Encounter - Smart Factory, 2015

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04 04 06 06

LOUNGE

Audi Rethinks Production.

The future of the factory has begun. Intelligent sy

stems,

innovative technologies,

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Smart Factory

2015

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The fact is that the digital world is merging with the real The fact is that the digital world is merging with the real world of our production. For us “Audianer” it is important that we world of our production. For us “Audianer” it is important that we take the leading role. One key factor is to make effective use of our take the leading role. One key factor is to make effective use of our knowledge of the interfaces in the interaction of all production knowledge of the interfaces in the interaction of all production units. We also need network architects and programmers to units. We also need network architects and programmers to con-figure machines in future in a way that ensures all processes are figure machines in future in a way that ensures all processes are heavily synchronized with one another and that the factory heavily synchronized with one another and that the factory technol-ogy provides employees with the

ogy provides employees with the best possible support.best possible support. Even in the face of

Even in the face of all this automation, the worker re-all this automation, the worker re-mains at the center. Job profiles may change, but Audi will never mains at the center. Job profiles may change, but Audi will never have a factory devoid of

have a factory devoid of people. Rather, people and machines willpeople. Rather, people and machines will complement one another in

complement one another in their strengths. While robots handletheir strengths. While robots handle monotonous, physically strenuous and stressful jobs, it is people monotonous, physically strenuous and stressful jobs, it is people who will be executing value-adding production processes – and it who will be executing value-adding production processes – and it will always be down to them when creativity and innovation are the will always be down to them when creativity and innovation are the order of the day. When I think of

order of the day. When I think of Audi, I always picture a team inAudi, I always picture a team in which every individual is bubbling over

which every individual is bubbling over with energy and motivation.with energy and motivation. It is our ideas that

It is our ideas that will bring us forward in future, too. And that will bring us forward in future, too. And that isis why the human being will remain the key

why the human being will remain the key to successful production.to successful production. Our task now is to transfer the idea of the Smart Factory Our task now is to transfer the idea of the Smart Factory to all our plants and thus set ourselves on a

to all our plants and thus set ourselves on a broad and firm founda-broad and firm founda-tion. What we want to generate throughout our entire organization tion. What we want to generate throughout our entire organization is a permanent state of creative restlessness. Everyone is called is a permanent state of creative restlessness. Everyone is called upon to keep searching for opportunities for improvement. We upon to keep searching for opportunities for improvement. We question the status quo in order to become even better and stronger question the status quo in order to become even better and stronger – in the interests of

– in the interests of our customers. In this Encounter Magazine, weour customers. In this Encounter Magazine, we show you the stages we have already completed and the routes that show you the stages we have already completed and the routes that still lie ahead on the path to the Smart Factory. You will be surprised still lie ahead on the path to the Smart Factory. You will be surprised by the diversity of the solutions we have already implemented in by the diversity of the solutions we have already implemented in Audi Production. This is how we are securing progress in this field Audi Production. This is how we are securing progress in this field of innovation, too.

of innovation, too. I wish you an enjoyable read! I wish you an enjoyable read! Our sector i

Our sector i s currently undergoing the greatest upheav-s currently undergoing the greatest upheav-al of its

al of its more than one-hundred year history. An increasing numbermore than one-hundred year history. An increasing number of customers are seeking highly

of customers are seeking highly individual automobiles that can beindividual automobiles that can be further individualized even after purchase. On the one hand, a further individualized even after purchase. On the one hand, a di- di-verse array of

verse array of model variants expands our product lineup, while, onmodel variants expands our product lineup, while, on the other, increasing the complexity of our global

the other, increasing the complexity of our global production pro-production pro-cesses. “Vorsprung durch Techn

cesses. “Vorsprung durch Technik” is in ik” is in the DNA of every the DNA of every Audi. VeryAudi. Very fitting to this is the way we manufacture an Audi – always to the fitting to this is the way we manufacture an Audi – always to the very latest state of the art. Our production will continue to set very latest state of the art. Our production will continue to set benchmarks in future, too.

benchmarks in future, too. This leads us to

This leads us to strive to make processes efficient, flex-strive to make processes efficient, flex-ible, highly automated and future-proof. The guideline i ible, highly automated and future-proof. The guideline i n so doingn so doing is to fulfill to the utmost the customer wishes of tomorrow and is to fulfill to the utmost the customer wishes of tomorrow and the day after. Therefore, we are digitalizing and networking the day after. Therefore, we are digitalizing and networking inno-vative technologies, factories and all business functions vative technologies, factories and all business functions intelli-gently with one another and enabling humans and machines to gently with one another and enabling humans and machines to work together hand-in-hand.

work together hand-in-hand.

