Carmakers including Audi, BMW and Mercedes-Benz are exploring the use of humanoid robotics for lineside logistics, backed up by the latest digital technology, including artificial intelligence (AI) and machine learning. The robots are being tested as part of a wider drive to automation in vehicle manufacturing and logistics. Humanoid robots offer greater flexibility and dexterity to the performance of repetitive and laborious lineside or warehouse tasks. They can also operate in environments already designed for humans.  

Audi started assembly in the battery electric vehicles (BEVs) with its Chinese partner FAW at the end of 2024 at a plant in Changchun, China. Audi FAW NEV is making the BEVs, starting with Q6L e-tron, based on the compact Premium Platform Electric (PPE) model, which Audi developed with Porsche.  

The Changchun production plant has an installed annual production capacity of over 150,000 BEVs and also produces the batteries for the vehicles. The production system is fully automated and digitalised, having been designed with digital twin technology. Day-to-day manufacturing and logistics is also digitalised with all processes (including maintenance) networked with each other via one single IT architecture using the S/4Hana cloud-based data system to store and share information throughout the plant. 

The Changchun body shop is automated with 800 robots, quality control is managed with visual recognition technology and there is an automated crane in the press shop to streamline operations. Audi and FAW are using a driverless transport system and a 24-metre-high warehouse that uses a fully automated storage and retrieval system.  

Process acceleration 
The carmakers are also exploring the use of humanoid robots on the assembly line. Audi FAW NEV has a memorandum of understanding (MoU) with the Beijing Innovation Center of Humanoid Robotics and UBtech Robotics to further explore the use of the technology.  

“Technology helps amplify the synergies between the teams from Germany and China,” said Helmut Stettner, CEO of Audi FAW NEV in December. “It also enables us to be fast and highly efficient and speed up processes – both during construction and in day-to day-operation. We create an ideal synergy between our highly skilled workforce and cutting-edge technology at the site.”  

At last November’s Automotive Logistics and Supply Chain Mexico conference, Dieter Braun, head of supply chain at Audi, outlined how the transition to BEV making necessitated a more flexible approach to sustainable manufacturing which involves embracing new technologies such as automation and applying those technologies quickly, measuring the results and using them to stay competitive.  

One of Audi’s guiding principles is to push the limits of innovative and sustainable production, according to Braun. That involves embracing new technologies such as automation and applying those technologies quickly, measuring the results and using them to stay competitive.   

As part of its comprehensive Factory360 strategy for production and logistics, Braun reiterated Audi’s guiding maxim that it is pushing the limits of innovative and sustainable production. Braun said that over the last five years a lot of new technology has come to market, such as those used in factory and warehouse automation. 

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