Global Compact International Yearbook 2016

workers will be in demand and coveted.
Identifying problems and indicating
them to the workers – the rectification
process, for example – will also proceed
much faster thanks to integrated diagnostics
systems.
Clearly, however, the standards involved
in working in the production plant of the
future will rise. The workers are therefore
supported by elaborate information
systems because the extreme variations
in products has resulted in a very large
scope of tasks. At the interfaces between
electronic and mechanical systems, for
example, software experts ensure that
sensors are set and functioning optimally.
Network architects ensure that machines
and workers can communicate. So the
high levels of technology and integration
already require one thing above all: the
adequate qualification and advancement
of the workers.
New robots facilitate work
In the production plant of the future,
robots can support the workers in many
different ways. For example, machines
can supply them with important information
as needed, or step in to perform
non-value-adding activities. The division
of labor runs along the same principles
as in the operating room: prepare – pass
on – operate.
the workers of the need to do physically
strenuous tasks. Audi’s goal is to make
every workstation as ergonomic as possible.
Assembly Technology Development,
for example, is working on increasingly
transferring burdensome tasks from
workers to robots. This aspect is especially
relevant in production, because
that is where most physical effort is
required, and demographic change is
forcing through fresh solutions.
Beyond the confines of the plant –
globally integrated
Digitalization is making inroads not just
within a production location, but across
the entire global production chain. The
Audi Group currently builds vehicles at
17 locations in 13 countries. The new
plant in Mexico was added in 2016. More
than 85,000 employees throughout the
Group work simultaneously on creating
high-quality products all over the world.
To do this, a huge amount of data needs
to be shared between the plants because
they are all interconnected non-centrally.
Networking this working data intelligently
and processing it in real time
are therefore major priorities. The key
thing is to send and evaluate enormous
data flows quickly and at high speed.
Data security is obviously hugely important
for this “big data”: As early as
the research phase, the company uses
recognized and tested embedded security
mechanisms and standards. To enable
smooth communication, international
standards must also be clarified.
Ideas from our own ranks
Preparing the way to the Smart Factory
of the future is not merely the task of
designated experts in creative teams. Ever
since 1969, each individual employee
at Audi has had the opportunity to put
forward their own ideas; in 1994 this
suggestions scheme gave birth to the
Audi Ideas Program. The large number
of innovative suggestions has resulted
in both minor and far-reaching process
improvements, all of which save
costs. Since the program was introduced,
AUDI AG has realized savings in the order
of € 780 million. Audi examines the
benefits and feasibility of every idea submitted
with a view to raising efficiency
or improving the working environment.
It is quite common for them even to
result in successful patents, such as the
helical-thread mold.
For the past two years, smaller robots
operating according to this principle
have been in action on the Audi assembly
line without any safety fence. The
work that these new “colleagues” do is
often relatively simple, but they relieve
Left: Efficient and kind on the back:
The robot offers the container at the very
moment the worker needs it.
Right: A highly efficient factory:
The Audi A3 body shop with innovative
technologies and cutting-edge equipment.
Efficiency and sustainability were the priorities
when planning the production hall.
Global Compact International Yearbook 2016 109