You can imagine the future of Audi Production thus: You can imagine the future of Audi Production thus: Bodyshells come precision-made from the 3D printer; driverless Bodyshells come precision-made from the 3D printer; driverless transport systems move cars of

transport systems move cars of different model ranges freely fromdifferent model ranges freely from station to station as required for the next assembly step, instead station to station as required for the next assembly step, instead of to a tight, sequentially fi

of to a tight, sequentially fi xed rhythm; and robots assist employees,xed rhythm; and robots assist employees, knowing for themselves what is required of them next. That is our knowing for themselves what is required of them next. That is our vision for the factory of the future – we

vision for the factory of the future – we call it the “Smart Factory”.call it the “Smart Factory”. The word smart – meaning clever, intelligent, neat – The word smart – meaning clever, intelligent, neat – stands for our passion for driving innovation and for continually stands for our passion for driving innovation and for continually developing ourselves. This is how we

developing ourselves. This is how we create ever better solutionscreate ever better solutions that keep us one step ahead of the competition. Therefore, as we that keep us one step ahead of the competition. Therefore, as we see it, the Smart Factory is a better expression of the dynamics see it, the Smart Factory is a better expression of the dynamics behind this process than the

behind this process than the popular term “Industry 4.0”. Smartpopular term “Industry 4.0”. Smart Factory is a vision that we will pursue with all

Factory is a vision that we will pursue with all our might.our might. The factory of the future offers us enormous potential The factory of the future offers us enormous potential that has yet to be exploited. Take data, for instance – it that has yet to be exploited. Take data, for instance – it will becomewill become as valuable in future as a raw material as oil or gold. How can we as valuable in future as a raw material as oil or gold. How can we make this raw material a central factor of production? How can we make this raw material a central factor of production? How can we use even more artificial intelligence in our tools and machines? On use even more artificial intelligence in our tools and machines? On this time travel to the Smart Factory, we are continuously asking this time travel to the Smart Factory, we are continuously asking ourselves the questions: Is our process quality right? Are we agile ourselves the questions: Is our process quality right? Are we agile and sustainable enough? And, above all: Do our products meet and sustainable enough? And, above all: Do our products meet thethe highest standards of premium

highest standards of premium quality?quality?

EDITORIAL

Prof. Dr. Hubert Waltl

Member of the Board of Management of AUDI AG,

Production

The digital world is merging with the real world of our production.

For us “Audianer” it is important that we take the leading role.

Prof.

Prof. Dr.

Dr. Hubert

Hubert Waltl

Waltl

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2 EncounterEncounter Smart Factory Smart Factory 33 EncounterEncounter Smart Factory Smart Factory

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Hot Heart Hot Heart A visit to

A visit to Ducati’s legendary engine-Ducati’s legendary engine-makers in Bologna

makers in Bologna

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A Production Line of Ideas A Production Line of Ideas Many employee ideas further improve Many employee ideas further improve production flow production flow

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Carrozzeria Carbonara Carrozzeria Carbonara

In Sant’Agata Bolognese, hi-tech In Sant’Agata Bolognese, hi-tech mono-coques are made from CFRP coques are made from CFRP

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Motion Pictures Motion Pictures

A nighttime photo tour through the A nighttime photo tour through the Belgian A1 plant Belgian A1 plant

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Imprint Imprint

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The Summiteers The Summiteers

Board member for Production Prof. Dr. Board member for Production Prof. Dr. Hubert Waltl talks to the “Huberbuam” Hubert Waltl talks to the “Huberbuam” (the Huber boys)

(the Huber boys)

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Smart Faction Smart Faction The future of

The future of networked productionnetworked production has already begun at Audi has already begun at Audi

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The Best of Friends The Best of Friends

Humans and robots are working together Humans and robots are working together ever more productively

ever more productively

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Robbie Talkie Robbie Talkie Prof. Dr. Gerhard Rigoll Prof. Dr. Gerhard Rigoll on communication with steel on communication with steel co-workers co-workers

SKILLS.

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Print on Demand! Print on Demand! Audi’s new 3D printers can print Audi’s new 3D printers can print prototypeprototype parts from metal

parts from metal

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Viva México Viva México

Audi is conducting training in Germany Audi is conducting training in Germany for a large number of employees from the for a large number of employees from the new Q5 plant new Q5 plant

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Dream Machines Dream Machines

Audi is saving lots of time and money with Audi is saving lots of time and money with virtual and augmented-reality tools. virtual and augmented-reality tools.

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The Networkers The Networkers

Prof. Dr. Waltl and Prof. Dr. Neugebauer Prof. Dr. Waltl and Prof. Dr. Neugebauer discuss the Smart Factory discuss the Smart Factory

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Bobby Drives Himself Bobby Drives Himself

Self-driving cars will be able to leave the Self-driving cars will be able to leave the factory on their own

factory on their own

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The Factory Gets Smart The Factory Gets Smart The future of the

The future of the highly networked Smarthighly networked Smart Factory has already begun at Audi Factory has already begun at Audi

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Factory on Air Factory on Air

Drones could serve in future as Drones could serve in future as rapidrapid transporters on the factory site transporters on the factory site

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The Audi Hour The Audi Hour What happens in the

What happens in the Audi ProductionAudi Production network in the space of 60 minutes? network in the space of 60 minutes?

