In a groundbreaking move, Audi has begun utilizing artificial intelligence (AI) for quality control in car manufacturing. This innovative approach, part of the brand’s ongoing digitalization of production, promises to revolutionize the way vehicles are produced and inspected.
AI Revolution in Quality Control
Audi’s AI system, developed and tested at the Neckarsulm site, is designed to analyze around 1.5 million spot welds on 300 vehicles each shift. This is a significant leap from the previous manual monitoring method, where production staff used ultrasound to check around 5,000 spot welds per vehicle.
With AI, employees can now focus on potential anomalies, enabling them to control quality more efficiently and in a more targeted way.
The Role of Audi AI in Spot Welds Quality Control
The AI system is a game-changer for quality control in car manufacturing. It allows for a more comprehensive and efficient inspection process, freeing up employees to focus on areas of concern. As Gerd Walker, Audi Board Member for Production and Logistics, puts it:
“Digitalized assembly lines are a foundation for Audi’s vision for the production of the future… the use of artificial intelligence in series production promises huge potential.”
Expansion of Audi AI Technology Across Volkswagen Group
The success of the AI system has prompted Volkswagen Group to begin installing the technical infrastructure in additional plants. The technology is currently being installed at Audi Brussels, and the Volkswagen plant in Emden and Audi’s headquarters in Ingolstadt are scheduled to follow suit later this year.
Future Prospects: AI for Predictive Maintenance and Digitalized Assembly Lines
The data generated through the use of the AI system can also be used to optimize other processes in the future. For instance, the Audi team is currently exploring the possibility of using the data for predictive maintenance. This is part of Audi’s broader vision for digitalized assembly lines and more efficient production worldwide.
Collaboration with Audi DGQ, Fraunhofer IAO, and Fraunhofer IPA
To ensure the process is audit- and certification-proof, Audi has collaborated closely with the German Association for Quality (DGQ), the Fraunhofer Institute for Industrial Engineering (IAO), and the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA). This collaboration is crucial as there are currently no standards or certifications issued by an independent body for AI applications.
The AI25 Initiative: A Step Towards Digital Factory Transformation
The AI system also serves as a use case for the Automotive Initiative 2025 (AI25) launched by Audi. This initiative aims to establish a competence network for digital factory transformation and innovation. Audi is leveraging digitalization to make production and logistics more flexible and efficient, testing digital solutions in a real manufacturing environment in Neckarsulm.
Audi’s use of AIfor quality control in car manufacturing marks a significant step forward in the automotive industry’s digitalization journey. As we look towards the future, it’s clear that AI and digital technologies will continue to play a pivotal role in shaping the way vehicles are produced and inspected.
