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Production to become digital

Production to become digital

Digitalization initiative of the Volkswagen Group: Numerous sites are running pilot projects to implement virtual reality solutions and pioneering technologies

What does a VR developer actually do?

The Volkswagen Group is increasingly becoming more digitalized. Numerous pilot projects are revolutionizing operational production and logistic processes. The Group adopted virtual reality solutions to enable collaborations across all sites and brands. 


The platform ‘Volkswagen Digital Realities Hub’, developed in association with the start-up Innoactive, unites virtual reality applications, tools and participants from different sites and business units. The central platform allows different units to exchange knowledge, put new applications into practice and interactively plan operational processes. This is achieved by using a HTC VIVE headset, a VR end user device, specifically developed for business purposes.

The Volkswagen Brand and Group also adopted other innovative technologies. The Salzgitter plant is being supported by human-robot collaboration. A total of seven cooperating robots support the production line and are used at points, where the assembly line is particularly ergonomically aligned.

ŠKODA implemented the use of drones for inventory and area monitoring, which are being navigated by realtime visualization of 3D maps. The so-called ‘flying inventory’ marks yet another milestone towards autonomous logistics.

An overview of all the development and pilot projects can be found here:

Germany See the map below
7. Human Robot Robotic Assembly Audi, Győr
12. Automated Vehicles Smart Transport Scania, Södertälje
13. Technical Support with AR Technology Scania, Södertälje
14. Evaluating Human Robot Projects Scania, Södertälje
15. Optimizations for Logistics Scania, Södertälje
16. Preventive Maintenance Sensors Scania, Södertälje
17. Tracking System in Workshop Scania, Södertälje
18. Simulation Assembly and Work Scania, Södertälje
19. Human Robot Collaboration ŠKODA, Vrchlabí
22. Automated Small Parts Warehouse ŠKODA, Kvasiny
21. Big Data in Logistics ŠKODA, Mladá Boleslav
20. Videomapping Augmented Reality ŠKODA, Mladá Boleslav
23. Flying Inventory with Drones ŠKODA, Mladá Boleslav
27. JOMER AGV in Logistics SEAT, Barcelona
9. RIO Platform Digital Transport TRATON GROUP, multi-site
35. DISCOVERY Digital Platform Volkswagen Group, multi-site
34. 3D Printing Overview Volkswagen Group, multi-site
24. Virtual Reality Tractor Simulator SEAT, Martorell
25. Computer Vision Supply Process SEAT, Martorell
26. Laser Mapping Automated Vehicles 3.0 SEAT, Martorell
10. RIO-Box, Vehicle Tracking TRATON AG, Munich
11. LOADFOX Digital Platform TRATON AG, Munich
31. Sensor Jacket for Training Volkswagen, Gläserne Manufaktur Dresden
6. Parking Robot Ray Transport Logistic Audi, Ingolstadt
4. Robot Assistance at Glue Application Audi, Ingolstadt
8. Pro Glove New Scanners Audi, Ingolstadt
1. New Models in Virtual Reality Audi, Ingolstadt
3. 3D Printing Metal Parts Audi, Ingolstadt
5. Driverless Industrial Logistics Audi, Ingolstadt
2. VR-Training, Packaging Logistics Audi, Ingolstadt
28. First Cooperating Robot Volkswagen, Salzgitter
30. Pick-by-Light Faster Picking Volkswagen Group, Wolfsburg
29. Robot assists with assembly Volkswagen, Wolfsburg
32. VR Apps & Tools Group Platform Volkswagen Group, Wolfsburg
33. Automation without Safety Fences Volkswagen Group, Wolfsburg
36. Virtual Meisterbock Volkswagen, Wolfsburg
37. Virtual Audit at the VMB Volkswagen, Wolfsburg

Audi

  • 1. Ingolstadt: Virtual Reality Holodeck

    The „Virtual Reality Holodeck“ allows you to get an previous impression of new models. It creates a pleasant, virtual environment with a three-dimensional image of each car. This saves the company development time and costs.

    For more information click here.

  • 2. Ingolstadt: VR-Training Logistics

    With the use of VR-glasses and two controllers, the employees of Audi packaging logistics are currently training the new CKD-packaging process (Completely Knocked Down). A trainer can follow their progress via tablet and can provide assistance if needed.

    For more information click here.

  • 3. Ingolstadt: metal 3D printing

    In the new metal 3D printing center, Audi has installed 3D printers, that are using lasermelting technology to produce steel and aluminum parts from metal powder. Many specialists from the toolmaking and the foundry department work closely together there.

    For more information click here.

  • 4. Ingolstadt: Human Robot Collaboration

    Employees and robots work side by side when it comes to the Audi A4/A5 assembly: the "glue application with robot assistance", called KLARA, supports the installation of large CFRP-roofs on the new Audi RS 5 Coupé.

    For more information click here.