92

Tooling Up Tooling Up

Intelligent press tools make Intelligent press tools make sheet-metalsheet-metal parts even more precisely

parts even more precisely

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The Power Line The Power Line The Audi A3 Sportback e-tron The Audi A3 Sportback e-tron is builtis built at the main Ingolstadt plant at the main Ingolstadt plant

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Sit-in Sit-in

The Chairless Chair improves The Chairless Chair improves ergonomics at many workstations ergonomics at many workstations

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Weight Watchers Weight Watchers

Hi-tech in Bodyshell Manufacturing – the Hi-tech in Bodyshell Manufacturing – the new Audi R8 and the new Audi Q7 new Audi R8 and the new Audi Q7

114

Less Is More Less Is More

Audi is pursuing the vision of Audi is pursuing the vision of buildingbuilding its cars CO₂-neutrally in future its cars CO₂-neutrally in future

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Hot Heart Hot Heart A visit to

A visit to Ducati’s legendary engine-Ducati’s legendary engine-makers in Bologna

makers in Bologna

124

A Production Line of Ideas A Production Line of Ideas Many employee ideas further improve Many employee ideas further improve production flow production flow

132

Carrozzeria Carbonara Carrozzeria Carbonara

In Sant’Agata Bolognese, hi-tech In Sant’Agata Bolognese, hi-tech mono-coques are made from CFRP coques are made from CFRP

140

Motion Pictures Motion Pictures

A nighttime photo tour through the A nighttime photo tour through the Belgian A1 plant Belgian A1 plant

148

Imprint Imprint

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The Summiteers The Summiteers

Board member for Production Prof. Dr. Board member for Production Prof. Dr. Hubert Waltl talks to the “Huberbuam” Hubert Waltl talks to the “Huberbuam” (the Huber boys)

(the Huber boys)

26

Smart Faction Smart Faction The future of

The future of networked productionnetworked production has already begun at Audi has already begun at Audi

32

The Best of Friends The Best of Friends

Humans and robots are working together Humans and robots are working together ever more productively

ever more productively

38

Robbie Talkie Robbie Talkie Prof. Dr. Gerhard Rigoll Prof. Dr. Gerhard Rigoll on communication with steel on communication with steel co-workers co-workers

SKILLS.

42

Print on Demand! Print on Demand! Audi’s new 3D printers can print Audi’s new 3D printers can print prototypeprototype parts from metal

parts from metal

52

Viva México Viva México

Audi is conducting training in Germany Audi is conducting training in Germany for a large number of employees from the for a large number of employees from the new Q5 plant new Q5 plant

60

Dream Machines Dream Machines

Audi is saving lots of time and money with Audi is saving lots of time and money with virtual and augmented-reality tools. virtual and augmented-reality tools.

68

The Networkers The Networkers

Prof. Dr. Waltl and Prof. Dr. Neugebauer Prof. Dr. Waltl and Prof. Dr. Neugebauer discuss the Smart Factory discuss the Smart Factory

76

Bobby Drives Himself Bobby Drives Himself

Self-driving cars will be able to leave the Self-driving cars will be able to leave the factory on their own

factory on their own

78

The Factory Gets Smart The Factory Gets Smart The future of the

The future of the highly networked Smarthighly networked Smart Factory has already begun at Audi Factory has already begun at Audi

84

Factory on Air Factory on Air

Drones could serve in future as Drones could serve in future as rapidrapid transporters on the factory site transporters on the factory site

86

The Audi Hour The Audi Hour What happens in the

What happens in the Audi ProductionAudi Production network in the space of 60 minutes? network in the space of 60 minutes?

92

Tooling Up Tooling Up

Intelligent press tools make Intelligent press tools make sheet-metalsheet-metal parts even more precisely

parts even more precisely

100

The Power Line The Power Line The Audi A3 Sportback e-tron The Audi A3 Sportback e-tron is builtis built at the main Ingolstadt plant at the main Ingolstadt plant

104

Sit-in Sit-in

The Chairless Chair improves The Chairless Chair improves ergonomics at many workstations ergonomics at many workstations

106

Weight Watchers Weight Watchers

Hi-tech in Bodyshell Manufacturing – the Hi-tech in Bodyshell Manufacturing – the new Audi R8 and the new Audi Q7 new Audi R8 and the new Audi Q7

114

Less Is More Less Is More

Audi is pursuing the vision of Audi is pursuing the vision of buildingbuilding its cars CO₂-neutrally in future its cars CO₂-neutrally in future

124

14

118

68

106

106 1,792

2.5 1,792

2.5

Audi Q7 Bodyshell Manufacturing Audi Q7 Bodyshell Manufacturing The bodyshell of the Audi Q7

The bodyshell of the Audi Q7 is built at the Bratislava plant in ais built at the Bratislava plant in a new multi-material construction. The primary challenge is connecting new multi-material construction. The primary challenge is connecting hot-formed steel with aluminum.

hot-formed steel with aluminum.

