How Siemens & Audi Are Revolutionising Shopfloor Inspection
Siemens and Audi are pushing the boundaries of shopfloor automation by integrating AI and software-defined automation at scale.
Their long-standing partnership is driving innovation in the automotive industry through the fusion of virtual and hardware controllers, improved safety functions and more efficient production processes.
A key development is Audi’s use of AI-driven automation for optical inspection, which enhances the detection and removal of weld spatter on vehicle bodies.
This customer-trained AI algorithm, combined with high-resolution imaging, is delivering higher car body quality and more efficient manufacturing.
“A virtualised shop floor is a key enabler for a flexible production,” says Gerd Walker, AUDI AG Board Member for Production and Logistics.
“Siemens’ software-defined automation portfolio empowers us to rapidly respond to market changes and optimise our manufacturing for more efficiency and flexibility.”
Virtualising the shopfloor with software-defined automation
Audi is leveraging Siemens’ automation portfolio to standardise and optimise its shopfloor operations, resulting in a more agile, flexible and secure production environment.
To accelerate the transition from automated to highly adaptable production, the company is merging IT and operational technology by progressively virtualising its shopfloor.
A crucial element of this transformation is Siemens’ Simatic S7-1500V, the first entirely virtual controller.
Audi has deployed this software-driven programmable logic controller (PLC) for its car body assembly line at the Böllinger Höfe factory in Neckarsulm, Germany.
Cedrik Neike, CEO of Digital Industries and Member of the Managing Board of Siemens AG wrote about this recent visit on his LinkedIn.
"Having seen countless factories over the past years, the visit to AUDI AG’s Böllinger Höfe site truly felt like a revolution," he wrote.
"Together we are virtualising the shop floor with software-defined automation,"
"Controllers are the ‘brains’ of machines and factories.
"Now we are virtualising these brains, creating one ‘super brain’ for entire lines and factories.
"Seeing our first fail-safe virtual PLC in action at Audi’s car body assembly line is a great milestone.
"This will enable Audi to automate at the speed of software, create a more agile, flexible and safe production environment and adapt to market changes flexibly.
"Big thanks to Gerd Walker and our teams for the great collaboration and the factory tour!"
The virtual PLCs are compatible with Audi’s cloud infrastructure platform, Edge Cloud 4 Production and are set to be rolled out in the Neckarsulm body shop this year.
Part of the Siemens Xcelerator portfolio, the Simatic S7-1500V enables seamless integration of IT and software capabilities into automation.
As a hardware-independent solution, it offers the same functionalities as a Siemens hardware controller and is fully compatible with Siemens’ Totally Integrated Automation (TIA) portfolio.
Engineered via the TIA Portal, it provides a familiar environment for users transitioning from hardware PLCs.
Available via Industrial Edge, it allows Audi to centrally manage and flexibly adapt the virtual PLC, facilitating scalable PLC projects and open data integration with other IT solutions.
The power of virtual controllers & vision inspection
Siemens has achieved a significant milestone with the TÜV safety certification for its virtual PLC. The Simatic S7-1500V F is the first fail-safe virtual controller on the market.
Implementing advanced safety functionalities in automation technology is essential for protecting production workers and ensuring consistent machine performance.
Previously, fail-safe components required specialised hardware to meet safety standards, but Siemens has now embedded these capabilities into an industrial edge environment.
This enables safety-sensitive applications to migrate to software-defined automation settings, reinforcing reliability and security in manufacturing processes.
Siemens has equipped Audi with the necessary infrastructure to deploy an AI-driven system for real-time quality control in car body construction.
This move has made Audi’s production processes AI-ready. By employing the Siemens Industrial AI Suite and the Simatic industrial PC BX-59A as an edge device, the solution allows for complex AI-based quality inspections.
It meets the stringent requirements for automated weld spatter removal, significantly boosting Audi’s production rates and enhancing workplace safety.
Panel discussion at Hannover Messe 2025
At Hannover Messe 2025, Siemens and Audi are set to present a joint panel discussion on enhancing car manufacturing through IT-driven automation.
Henning Löser, Head of Production Lab at AUDI AG, Sven Müller, Project Lead Edge Cloud 4 Production at AUDI AG and Rainer Brehm, CEO of Factory Automation at Siemens AG, will explore the benefits and transformative potential of software-defined automation and industrial AI solutions, exploring the achievements made at Audi's Böllinger Höfe factory.
The discussion will take place at the Siemens booth on Monday, 31 March, at 16:40 CEST and is set to be a insightful and valuable discussion for manufacturing leaders invested in the future of automation, AI and digital manufacturing.
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