With the rise of automation in the automotive industry, businesses are looking for ways to improve production processes, address labor shortages and find that competitive advantage. One way to do this is by implementing RFID (Radio Frequency Identification) technology. RFID is a wireless technology that uses radio waves to identify and track objects. It can be used to track products, vehicles and even people.
RFID uses electromagnetic waves to enable processes to be automated via contactless reading and storage of data. The corresponding read/write devices operate in the ultra-high frequency band between 860 and 960 MHz, which is suitable for especially large scanning ranges and fast transmission to identify the relevant production step.
RFID systems offer a range of benefits for numerous industries but are used very often in automotive environments. The technology improves accuracy and efficiency in production processes, while also reducing costs. RFID tags can be used to track and store data, allowing businesses to monitor performance and make informed decisions. SICK’s RFID tags are designed to be robust and reliable, with the ability to withstand extreme temperatures and harsh environments sometimes seen in automotive production sites.
Implementing RFID at Audi’s Southern Germany Production Site
RFID technology is already being used at Audi’s Neckarsulm site in Southern Germany to improve production and logistics. Audi has implemented RFID technology from SICK to track the production of cars, which started in 2015 with the Audi A8 and is now standard for all production processes.
From body shop to delivery, all models carry a personal ID with them: an RFID data carrier or a tag. It contains the identification number of the vehicle and allows a contactless data exchange of vehicle data via UHF RFID read/write devices. RFID is the primary identification medium across the entire production process.
One of the reasons for this extensive use of RFID is the growing individualization of customer requests. From custom rims to infotainment systems to seat covers to other customizations, manufacturers now provide more opportunities to create your dream car beyond just color and engine type. And accomplishing this requires a great deal of flexibility in Audi’s production to handle the varying requests.
Because of this, it has become increasingly important to be able to correctly identify each vehicle in production and delivery logistics. A transparent and infallible method of knowing what the next step is and how it should occur is required in practically every area. Every Audi model must roll off the production line as it was designed and requested, guaranteed to arrive at the correct destination. This reliability has been perfected and standardized through the consistent use of RFID technology throughout the facility.
How Audi Uses RFID
Every Audi manufactured at this location – from the Audi A4 to the fully electric Audi e-tron GT – immediately receives an RFID tag at the first manufacturing step: body construction. This is applied at the right rear section of the car body and then accompanies every vehicle into the paint shop, assembly and delivery to its customer. It also brings an additional benefit to Audi. The ability to apply the 30×50 mm sized tag directly to the metal provides greater flexibility in positioning it on the vehicle. And in contrast to previous labels, this transponder remains on the vehicle, even after production is finished. The bracket previously required to attach the label is also no longer required.
The radio-based, passive data medium contains an antenna and a chip. Through the digital exchange of data via the tag, it is possible to localize and identify all workpieces at every station, from body construction to the paint shop to final assembly. Being a passive RFID label, it receives its energy for data transmission from the read/writes device.
Both the transponder label and the on-metal transponder (OMT) are suitable for all manufacturing processes, even in demanding environments. The RFID device exhibits exceptional resistance to external influences when exposed to extreme conditions in production. The RFID data medium can even withstand the high demands of a paint shop and is impervious to electrostatic fields, temperatures of 200 °C and above, being sprayed with corrosion inhibitors and immersion in the paint pre-treatment step.
The infallible identification ensures the next (individualized) step of production is immediately clear to the person working on the vehicle. The data medium is rendered permanently unreadable at the end of production.
A further advantage of the RFID-based data overview is the consistency throughout the entire process, as opposed to the hodgepodge approach of using different technologies. This allows for more informative analyses of trends as the various read situations can be compared with one another. The better the information, the greater the potential for optimizing the production process. This enables opportunities for improvement and deviations to be predicted even before they occur.
With a fully connected solution, the Audi site in Neckarsulm has been able to not only increase the availability but also the efficiency of the plant. RFID technology provides an important foundation for a fully connected factory and is expected to become standard in all areas of Audi plants worldwide over the coming years.
This has allowed Audi to improve the production process by eliminating human error and reducing the amount of time needed to produce each car. Audi is also using RFID technology to improve the logistics of the supply chain. By tracking parts and components with RFID tags, Audi can ensure that the right parts are in the right place at the right time.
