armed to deal with the forthcoming challenges of the working environment working environment.

armed to deal with the forthcoming challenges of the working environment.working environment.

4 4 1 1 Walking – Walking – The exoskeleton is The exoskeleton is worn on the back of the worn on the back of the legs and gives the legs and gives the worker great freedom worker great freedom of movement. of movement. 2 2 Sitting – Sitting – The seating surface The seating surface supports the hind- supports the hindquarters and thighs, quarters and thighs, even at short assembly even at short assembly

intervals. intervals. 3 3 Relief – Relief – Belts fasten the Chair- Belts fasten the Chair- less Chair to the less Chair to the hips, thighs and ankles. hips, thighs and ankles. It can be individually It can be individually adapted to different adapted to different body sizes. body sizes. → → Chairless Chair – Chairless Chair – The innovative seating The innovative seating aid weighs around aid weighs around three kilograms at its three kilograms at its

current stage current stage of development. of development. 3 3 2 2 1 1 104

It is the moment when the car It is the moment when the car receives its enduring identity; receives its enduring identity; that process step that turns welded sheet metal, hi- that process step that turns welded sheet metal, hi- tech and expertise into a unique Audi – when the in- tech and expertise into a unique Audi – when the in- dividual chassis number (VIN) is

dividual chassis number (VIN) is stamped inside thestamped inside the engine bay.

engine bay.

During the stamping process, the worker During the stamping process, the worker carries out assembly work inside the engine bay. In carries out assembly work inside the engine bay. In order to be able to work here completely ergonomi- order to be able to work here completely ergonomi- cally, the worker needs a chair, which he has to take with cally, the worker needs a chair, which he has to take with him and place in the

him and place in the working position. Today, it’s a lotworking position. Today, it’s a lot easier – and more ergonomic – with the “Chairless Chair”. easier – and more ergonomic – with the “Chairless Chair”. The worker walks a few steps, suddenly sits down, ap- The worker walks a few steps, suddenly sits down, ap- parently on nothing, and remains relaxed in parently on nothing, and remains relaxed in this posi-this position, which is the perfect one for

tion, which is the perfect one for the procedure in ques-the procedure in ques- tion. Her concentration remains fully on her work. tion. Her concentration remains fully on her work.

What looks like magic is, in fact, a piece of What looks like magic is, in fact, a piece of hi-tech. The Chairless Chair is an exoskeleton worn on hi-tech. The Chairless Chair is an exoskeleton worn on the back of the legs and fitted

the back of the legs and fitted with straps at the hips,with straps at the hips, knees and ankles. The seating surface supports the knees and ankles. The seating surface supports the hindquarters and thighs; the two braces made from hindquarters and thighs; the two braces made from carbon-fiber reinforced plastic (CFRP) adapt to the con- carbon-fiber reinforced plastic (CFRP) adapt to the con- tours of the legs. They are equipped with joints at tours of the legs. They are equipped with joints at kneeknee height and are hydraulically adjusted to the size of the height and are hydraulically adjusted to the size of the respective user and to set the desired seating position. respective user and to set the desired seating position. The bodyweight is transferred into the ground via The bodyweight is transferred into the ground via thesethese adjustable elements. The Chairless Chair itself adjustable elements. The Chairless Chair itself weighsweighs around three kilograms at its

around three kilograms at its current stage of develop-current stage of development. The target weight is 2.4

ment. The target weight is 2.4 kilograms.kilograms. The Chairless Chair by noonee AG in Rüti, The Chairless Chair by noonee AG in Rüti, Switzerland, is still undergoing tests, in the likes of Switzerland, is still undergoing tests, in the likes of cockpit assembly at the Neckarsulm plant. However, cockpit assembly at the Neckarsulm plant. However, plans are already in place for its use in a wide variety of plans are already in place for its use in a wide variety of locations throughout the

locations throughout the production process.production process.

Audi has been a leader in the field Audi has been a leader in the field of ergo-of ergonomics in the automotive industry for many years and nomics in the automotive industry for many years and raises awareness throughout the entire company of raises awareness throughout the entire company of good work planning – both in the production halls and good work planning – both in the production halls and in the offices. The ergonomic strategy “We stand for in the offices. The ergonomic strategy “We stand for us. Actively into the future” is a

us. Actively into the future” is a response to currentresponse to current and forthcoming challenges, such as changes in the and forthcoming challenges, such as changes in the world of work resulting from an increasing diversity of world of work resulting from an increasing diversity of variants and complexity in automotive design, as well variants and complexity in automotive design, as well as the continually expanding worldwide production as the continually expanding worldwide production network.

network.

