Transforming Production to Meet Variable EV Demand

August 21, 2024

August 21, 2024

Welcome to MetalForming Automotive, where you’ll find a variety of news and information from this quickly evolving industry, including links to the latest information from our industry partners: AISI, Automation Alley, CAR and MEMA (formerly OESA).

Please share any questions or comments by emailing editorial director Brad Kuvin.

As automotive suppliers up and down the supply chain look to rework their operations—from design through production and on to shipping—to accommodate the relatively low-volume and variable production of electric vehicles, a new form of “technological assist” comes to the rescue. That’s the takeaway from this RTInsights article that discusses how digital modeling, digital twins and virtual commissioning can be used to retrofit and update factories to accommodate the new requirements of EV production.

WATCH: Audi’s “360factory” Sustainability Strategy in Action

Audi has begun producing its new A5 family of sedans in Neckarsulm, Germany, in a modernized facility using advanced production processes designed to significantly reduce energy consumption and promote sustainable water use. Check it out in this 14-min. video providing a tour of the plant’s body shop, paint shop and assembly line.

Audi's "360factory" strategy aims for net carbon-neutral production by 2025, utilizing more efficient lines and increased use of automation. For example, the updated paint shop features energy-efficient processes that reportedly save as much as 140 kWh/vehicle. And, quality control has been enhanced through the use of augmented reality for inspections.

WATCH: Digital Integration of the Stamping and BiW Process Chains

Digitalization of the complete BiW process chain is one of the keys to master the challenges car body engineers are facing due to trends like electrification, new mobility concepts, autonomous driving and shortening time-to-market. While product development and stamping engineering have seen enormous advances to accelerate the engineering process by using digital tools, the BiW assembly process and its upstream implications for the design and production of single body parts has seen much less attention in terms of digital process simulation.

Automotive Industry News

Rahal Indy Car, Sponsored by Amada, to Sport FABTECH Orlando 2024 Logo
Schuler Expansion Makes Way for New Hydroforming Cell
Nominate Women of Excellence in Metal Forming and Fabricating 2024
JK Tool Acquires Precise Tool & Die

Partner Content

From AISI: AISI and Partners Receive EPA Grant to Enhance Emissions Reporting for Steel Construction Projects
From CAR: CAR President and CEO Alan Amici Discusses Q2 Auto Sales
From Automaton Alley: Setting the Stage for Advancements in Mobility and Electrification; Will ICE have a horse and buggy moment?
From MEMA: Navigating the Rocky Road Through Customs and International Trade Laws

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100% Optical Inspection of Safety-Critical Parts

German manufacturer Plogsties GmbH attains zero-defect production of millions of parts/yr. through 100% inspection, including the support of state-of-the-art vision systems.

Lubrication Innovation Abates Waste

Heavy-gauge stamping specialist Pentaflex overhauls its die-lubrication strategy, first by reducing the number of lubricants it uses among its numerous high-tonnage presses from six formulations down to two, and then by installing a central, proportional mixing system plumbed to 12 presses.

Applause for Funding Awarded to Automotive-Parts Suppliers

A recent public statement from vehicle-supplier association MEMA applauds actions taken by the Biden-Harris Administration in support of small- and medium-sized manufacturers of automotive parts.