  • 5. Ingolstadt: Driverless Industrial Trucks in Logistics

    In hall B of the Ingolstadt GVZ, Driverless Industrial Trucks are being used for the first time. They move automatically and sense each other via sensors and control algorithms. Collisions with people can be prevented with the help of laser scanners.

  • 6. Ingolstadt: Parking robot „Ray“ in transport logistic

    The electrically driven parking robot "Ray" sorts up to 2,000 cars a day so that they can be loaded onto railway wagons. Using laser sensors, he measures the position, length and width of a car and adjusts the lifting systems accordingly. Ray also won Audi the VDA Logistics Award 2017.

    For more information click here.

  • 7. Győr: Human Robot Collaboration in assembly

    Two robotic colleagues, called Ádám and Éva, work hand in hand with their colleagues in the automotive production at Győr in Hungary and measure the gap dimensions in flow operation.

    For more information: Communication Audi Hungary

  • 8. Ingolstadt: "Pro Glove"

    "Pro Glove" is going to replace conventional barcode scanners, because the scanner is already integrated in it. By pressing the thumb and index finger together, the scanning function is triggered, leaving both hands free for employees and saving them additional work.

    For more information click here.

TRATON GROUP

  • 9. From Digitalization and Networking to Transport and Logistics (TRATON GROUP)

    RIO Essentials from the TRATON GROUP supports customers and consumers in the digital transformation of the transport ecosystem. The open, cloud-based RIO platform provides precise information on mileage, tank level, driver identification and a comprehensive performance analysis for each registered vehicle at any time.

    For more information click here.

  • 10. Munich: Vehicle tracking from end of line to customer handover (TRATON GROUP)

    The RIO box can be used to track the GPS position of all vehicles recorded from the end of the line until they are handed over to the customer. This improves processes in rework and shipping, where employees can now find vehicles faster via GPS.

    For more information click here.

  • 11. Munich: The digital platform LOADFOX (TRATON GROUP)

    LOADFOX is a platform for freight forwarding and transport companies. The focus lies on an algorithm that combines the set loads, taking other data (searches, road data, shift times, etc.) into profitable tour suggestions.

    For more information click here.

Scania

  • 12. Södertälje: AGV solutions in Scania Production & Logistics

    The Smart Factory Lab is testing Automated Guided Vehicles (AGVs) with functions such as Smart and Real-Time Solutions (RTLS). A task force implements the AGVs in our workshop.

    For more information click here.

  • 13. Södertälje: Distance Guiding in Scania Production & Logistics

    Technical support from a distance is being evaluated within our Smart Factory Lab with use of AR technology.

    For more information click here.

  • 14. Södertälje: Human Robot Collaboration in Scania Production & Logistics

    Human Robot Collaboration is being evaluated within our Smart Factory Lab. Global network within Scania is established to support learning process within P&L. We are now working together with Fraunhofer IFF to identify possible pilots to start.

    For more information click here.

  • 15. Södertälje: Picking technologies in Scania Production & Logistics

    At our Smart Factory Lab several different alternatives are being evaluated at the moment. Additional efforts are gathered under the Connected Worker Platform umbrella where these technologies will be piloted on the P&L shopfloor.

    For more information:
    Pick by light

    Pick by voice

    Pick by tablet

    Finger scanner

  • 16. Södertälje: Preventive maintenance sensors in Scania Production & Logistics

    “Standalone“ sensors are being evaluated to support our ambition towards enhancing our abilities within the area of preventive maintenance – hybrid solutions with both integrated and external sensors are needed.

    For more information click here.

  • 17. Södertälje: Real Time Location Systems in Scania Production & Logistics

    Real Time Location Systems are going to monitor the whereabouts of pallets and temporary buffer zones in the workshop. As of now, different solutions are being tested in our Smart Factory Lab and planning for pilots is ongoing.

    For more information click here.

  • 18. Södertälje: Simulation abilities in Scania Production & Logistics

    We are working intensively to enhance our ability using simulation as or base for testing and verifying assembly sequences, ergonomic work positions, factory installations and factory layout and flow proposals.

    For more information click here.

ŠKODA

  • 19. Vrchlabí: Human Robot Collaboration in Production & Logistics

    At our location in the Czech Republic, an HRC-robot supports the employees by taking over the insertion of the gear positioner pistons in the DQ 200 transmission.

    For more information click here.

  • 20. Mladá Boleslav: Videomapping – augmented reality in Logistics

    As a new strategic system, the video mapping supports employees in logistical operations for material picking. It not only provides extended information, but also points directly to process errors.

  • 21. Mladá Boleslav: Big Data in Logistics

    ŠKODA uses Big Data to identify the causes of historical IO/NIO deliveries. Big Data contributes to the cleanliness of the data track through the realization of the retrievals and identification of the main causes and the trends about unfair safeguarding.