In Germany, in particular, this includes a In Germany, in particular, this includes a further challenge – demographic change. In a few years, further challenge – demographic change. In a few years, half of the workforce will be over 50 years old. At the half of the workforce will be over 50 years old. At the same time, young people from “Generation Y” are join- same time, young people from “Generation Y” are join- ing the company – with a whole new

ing the company – with a whole new set of expectationsset of expectations from their working

from their working environment.environment.

Ergonomics experts at Audi are addressing Ergonomics experts at Audi are addressing the changing world of work, demographic develop- the changing world of work, demographic develop- ments and the generational shift in values ments and the generational shift in values with definedwith defined areas of action. Holistic ergonomics methods focus on areas of action. Holistic ergonomics methods focus on both the physical and the psychological wellbeing of both the physical and the psychological wellbeing of the workforce. New group working and rotation con- the workforce. New group working and rotation con- cepts are part of intelligent work organization, and cepts are part of intelligent work organization, and ergonomics in production will play an even more ergonomics in production will play an even more impor-impor- tant role in the design process in future. Building an tant role in the design process in future. Building an ergonomics network across all Audi plants and estab- ergonomics network across all Audi plants and estab- lishing common global standards for ergonomics is also lishing common global standards for ergonomics is also part of the ongoing internationalization of the com- part of the ongoing internationalization of the company. All plans from the area of ergonomics are being pany. All plans from the area of ergonomics are being communicated through a number of

communicated through a number of different channelsdifferent channels and the dialogue with employees further expanded. and the dialogue with employees further expanded. The principle at Audi

The principle at Audi for the holistic design of for the holistic design of attractiveattractive and productive working conditions is and will remain and productive working conditions is and will remain inin future – people are what

future – people are what matter.matter. Text

Text Paul-Janosch Ersing

Paul-Janosch Ersing PhotosPhotosStefan Sauer, Matt StarkStefan Sauer, Matt Stark

Illustrations Illustrations noonee AG noonee AG

What looks like magic is,

in fact, a piece of hi-tech. The

Chairless Chair is an

exoskeleton worn on the

back of the legs

Generation Y Generation Y Members of “Genera- Members of “Genera- tion Y” (18 to 30 tion Y” (18 to 30 years old) currently years old) currently make up around make up around 20 percent of the work- 20 percent of the workforce. They differ force. They differ considerably from their considerably from their parents in terms of parents in terms of their values, attitudes their values, attitudes and behavior patterns. and behavior patterns. They strive more for They strive more for meaning, responsibility meaning, responsibility and appreciation; and appreciation; they want to work flex- they want to work flex- ibly and they set ibly and they set great store by the emo- great store by the emo-

tional aspects tional aspects and image of their and image of their employer. employer.

Y

4 4 Healthy – Healthy – The Chairless Chair The Chairless Chair ensures the right ensures the right stance during assembly stance during assembly of the engine support. of the engine support.

5 5 Comfortable – Comfortable – The Chairless Chair The Chairless Chair takes the load takes the load off the legs during off the legs during tasks such as door tasks such as door preassembly. preassembly. 6 6 Practical – Practical – When stamping the When stamping the chassis number, chassis number, the worker in the pilot the worker in the pilot phase no longer phase no longer has to pull up a chair. has to pull up a chair.

5 5 6 6

SIT-IN

People Matter

Audi leads the field in ergonomics within the automotive industry.