Two-and-a-half millimeters – is the thickness of sheet steel that can be bonded Two-and-a-half millimeters – is the thickness of sheet steel that can be bonded with sheet aluminum using friction welding.

with sheet aluminum using friction welding. → Page 106

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VR and AR tools VR and AR tools Audi uses virtual and

Audi uses virtual and augmented-reality applicationaugmented-reality applications in much s in much of its planningof its planning and development work. They transfer the user into data worlds and superimpose and development work. They transfer the user into data worlds and superimpose reality with

reality with computer-genercomputer-generated imagery.ated imagery.

The four computers for visualization in the 3D Cave in the Preproduction Center use a total The four computers for visualization in the 3D Cave in the Preproduction Center use a total of 1,792 processor units to generate the imagery.

of 1,792 processor units to generate the imagery. → Page 60

→ Page 60

1,792

2.5 1,792

2.5

Audi Q7 Bodyshell Manufacturing Audi Q7 Bodyshell Manufacturing The bodyshell of the Audi Q7

The bodyshell of the Audi Q7 is built at the Bratislava plant in ais built at the Bratislava plant in a new multi-material construction. The primary challenge is connecting new multi-material construction. The primary challenge is connecting hot-formed steel with aluminum.

hot-formed steel with aluminum.

Two-and-a-half millimeters – is the thickness of sheet steel that can be bonded Two-and-a-half millimeters – is the thickness of sheet steel that can be bonded with sheet aluminum using friction welding.

with sheet aluminum using friction welding. → Page 106 → Page 106 03 03 04 04 06 06 CFRF monocoque at Lamborghini CFRF monocoque at Lamborghini

The monocoques of the Aventador super sports car are made The monocoques of the Aventador super sports car are made completelycompletely from CFRP. At the Lamborghini factory

from CFRP. At the Lamborghini factory in Sant’Agata Bolognese, the proportionin Sant’Agata Bolognese, the proportion of highly qualified manual work is extremely high.

of highly qualified manual work is extremely high.

The prepreg CFRP mats arrive at the factory from the supplier pre-cooled and are The prepreg CFRP mats arrive at the factory from the supplier pre-cooled and are further processed here at room temperature.

further processed here at room temperature. → Page 132

→ Page 132

-21°/+21°

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The Factory of the day after tomorrow

How will Audi build cars 20 years from

How will Audi build cars 20 years from now? Will big factories have to givenow? Will big factories have to give

way to small, decentralized units? How can the

way to small, decentralized units? How can the immense data flows be channeled?immense data flows be channeled?

Experts think about the Smart Factory of

Experts think about the Smart Factory of the future.the future.

Cars in the year 2030 will s

Cars in the year 2030 will still have four wheels; we can be sure of till have four wheels; we can be sure of that.that.

But production will have changed dramatically.

→ Page 26

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03 03 04 04 06 06 CFRF monocoque at Lamborghini CFRF monocoque at Lamborghini

The monocoques of the Aventador super sports car are made The monocoques of the Aventador super sports car are made completelycompletely from CFRP. At the Lamborghini factory

from CFRP. At the Lamborghini factory in Sant’Agata Bolognese, the proportionin Sant’Agata Bolognese, the proportion of highly qualified manual work is extremely high.

of highly qualified manual work is extremely high.

The prepreg CFRP mats arrive at the factory from the supplier pre-cooled and are The prepreg CFRP mats arrive at the factory from the supplier pre-cooled and are further processed here at room temperature.

further processed here at room temperature. → Page 132

→ Page 132

-21°/+21°

4

The Factory of the day after tomorrow

How will Audi build cars 20 years from

How will Audi build cars 20 years from now? Will big factories have to givenow? Will big factories have to give

way to small, decentralized units? How can the

way to small, decentralized units? How can the immense data flows be channeled?immense data flows be channeled?

Experts think about the Smart Factory of

Experts think about the Smart Factory of the future.the future.

Cars in the year 2030 will s

Cars in the year 2030 will still have four wheels; we can be sure of till have four wheels; we can be sure of that.that.

But production will have changed dramatically.

→ Page 26

Night in Brussels Night in Brussels

The Brussels plant has been part of

The Brussels plant has been part of the Audi Production network since 2007.the Audi Production network since 2007. More than 115,000 Audi A1 left the production line there last year. We take a photographic More than 115,000 Audi A1 left the production line there last year. We take a photographic trip through the Belgian plant.

trip through the Belgian plant.

