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Quality has always been part of AudisDNA, and its also the aim of apilot project launched last year at the Neckarsulmsite to check the correct execution of spot welds in high-volume production. The partners in this project, which is part of theVolkswagen Groups Industrial Cloudwhich is to be implemented in other plants, are SiemensandAmazon Web Services.

In the body of a car like theAudi A6, around 5,300 spotweldsare required. Up until now, thequalityof the welds has been monitored manually by technicians using ultrasound on the basis ofrandom analyses. In theWPS Analytics pilot project, in which specialists from the fields of manufacturing, innovation management, planning, digitization and IT are involved,artificial intelligenceis used to detect quality anomalies automatically and in real time.

The WPS Analytics Pilot Project

TheWPS Analytics team is led by Mathias Mayer and Andreas Rieker. Michael Haeffner, Head of Delivery Management DigitalizationforProduction and Logisticsat AUDI AG, says: Our goal is to test and developdigital solutionsfor vehicle manufacturing right through to their use in seriesproduction. With the use ofAI, we are testing an important key technology here that will make Audi and the location fit for the future.

The system consists of analgorithm, a graphical user interface (dashboard) and anapplicationfor more in-depth analyses. Thetargetof thisprojectis for the algorithm to be able to evaluate close to 100% of the set welding points, while the long-term goal is that the quality of theweldingprocesses can be automatically controlled and continuously optimized.

Artificial Intelligence In Production

The algorithm serves as a blueprint for further applications in connected manufacturing and allows us to make advancements to existing digital solutions, such as predictive maintenance, explains Mayer, who has already been working on the application of artificial intelligence in Audi production for some five years.

TheIngolstadt-based company is taking the lead in driving forward this pilot project within theVolkswagen GroupsIndustrial Cloud, which brings together production data from all of the Groupsfactoriesworldwide, with the main aim of increasingefficiencyand reducingcosts. Each cloud connected site can download applications and updates for its machines and systems, similar to an app store, increasing process efficiency.

Synergies Through The Industrial Cloud

The experience with WPS Analytics at Neckarsulmhas already proved useful at theVolkswagen siteinEmden, wherespot weldingis controlled byalgorithmsthanks to lessons learned from the projects that feed into theIndustrial Cloud. InIngolstadt, a further application is being implemented that uses an algorithmto make work in the press shop more efficient.Artificial intelligencewill be used to detect defects such as small cracks in the car body.

This project is also part of theAutomotive Initiative2025 (AI25), an initiative that brings together partners from the academic world and the IT sector to make plants, and therefore production and logistics, more flexible and smarter throughdigitalization. Already today, someinnovativetechnologiesare helping employees in practice, relieving them of monotonous and strenuous physical and manual tasks.

Source:AUDI AG

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