Innovative technologies are part of the strategy to promote the physical and

psychologi

psychological wellbeing of cal wellbeing of the workforce. Audi is the workforce. Audi is therefore welltherefore well

armed to deal with the forthcoming challenges of the

armed to deal with the forthcoming challenges of the working environment.working environment.

current stage current stage of development. of development. 3 3 2 2 1 1 104

104 EncounterEncounter Smart Factory Smart Factory 105105 EncounterEncounter Smart Factory Smart Factory

W E I G H T

W A T C H E R S

A U D I I S E X P A N D I N G I T S L E A D I N G R O L E A U D I I S E X P A N D I N G I T S L E A D I N G R O L E I N L I G H T W E I G H T D E S I G N E VI N L I G H T W E I G H T D E S I G N E V E NE N F U R T H E R W I T H T H E R F U R T H E R W I T H T H E R 8 S P O R T S C A R A N D 8 S P O R T S C A R A N D T H E L A R G E T H E L A R G E Q 7 S U V .Q 7 S U V . T H E N E W T H E N E W M O D E L S , W I T H T H E I R M O D E L S , W I T H T H E I R M U L T I - M AM U L T I - M AT E R I A L B O D Y S H E L L S ,T E R I A L B O D Y S H E L L S , L E A V E T H E P R O D U C T I O N F A C I L I T I E S L E A V E T H E P R O D U C T I O N F A C I L I T I E S C L O S E T O N E C K A R S U L M A N D C L O S E T O N E C K A R S U L M A N D I NI N B R A T I S L A V A . A T B O T H P L A N T S , A U D I P U L L S O U T A L L T H E B R A T I S L A V A . A T B O T H P L A N T S , A U D I P U L L S O U T A L L T H E S T O P SS T O P S I N B O D Y S H E L L M A N U F A C T U R I N G – A L B E I T I N D I F F E R E N T I N B O D Y S H E L L M A N U F A C T U R I N G – A L B E I T I N D I F F E R E N T W A Y S .W A Y S . Text Text Johannes Köbler Johannes Köbler Photos Photos Stefan Sauer Stefan Sauer Stefan Warter Stefan Warter 1 1 Automated – Automated – The aluminum The aluminum ASF of the new Audi R8 ASF of the new Audi R8 high-performance high-performance sports car in sports car in the machining cell. the machining cell.

2 2 Manual work – Manual work – The exterior skin The exterior skin receives its final finish receives its final finish in the grinding in the grinding tunnel prior to tunnel prior to painting.painting.

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W E I G H T

W A T C H E R S

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106 EncounterEncounter Smart Factory Smart Factory

Bodyshell manufacturing for Bodyshell manufacturing for the new Audi R8 is a very spe- the new Audi R8 is a very spe- cial low-volume production operation. The facility at cial low-volume production operation. The facility at Audi Böllinger Höfe close to Neckarsulm, opened in Audi Böllinger Höfe close to Neckarsulm, opened in fall 2014, is set up for small production runs and fall 2014, is set up for small production runs and broad diversity – and for

broad diversity – and for high-end expertise in light-high-end expertise in light- weight engineering. The high-performance sports weight engineering. The high-performance sports car’s multi-material Audi Space Frame (ASF) weighs car’s multi-material Audi Space Frame (ASF) weighs just 200

just 200 kilograms, yet kilograms, yet is extremely is extremely stiff and stiff and impactimpact safe. It is made 70 percent from aluminum and 13 safe. It is made 70 percent from aluminum and 13 percent from carbon-fiber reinforced plastic percent from carbon-fiber reinforced plastic (CFRP)(CFRP) – in accordance with the Audi motto “The – in accordance with the Audi motto “The right mate-right material in the right amounts

rial in the right amounts in the right place.”in the right place.” “At full capacity, we will produce 40 body- “At full capacity, we will produce 40 body- shells per day in two-shift operation,” explains Jochen shells per day in two-shift operation,” explains Jochen Wagner

Wagner, Head , Head of Production quattro GmbH. of Production quattro GmbH. “We“We have divid

have divided bodyshell production into two mained bodyshell production into two main areas – Body

areas – Bodyshell Production 1 is for the aluminumshell Production 1 is for the aluminum elements, and Bodyshell Production 2 is for adding elements, and Bodyshell Production 2 is for adding the CFRP parts. In Bodyshell Production 1, we also the CFRP parts. In Bodyshell Production 1, we also differentiate between the zone for welding work and differentiate between the zone for welding work and the area for bolt-on parts and finish. The flexibility we the area for bolt-on parts and finish. The flexibility we gain throug

gain through this helps us when h this helps us when it comes to it comes to buildingbuilding derivatives such as the R8

derivatives such as the R8 LMS GT3 race car.”LMS GT3 race car.”