The Audi A1 drives the first kilometers under its own power on a test rig. The Audi A1 drives the first kilometers under its own power on a test rig. And it is subject to a real power shower to ensure it is absolutely watertight. And it is subject to a real power shower to ensure it is absolutely watertight. → Page 140 → Page 140

115,000

1,500,000

115,000

1,500,000

Robot co-worker Robot co-worker

Audi is gradually dismantling the safety fences between humans Audi is gradually dismantling the safety fences between humans and robots. The

and robots. The latest-generation automatons register their surroundingslatest-generation automatons register their surroundings so precisely that direct cooperation is

so precisely that direct cooperation is now possible.now possible.

Roughly estimated, 1.5 million industrial robots were in use worldwide in 2014. Roughly estimated, 1.5 million industrial robots were in use worldwide in 2014. Robots are becoming ever better at assisting people.

Robots are becoming ever better at assisting people. → Page 32

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Night in Brussels Night in Brussels

The Brussels plant has been part of

The Brussels plant has been part of the Audi Production network since 2007.the Audi Production network since 2007. More than 115,000 Audi A1 left the production line there last year. We take a photographic More than 115,000 Audi A1 left the production line there last year. We take a photographic trip through the Belgian plant.

trip through the Belgian plant.

The Audi A1 drives the first kilometers under its own power on a test rig. The Audi A1 drives the first kilometers under its own power on a test rig. And it is subject to a real power shower to ensure it is absolutely watertight. And it is subject to a real power shower to ensure it is absolutely watertight. → Page 140 → Page 140

115,000

1,500,000

115,000

1,500,000

Robot co-worker Robot co-worker

Audi is gradually dismantling the safety fences between humans Audi is gradually dismantling the safety fences between humans and robots. The

and robots. The latest-generation automatons register their surroundingslatest-generation automatons register their surroundings so precisely that direct cooperation is

so precisely that direct cooperation is now possible.now possible.

Roughly estimated, 1.5 million industrial robots were in use worldwide in 2014. Roughly estimated, 1.5 million industrial robots were in use worldwide in 2014. Robots are becoming ever better at assisting people.

Robots are becoming ever better at assisting people. → Page 32

→ Page 32

MINDSET

It is the courage to innovate that put Audi

at the top. The company wants to

expand that lead even further with a continual

flow of new ideas and a clear approach.

——

THE SUMMITEERS

Prof. Dr. Hubert Waltl talks

to the “Huberbuam” (the Huber boys)

14

14 SMART FACTION

SMART FACTION

Audi conceives the

networked factory of tomorrow

26

26 THE BEST OF FRIENDS

THE BEST OF FRIENDS

The protective fence between humans

and robots comes down

32

32 ROBBIE TALKIE

ROBBIE TALKIE

How do we actually communicate

with our metal co-workers?

38

Encounter

Encounter Smart Factory Smart Factory

1

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MINDSET

It is the courage to innovate that put Audi

at the top. The company wants to

expand that lead even further with a continual

flow of new ideas and a clear approach.

——

THE SUMMITEERS

Prof. Dr. Hubert Waltl talks

to the “Huberbuam” (the Huber boys)

14

14 SMART FACTION

SMART FACTION

Audi conceives the

networked factory of tomorrow

26

26 THE BEST OF FRIENDS

THE BEST OF FRIENDS

The protective fence between humans

and robots comes down

32

32 ROBBIE TALKIE

ROBBIE TALKIE

How do we actually communicate

with our metal co-workers?

38

Encounter

1

122 1313 EEnnccoouunntteerr Smart Factory Smart Factory

Pushing past the limits – that’s what extreme mountain climbe

rs

Thomas and Alexander Huber, the “Huberbuam” (Huber boys), are all

about. They

take the seemingly impossible and make it pos

sible.

That’s also the standard set by

Prof. Dr. Hubert

Waltl, Member of the

Board of Management of AUDI

AG responsible for Production.

We

talk

to

them about

the means

to t

he end,

about

visions, passion,

risks, setbacks – and the moment that makes i

t all worthwhile.

Text Text Barbara Wege Barbara Wege

THE

SUMMITEERS

Photos Photos Katrin Ebner Katrin Ebner Franz

Franz HinterbrandHinterbrandnerner

Huberbuam Huberbuam Michael Meisl Michael Meisl Heinz Zak Heinz Zak

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Pushing past the limits – that’s what extreme mountain climbe

rs

Thomas and Alexander Huber, the “Huberbuam” (Huber boys), are all

about. They

take the seemingly impossible and make it pos

sible.

That’s also the standard set by

Prof. Dr. Hubert

Waltl, Member of the

Board of Management of AUDI

AG responsible for Production.

We

talk

to

them about

the means

to t

he end,

about

visions, passion,

risks, setbacks – and the moment that makes i

t all worthwhile.

Text Text Barbara Wege Barbara Wege

THE

SUMMITEERS

Photos Photos Katrin Ebner Katrin Ebner Franz

Franz HinterbrandHinterbrandnerner

Huberbuam Huberbuam Michael Meisl Michael Meisl Heinz Zak Heinz Zak Encounter

1

144 1919 EEnnccoouunntteerr Smart Factory Smart Factory

1

Board Member for Production,AUDIAG

HubertWaltl wasborn September 10,1958in Baar,

Bavaria.

