At Audi, body shop workers strive for perfect precision, often using fine shims to adjust equipment by tenths of a millimeter. “Agile shimming,” a unique technology implemented at the Audi Sport plant in Böllinger Höfe, has revolutionized this process. This innovation automates the shimming during the fitting of exterior side parts, linking it to an in-line measurement station through a control circuit. An algorithm then automatically adjusts the actuators, ensuring precision. This technology was developed collaboratively by Audi employees from Neckarsulm and Ingolstadt.
Manual shimming is a highly skilled task, where fine shims are added or removed at critical clamping points to adjust part positions by millimeters before final fitting. Previously, shimming relied solely on the experience of employees. Agile shimming, however, incorporates an algorithm that continuously monitors dimensional accuracy through in-line measurement technology, calculating optimal compensation values. Using this data, a built-in linear motor automatically adjusts the clamping points.“The measurements clearly show that agile shimming has made us even more precise”, says Wolfgang Shanz, Head of Audi Sport Production at Böllinger Höfe. “It is also noteworthy that the project was developed and implemented entirely in-house. ‘Agile’ describes not only the technology, but how we work.”
Currently being used in the body shop for the Audi e-tron GT, agile shimming serves as a real-world testing ground for the digitalization of production and logistics. Small-series production at Böllinger Höfe plays a crucial role in developing and testing smart, fully connected factory solutions, pushing the boundaries of intelligent manufacturing.