The bodyshell of the new

The bodyshell of the new Audi R8 is cre-Audi R8 is cre- ated in a production rhythm of 21.5

ated in a production rhythm of 21.5 minutes, withminutes, with people and robots alternating tasks. In the first step, people and robots alternating tasks. In the first step, specialists weld together the front end of the car, the specialists weld together the front end of the car, the central floor and the rear end from aluminum cast- central floor and the rear end from aluminum castings and extruded profile. They then connect the ings and extruded profile. They then connect the three modules to create the substructure. Robots three modules to create the substructure. Robots handle the cold jointing processes – the complete handle the cold jointing processes – the complete ASF consists of 270

ASF consists of 270 semi-hollow punch rivets, 270semi-hollow punch rivets, 270 blind rivets, 241 metric and 270 self-tapping screws; blind rivets, 241 metric and 270 self-tapping screws; the welded seams are a good 89 meters long. the welded seams are a good 89 meters long.

The bodyshell grows further with the The bodyshell grows further with the greenhouse and the roof. In a cell, a five-axis ma- greenhouse and the roof. In a cell, a five-axis ma- chine precision cuts the connecting points for the chine precision cuts the connecting points for the CFRP components, the suspension and the steering CFRP components, the suspension and the steering to within hundredths of a millimeter. Inline laser to within hundredths of a millimeter. Inline laser measuring equipment checks the dimensional ac- measuring equipment checks the dimensional ac- curacy of the ASF. At

curacy of the ASF. At a geometry station, techniciansa geometry station, technicians attach doors, lids, fenders and side parts – made attach doors, lids, fenders and side parts – made from aluminum – with the aid of precision-guided from aluminum – with the aid of precision-guided fixtures. fixtures. 6 6 Rear bulkhead Rear bulkhead installation – installation – Qualified technicians Qualified technicians set the screw fasteners set the screw fasteners

by hand. by hand. 7 7 Center tunnel Center tunnel installation – installation – The tunnel is positioned The tunnel is positioned

on a fixture, on a fixture, before the bodyshell is before the bodyshell is lowered onto it. lowered onto it. 3 3 Substructure welding – Substructure welding – Specialists weld Specialists weld together the together the profile and castings to profile and castings to form the rear end. form the rear end.

4 4 Roof framer – Roof framer – The roof is positioned The roof is positioned

on the ASF. on the ASF. The yellow grips are The yellow grips are for closing the for closing the tightening fixture. tightening fixture. 5 5 Rear bulkhead Rear bulkhead installation – installation – A robot inserts the A robot inserts the CFRP into the ASF, CFRP into the ASF, which has been turned which has been turned

onto its side. onto its side.

4 4 7 7 6 6 5 5 13 percent 13 percent of the ASF in the new of the ASF in the new Audi R8 is made Audi R8 is made from carbon-fiber rein- from carbon-fiber reinforced plastic (CFRP). forced plastic (CFRP).

13

O U R F L E X I B I L I T Y O U R F L E X I B I L I T Y I N B O D Y S H E L L M A N U F A C T U R I N GI N B O D Y S H E L L M A N U F A C T U R I N G H E L P S U S I N T H E P R O D U C T I O N O F H E L P S U S I N T H E P R O D U C T I O N O F D E R I V A T I V E S S U C H A SD E R I V A T I V E S S U C H A S T H E A U D I R 8 L M S G T 3 R A C E C A R . T H E A U D I R 8 L M S G T 3 R A C E C A R . Jochen Wagner,

Jochen Wagner, Head of Production quattro GmbH. Head of Production quattro GmbH. A L U M I N U M A N D C F R P C O M E A L U M I N U M A N D C F R P C O M E T O G E T H E R I NT O G E T H E R I N T H E A S F O F T H E N E W R 8 – M A R K I N G A N E T H E A S F O F T H E N E W R 8 – M A R K I N G A N E W V A R I A N TW V A R I A N T O F T H E M U L T I - M A T E R I A L A P P R O A C H . O F T H E M U L T I - M A T E R I A L A P P R O A C H .

A U D I R 8

3 3

New material pairing – New material pairing – CFRP (black) and aluminum form CFRP (black) and aluminum form

an extremely strong and an extremely strong and stiff composite in the ASF of the stiff composite in the ASF of the

new Audi R8. new Audi R8.

Scan the QR code to experience the production of the Scan the QR code to experience the production of the newAudi R8 in video format.

newAudi R8 in video format.

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