After school,hebegan training asa

After school,hebegan training asa tool mechanic.tool mechanic.

His first job came in 1976 as a cutter in

His first job came in 1976 as a cutter in the Toolmakingthe Toolmaking

departmentatAUDIAG.

Following further education asa

Following further education asa state-apprstate-approved machineoved machine

technician,hewasappointed asof1994toa

succes-sion of management positions within Audi Toolmaking

sion of management positions within Audi Toolmaking

andProductionPlanningattheIngolstadtandNeckar-sulm plants. In parallel with his work,

sulm plants. In parallel with his work, Waltl also studiedWaltl also studied

Production Technology at the College of

Production Technology at the College of CommerceCommerce

and Technology in Dresden.

In 2002, he took over responsibility for all of

In 2002, he took over responsibility for all of AudiAudi

Toolmaking. Additional responsibilities for Group

Tool-making aswell asBodyshell Planning

making aswell asBodyshell Planning and Toolmakingand Toolmaking

for theVolkswagen car brand camein 2007.

On October 1, 2009, he was appointed Board Member

for Production and Logisticsfor theVolkswagen car

brand.He received his doctorate (Dr.-Ing) on January 8,

2013 from the Faculty of

2013 from the Faculty of Mechanical EngineeringMechanical Engineering

at theTU Chemnitz.

HubertWaltl hasbeen Board Member for Production at

AUDIAG sinceApril 1,2014.

InFebruary2015,theTechnic

InFebruary2015,theTechnicalUniversityofChemnitzalUniversityofChemnitz

awardedHubertWaltlanhonoraryprofess

awardedHubertWaltlanhonoraryprofessorshipfor orshipfor auto-

auto-motiveproductio

motiveproductiontoolingintheFacultyofMechanicalntoolingintheFacultyofMechanical

Engineering.

Thomas and

Alexand

Alexander Hubeer Huberr

Alexander Huber

Born:December 30,1968

Birthplace:Trost

Birthplace:Trostberg,Bavariaberg,Bavaria

Profession:Moun

Profession:Mountain tain climberclimber

Height:176 cm Height:176 cm Weight:74 kg Weight:74 kg Reach:126 cm Reach:126 cm

Alexander Huber, born in 1968 in

Trostbe

Trostberg,istheyoungeroftheHuber-

rg,istheyoungeroftheHuber-buam and wasn’t allowed to join

buam and wasn’t allowed to join

the mountain trips with their father

until a littlelater,which madehis

rise all the faster. He climbed to the

top oftheworld in 1994with his

ascent of the Schleier Waterfall in

Tyrol,Austriaviathe“WhiteRose”

route;theworld’sfirstintheupper11

difficulty level. The first grade-11

routesinAlpineclimbs,free-climbing

routesand speed recordson the

big wallsoftheYosemite(USA),the

first ascent of the West Face of

theseven-thousa

theseven-thousand-meterLatokIInd-meterLatokII

(Pakistan) and thefreesoloascentof

thedirettissima on thebig peak of

theTreCimediLavaredo(Italy) –

thesearethehighlightsofhis

thesearethehighlightsofhislifelife

asamountaineer.Thegraduatephys-icistchosethispat

icistchosethispathinlifeoveronehinlifeoverone

in science. Like his

in science. Like his brother Thomas,brother Thomas,

hetellsofhisexperiencesintalks

(incl.

(incl.IntheLightoftheMountainsIntheLightoftheMountains),),

books(incl.

books(incl.TheMountainWithin:TheTheMountainWithin:The

True Story of the World’s Most

Ex-tremeFree-As

tremeFree-Ascent cent Climber Climber ) and) and

films(incl.

films(incl.TotheLimit TotheLimit ).Alexander).Alexander

HuberliveswithhisfamilyinScheffau HuberliveswithhisfamilyinScheffau in in BerchtesgadeBerchtesgaden.n. www.huberbuam.de www.huberbuam.de Thomas Huber Thomas Huber Born:November 18,1966 Born:November 18,1966 Birthplace:Pallin

Birthplace:Palling,Bavariag,Bavaria

Profession:Mount

Profession:Mountain ain climberclimber

Height:178 cm Height:178 cm Weight:76 kg Weight:76 kg Reach:120 cm Reach:120 cm

ThomasHuber,born 1966in Palling,

wasconstantlyoutandaboutwith

hisfather in theBerchtesgaden Alps

asa child.Whilestudying Sport,

hedecided,“Iwantto

hedecided,“Iwanttobea mountaibea mountainn

climber”.Hisbiggestsuccesseshave

been

theWestFaceoftheseven-thousand-meter Latok II(Pakistan),

thousand-meter Latok II(Pakistan),

thespeed-climbing record on the

“Nose” in YosemiteValley (USA) and

theThreePeaksProject(Italy) with

a combination ofmountain climbing

and base jumping. But 35 years

ofmountaineering alsomeanslots ofmountaineering alsomeanslots ofsetbacksandcountlessinjuries ofsetbacksandcountlessinjuries.. Thesedays,expeditionsareThomas Thesedays,expeditionsareThomas Huber’sspecialty

Huber’sspecialty.Healso.Healsomakesmakes

music–stonerrock,ofcourse.Only

athomein Berchtesgaden arethings

more-or-le

more-or-lessnormal,withhiswifessnormal,withhiswife

and threechildren – aside,perhaps,

from thetunnel in thebasement

with climbing gripsall theway up to

theceiling.

