi faced the dilemma of having to acquire more hardware devices, leading to longer delivery times and increased manual installation and maintenance costs essential for ensuring cybersecurity.

One of the key concerns in traditional manufacturing processes is the high power consumption associated with the operation of numerous hardware devices. Audi recognized the need to enhance energy efficiency in its plants and sought a solution that would address this issue while also improving overall production capabilities.

Audi's innovative software infrastructure, known as Edge Cloud 4 Production, draws inspiration from the architecture of data centers and leverages Siemens' SIMATIC S7-1500V virtual programmable logic controllers (PLCs) to revolutionize automation engineering in the automotive industry. According to Sven Müller, Project Manager of Edge Cloud 4 Production at Audi, the virtual PLC technology enables a complete reimagining of factory operations and infrastructure.

The transition to a digital infrastructure began in 2019 with the vision of virtualizing the shop floor, culminating in the development of a concept that aligned with Audi's production goals. The introduction of the virtual PLC in spring 2023 marked a significant milestone for Audi, signaling the start of the transformation of its assembly plants to the Edge Cloud 4 Production platform.

Since January 2024, Audi has successfully deployed two virtual PLCs on the assembly line of the Audi e-tron GT at its Böllinger Höfe factory in Neckarsulm. This software-based approach eliminates the need to wait for hardware deliveries, enabling seamless updates and app rollouts across the entire plant with minimal effort.

Despite initial skepticism from employees, Audi ensured a smooth transition by maintaining familiar interfaces and functions with the virtual PLC technology. Robin Fallmann, Production Planning Automation Engineering at Audi, emphasized the importance of detailed planning to address employee concerns and ensure the success of the project.

Looking ahead, Audi remains committed to further developing and refining the virtual controller and cloud-based infrastructure to enhance production efficiency and cybersecurity in both central and remote operations. The collaboration between Audi and Siemens continues to drive innovation in automotive manufacturing, setting new standards for the industry.

Sources: www.siemens.com; www.audi.com