Audi Implements AI for Spot Weld Quality Control

Audi has embarked on the digital transformation of its production processes, initiating the deployment of an artificial intelligence (AI) system for quality control of spot welds in car body construction. Building on a successful pilot project, the luxury automaker is utilizing AI to optimize spot weld assessment.

Developed and tested at the Neckarsulm plant, the AI system will be progressively introduced to three other Volkswagen Group locations by year-end. This strategic move aligns with Audi’s commitment to the Automotive Initiative 2025 (AI25), designed to catalyze digital factory transformation and innovation.

Driven by artificial intelligence, Audi now analyzes approximately 1.5 million spot welds on 300 vehicles during each shift at the Neckarsulm site. This approach supersedes the manual ultrasound technique previously employed for quality assessment of resistance spot welding (WPS). With AI, production staff can efficiently identify anomalies, enhancing quality control with targeted precision.

Expansion of this technology across other Volkswagen Group plants is underway. Audi Brussels, the Volkswagen plant in Emden, and Audi’s headquarters in Ingolstadt are primed to integrate AI infrastructure. The team is currently adapting the AI model by identifying weld setting differences, ensuring seamless implementation.

Beyond immediate gains, data harnessed from AI usage promises to optimize future processes. Audi envisions utilizing this data for predictive maintenance and broader enhancements. Gerd Walker, Audi Board Member for Production and Logistics, underscores the potential of AI in series production within the context of the 360 factory production strategy.

The collaborative effort with the German Association for Quality (DGQ), Fraunhofer Institute for Industrial Engineering (IAO), and Fraunhofer Institute for Manufacturing Engineering and Automation (IPA) ensures audit-proof development. Audi acknowledges the absence of established standards or certifications for AI applications and is committed to comprehensive transparency in its testing procedures.

The ‘WPS-Analytics’ project serves as a cornerstone of Audi’s AI25 initiative, aiming to foster a network of digital factory transformation. Audi’s embrace of digitalization strives for agile and efficient production. This evolution is realized through collaborative exploration of digital solutions in real manufacturing settings, with the intention of scaling these innovations to series production.