Think laterally and stick

with i

with it is tt is the mottohe motto..

Don’t be driven crazy by

the eternal doubters.

Prof.Dr.HubertWaltl

Board Member for Production,AUDIAG

We’re meeting today in the Rübezahl-Alm

on theWilder Kaiser Mountain.Whatdoes this

place mean to you?

Dr.HubertWal

Dr.HubertWaltl:tl:Ifind theWilder Kaiser exudesanIfind theWilder Kaiser exudesan

incredible force. I know it in and

incredible force. I know it in and out from skiing and hillout from skiing and hill

walking. But every time I see it (looks out the window),

Ithink tomyself–

Ithink tomyself–whata powerful whata powerful mountain;edgy,mountain;edgy,

rough,honest…

ThomasHuber:

ThomasHuber:…withevery…witheverythingthathingthatagoodmoun-

tagoodmoun-tain

tain needs.Thestoryneeds.ThestoryoftheoftheHuberbuambeganaHuberbuambeganafewfew

kilometersawayfromhere.Alexander

kilometersawayfromhere.AlexanderandIandIwentonwenton

ourfirstclimbingvacationwithoutourparentsat

ourfirstclimbingvacationwithoutourparentsatthethe

GaudeamusHutatthe footofthe

Törlspitzen.Iwassix-teenandhe

teenandhewasfourteen.Wehadtowasfourteen.Wehadtocallhomeeverycallhomeevery

evening.Bytheend

evening.Bytheendofthatweek,weofthatweek,wewereprettymuchwereprettymuch

establishedasaropeteam.

And since then,you have been climbing the

And since then,you have been climbing the world’sworld’s

toughestroutes,scaling the

toughestroutes,scaling the highestmountains,highestmountains,

walking to the ends of the earth – to Patagonia and

as far as Antarctica atminus 54 degrees Celsius.

Whatis itthatdrives you?

Alexander Huber:

Alexander Huber:Mountainsmean adventure.IfeltMountainsmean adventure.Ifelt

that from the very beginning. In the middle of civilized

Europe, they’re still quite wild even

Europe, they’re still quite wild even today. I still clearlytoday. I still clearly

remember standing on thesummitoftheSmall

Watz-mann in a snowstorm at the age of thirteen. I have

mann in a snowstorm at the age of thirteen. I have

neveragainexperiencedsuchan

neveragainexperiencedsuchanintensefeelingofintensefeelingofex-

ex-posure.Onceyou’vehad that,you wantmore.

posure.Onceyou’vehad that,you wantmore.

Dr.Huber

Dr.HubertWaltl:tWaltl:For me,it’sfirstand foremostmyFor me,it’sfirstand foremostmy

curiosity thatmotivatesme.Even asa child Ialways

wanted to know how everything worked. I took my toys

apartandput

apartandputthembacktogetherthembacktogetheragain.Sometimes,again.Sometimes,

there were bits left over (laughs). S

there were bits left over (laughs). Soon I became inter-oon I became

inter-ested in what could be done better. Just as you go to the

ested in what could be done better. Just as you go to the

limitswith

limitswithyourbodies,weyourbodies,wedowithdowithtechnology.We’retechnology.We’re

always asking ourselves the question: How can we push

theexisting boundaries–takethe

theexisting boundaries–taketheseemingly imseemingly impos-

pos-sibleand makeitpossible?

sibleand makeitpossible?

AlexanderHuber:

AlexanderHuber:ThemostsuccessfulmountaThemostsuccessfulmountainclimb-

inclimb-ersarethose

ersarethosewiththegreatestwiththegreatestinnovativepower,notinnovativepower,not

necessarily those with the most physical strength. The

key thing isthevision toseeasachievablewhatothers

simply can’t imagine. When we set off nowadays for the

HimalayasorAntarctica,I

HimalayasorAntarctica,Iamstillamstillexcitedbythisexcitedbythisven-

ven-tureintotheunknown – theidea ofbeing a pioneer.

tureintotheunknown – theidea ofbeing a pioneer.

