Audi plant in Ingolstadt
Clever Klaus supports assembly of the A4
The Smart Factory project at Audi in Ingolstadt is making production fit for the future. Smart Klaus" has already left the development stage behind him and is now being used in series production in door assembly for the current Audi A4.
At the Audi plant in Ingolstadt, the assembly lines for the Audi A3, A4, A5 and Q2 models run at a rate of 88 seconds. Every 30 seconds, a car is completed on one of the three lines and leaves the plant. This makes the Ingolstadt site the second largest car factory in Europe.
Ingolstadt is also increasingly focusing on disruptive change. Production is moving away from the assembly line and towards modular assembly using intelligent assistance systems. "Smart Klaus" is one such system and is now a welcome colleague in Ingolstadt. After all, he not only avoids errors, but also relieves the workers at the same time.
Artificial intelligence to reduce workload and avoid errors
"Smart Klaus" helps the workers in A4 door pre-assembly with the demanding and complex wiring. The range includes several hundred different variants. These had to be selected manually beforehand and installed in the right place. In the top versions of the A4 alone, up to 14 plug connections are integrated in the door panels (for window regulators, loudspeakers, central locking, mirror adjustment and other Audi special equipment).
Thanks to the combination of industrial image recognition and an intelligent database, the assistance system recognizes every step and accompanies the employee in real time throughout the entire assembly process. Following the simple principle: guide - check - confirm - document, even these complex processes become manageable.
Clever Klaus" always intervenes when errors occur. Correct hand movements are confirmed. Above an ergonomically designed work table, two high-resolution 2D cameras check whether all connectors are correctly engaged. The working sequence is irrelevant. Incorrect or missing connections are a thing of the past when fitting doors to the new Audi A4. Audi is delighted with the solution. On the one hand, door assembly is virtually error-free, and on the other, the employees feel supported and their workload is significantly reduced. as
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