Audi Sport, in collaboration with the Fraunhofer Heilbronn Research and Innovation Centers (HNFIZ), is pioneering a new era of automotive manufacturing by testing advanced digitalization technologies in a real-world laboratory at the Böllinger Höfe facility. This initiative is a key component of Audi’s broader 360factory vision and focuses on optimizing the manual picking process through artificial intelligence (AI) and robotics.
The “picking” process—where components are retrieved from logistics containers in a staging area known as the “supermarket” to supply the assembly line—is a critical yet physically demanding task in automotive production. To explore smarter and more ergonomic solutions, Audi Sport and researchers from the Fraunhofer IAO and IPA institutes are running trials in a specially designated test area modeled on a real production environment.
Following a comprehensive needs analysis to identify high-impact opportunities, the partners are now evaluating a range of technologies aimed at reducing employee strain, improving picking accuracy, and ensuring seamless supply to the assembly line. These include AI tools such as computer vision systems to support human workers in identifying and retrieving correct parts, as well as mobile robotic systems equipped with 3D sensors and adaptable grippers.
Real vehicle orders are used in simulations to create authentic testing conditions. By continuously evaluating AI and robotic solutions in this real-world lab, the team can better understand the technical and human-centered requirements for practical integration on the factory floor. “Low-volume production at Böllinger Höfe is ideal for such purposes. We produce the Audi e-tron GTfamily, for example. These vehicles feature a high degree of customization. That makes the picking process particularly complex and challenging due to the large number of different parts it involves,” said Alexander Müller, Head of Logistics at Audi Sport GmbH.
With direct input from employees, the approach ensures that new technologies not only enhance efficiency but also align with the needs of those working in the production process. The initiative is set to run through the end of the year, helping shape future-ready, worker-focused manufacturing at Audi. “The approach of first identifying where employees need support and then determining how new technologies can be used to address these needs reflects our overarching goal. We want to improve efficiency as well as the interaction between people and technology in the plant. To this end, we are bringing innovations and research to future users on site and evaluating possible solutions together,” explained Müller.