→ → Brave – Brave – Alexander Huber on Alexander Huber on

the“Pan Aroma” route

in theDolomites. in theDolomites. 1 1 Rustic – Rustic – Dr.HubertWaltl and Dr.HubertWaltl and theHuberbuam theHuberbuam metin metin theRübezahl-Alm in Ellmau,Austria. Alm in Ellmau,Austria. 2 2 Visionary – Visionary – Alexander Huber, Alexander Huber, ThomasHuber ThomasHuber and Dr.HubertWaltl and Dr.HubertWaltl strivetomakethe strivetomakethe impossiblepossible. impossiblepossible. 3 3 Inquisitive – Inquisitive –

Even asa child,

Dr.HubertWaltl

wanted toknow how

everything works. everything works. Prof. Dr. Prof. Dr. Hubert Waltl Hubert Waltl 2 2 3 3 WestPeak WestPeak North Face,2,973meters, North Face,2,973meters, Dolomites,South Tyrol,Italy Dolomites,South Tyrol,Italy Pan Aroma Pan Aroma 500meters,XI- od.8c 500meters,XI- od.8c FirstRedpointAscent FirstRedpointAscent 2007,Alexander Huber 2007,Alexander Huber WestPeak WestPeak 2007 2007 Encounter

Encounter SmartFactory SmartFactory

18

Encounter

Encounter SmartFactory SmartFactory

15

What does home mean for you?

Thomas Huber:

Thomas Huber: I absolutely love travelling all over the I absolutely love travelling all over the

world. I can’t imagine a better job. But when I open the

door of my house in

door of my house in Berchtesgaden, I know that this isBerchtesgaden, I know that this is

where I belong.

Dr. Hubert Waltl:

Dr. Hubert Waltl: My family, Bavaria with its My family, Bavaria with its successfulsuccessful

combination of laptop and lederhosen and, of course,

Audi – all of that is home to me. I

Audi – all of that is home to me. I began as an appren-began as an

appren-tice in our Ingolstadt Toolmaking department almost

tice in our Ingolstadt Toolmaking department almost

39 years ago. When the board member paid

39 years ago. When the board member paid a visit backa visit back

then, we spent the two weeks beforehand sweeping the

workshop (laughs). I could never have imagined that

would be me

would be me one day. When Volkswagen boss Prof. Dr.one day. When Volkswagen boss Prof. Dr.

Martin Winterkorn said to me in 2009 that I

Martin Winterkorn said to me in 2009 that I was to bewas to be

Board Member for Production at

Board Member for Production at VW, my first reactionVW, my first reaction

was “Can I even do that”?

You could.

Dr. Hubert Waltl:

Dr. Hubert Waltl: I spent five great years at Volkswagen I spent five great years at Volkswagen

– umpteen starts-of-production, new plants in

– umpteen starts-of-production, new plants in RussiaRussia

and India, learning about new cultures around the world

– all of that enriches you as a

– all of that enriches you as a person and as a manager.person and as a manager.

For me personally, it’s the combination of

For me personally, it’s the combination of internation-

internation-al experience and staying down to earth. So I have to

al experience and staying down to earth. So I have to

admit that, when I drove past Audi Toolmaking back

then, it always made me a little sad that I couldn’t

sim-← ← Exposed – Exposed – Alexander Huber Alexander Huber

on the Grand Capucin

in the French Mont

Blanc group. Blanc group. → → Adventure – Adventure – Alexander likes Alexander likes to think of himself to think of himself as a pioneer. as a pioneer. 4 4 Push yourself – Push yourself –

Take on challenges, fail,

grow, take new paths.

Alexander thinks that’s

what life is about.

5

Self-belief –

The mountain climber

sets his skill in

relation to the risk.

How do you turn the vision into reality?

Dr. Hubert Waltl:

Dr. Hubert Waltl: By sticking with it. Don’t let yourself By sticking with it. Don’t let yourself

be driven crazy by eternal doubters. Be confident and

approach your target step by step. And

approach your target step by step. And be determinedbe determined

to go that extra mile for a perfect result. How often

have I heard in my professional life “that won’t work

anyway”? And how often were we able to

anyway”? And how often were we able to say in the endsay in the end

“we did it”?

Alexander Huber:

Alexander Huber: Take on challenges, fail, then grow Take on challenges, fail, then grow

and take a new approach. That’s what life is all about.

Anything else would mean standing still.

Alexander and Thomas, you both consciously

put yourselves in danger in pursuit of your

objectives. Why?

Alexander Huber:

Alexander Huber: By its very nature, going to the limits By its very nature, going to the limits

involves risks and setbacks. There’s no such thing as

100-percent safety in life, and definitely not on a

moun-tain. What counts is to calculate the risk and weigh that

tain. What counts is to calculate the risk and weigh that

up against your own

up against your own capabilities.capabilities.

How do you deal with setbacks?

Dr. Hubert Waltl:

Dr. Hubert Waltl: First of all, I speak to my team. I rely First of all, I speak to my team. I rely

on their opinion. Then I tackle it o

on their opinion. Then I tackle it on my own, close then my own, close the

door, sketch the problem on a