  • 22. Kvasiny: AKL - Automatic KLT warehouse

    The Automated Small Parts Warehouse enables more efficient handling of the increasing variety of articles and makes the logistical processes in the plant even more flexible. The warehouse has an automatic goods receipt and issuing department with the help of robots, lifting tables and pushers.

    For more information click here.

  • 23. Mladá Boleslav: Drones in Logistics – flying inventory

    The use of drones represents a further step towards autonomous logistics and process optimization: In the so-called "flying inventory", drones are used for the inventory of empties on outdoor areas and for area monitoring.

SEAT

  • 24. Martorell: Virtual Reality Traktor Simulator

    With 3D glasses, employees can receive personal training with a static tractor using simulation and immersion. Virtual reality simulates situations and environments that employees will find at future workstations.

  • 25. Martorell: Computer Vision for an Automated Supply Chain

    SEAT realizes a fully automatic supply process with the help of "Computer Vision" and AGV technology (Automated Guided Vehicle). The AGV delivers containers to the place of consumption. This is where "Computer Vision" recognizes when containers are empty in order to exchange them for new containers.

  • 26. Martorell: AGV 3.0

    The new generation of AGV (Automated Guided Vehicles) is equipped with laser mapping technology: it enables continuous monitoring of the AGV position, virtual route definition and adaptability to new scenarios.

  • 27. Barcelona: JOMER (Just One Minute Exchange of Rack)

    JOMER describes an automated load exchange with AGV, which reduces the processes to less than one minute. The process describes the emptying of containers using a robot arm and the quick replacement of empty and new containers by driverless vehicles.

Volkswagen

  • 28. Salzgitter: Human-Robot-Cooperation (HRC) in Production & Logistics (Volkswagen)

    The groupwide first cooperating robot is being used in Salzgitter. The robot has been programmed, set up and certified by the company's HRC team without external support. Around 1,000 engines for T6 and Crafter are being assembled on this line every working day. The new robot is used on the ergonomics line.

  • 29. Wolfsburg: Human-Robot-Cooperation (HRC) in Production & Logistics (Volkswagen)

    At the Volkswagen plant in Wolfsburg, an HRC takes the strain off people during ergonomically unfavorable activities. A robot assists employees in the assembly of the power train to complete the individual power train components into an installable motor.

  • 30. Wolfsburg: Pick-by-Light in the Volkswagen Group

    Pick-by-Light is a wireless safety and acknowledgement system: An optical assistant supports employees on their way to the right component via LED indication and 3D camera. This facilitates faster picking at low error rates and contributes to increased productivity.

  • 31. Gläserne Manufaktur Dresden: Innovative sensor jacket trains industrial robots (Volkswagen)

    Volkswagen's Transparent Factory and Dresden's Wandelbots startup have agreed on an innovative joint project for human-robot collaboration (HRC). The aim is to test new HRC applications in vehicle assembly and make them ready for series production. For example, industrial robots are being trained efficiently using innovative sensor jackets.

    For more information click here.

  • 32. Wolfsburg: Virtual Reality Applications in Production & Logistics (Volkswagen Group)

    The Group platform "Volkswagen Virtual Reality Hub" brings together all VR applications, tools and participants from production and logistics that exist in the Group. “HTC Vive” glasses enable cross-location and cross-brand collaboration in virtual reality.

    For more information click here.

  • 33. Wolfsburg: Human-Robot-Cooperation (HRC) in Production & Logistics (Volkswagen Group)

    The Volkswagen Group is testing prototypes for the safe cooperation between humans and robots in "automation without safety fences". The industrial robots support employees in lifting heavy loads. Interactive protective fields using laser safety scanners guarantee safety.

    For more information click here.

  • 34. 3D printing in the Volkswagen Group

    3D printers are used in many ways: In contrast to "conventional" manufacturing processes, in which material is removed from a workpiece, material is added in 3D printing. A 3D object is created by applying the material layer by layer and then hardening it.

  • 35. The digital platform DISCOVERY (Volkswagen Group)

    "DISCOVERY" serves as a digital communication platform and as an efficient interface between suppliers and forwarders. The platform integrates all transport-relevant activities and information flows, so that master data and transmission errors can be greatly reduced.

    For more information click here.

  • 36. Wolfsburg: Virtual Meisterbock (Volkswagen)

    Virtual Meisterbock

    The Virtual Meisterbock (VMB) is used for the qualification of exterior components from vehicle construction on the basis of a virtual model. From the individual part through assembly to the finished body with add-on parts, the components are measured optically, deformed with the aid of numerical simulations and then virtually played together. The assembly situation corresponds to that of a physical master buck.

  • 37. Wolfsburg: Virtual Audit at the VMB (Volkswagen)

    The virtual audit is currently performed in 2D or 3D (with VR glasses) with the design software Autodesk VRED. The simulated or measured physical components are loaded into the software as STL data sets. The rest of the virtual process is similar to the MBC audit.

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