When the VW group unveiled its Audi A3 at the Geneva Auto Show back in 2012, the group proudly announced the model would be a debut for VW’s ambitious Modularer Querbaukasten (MQB) manufacturing platform. The modular manufacturing platform was predicted to save 20% on costs and reduce production time per unit by 30% by allowing VW to manufacture interchangeable parts for 40 models across its Audi, VW, Skoda and Seat brands. Hardly surprising then that VW described the $8bn investment as its ‘strategic weapon’.
Even in 2012, modular assembly wasn’t an entirely new concept in automotive manufacturing: automakers have shared manufacturing platforms across models and brands for decades. However, the process meant vehicles had to share chassis setups and other features, resulting in some uniformity across the finished models. VW’s ambitious MQB vision was the first time a major auto manufacturer had used modular manufacturing—using a single production line to produce diverse vehicles sharing common components.
A decade on, VW’s MQB platform is now in its third ‘Evo’ iteration, and the addition of the Ford Tourneo Connect to its manufacturing lineup in 2020 is a testament to the platform’s enduring versatility. As the prospect of electrification and increased connectivity forces automakers and OEMs to adopt careful make vs buy strategies over the coming decade and beyond, modular manufacturing will become a mainstay of the manufacturing landscape.
As more car manufacturers adopt modular manufacturing, this approach may become the standard manufacturing workflow, placing VW’s impressive time and cost savings within reach for the rest of the automotive industry. However, this is just one of many anticipated benefits:
Increased efficiency
Modular manufacturing allows car manufacturers to streamline production processes, reduce waste and increase efficiency. For example, Audi’s latest modular manufacturing plant in Ingolstadt, Germany, uses flexible ‘production islands’ serviced by automated guided vehicles (AGVs). Components can be assembled independently of the production line. Audi says modular manufacturing techniques at Ingolstadt have led to a 20% boost in efficiency and productivity.
Improved flexibility
Modular manufacturing allows manufacturers to easily customise vehicles to meet specific customer and dealership needs and quickly respond to market demands for new features.
Faster production times
Because modular manufacturing involves building cars from pre-assembled components, it can help manufacturers reduce production times and get vehicles to market faster with less time and manpower required for re-tooling and refitting production lines.
Improved quality control
Modular manufacturing allows manufacturers to implement quality control and oversight over individual components to ensure that each is built to the same standards.
Simpler aftermarket maintenance and repairs
Modular manufacturing puts common parts to use across many, making it easier for mechanics to source replacements and perform repairs. It also means dealers and manufacturers can hold fewer parts in stock.
Reduced environmental impact
Modular manufacturing sees vehicles stay stationary throughout the production cycle while teams of skilled workers carry out work at different stages. So, the workflow requires less space, energy and manpower than a conventional production line. The production of uniform parts also results in decreased waste.
Greater innovation
By allowing manufacturers to quickly make changes to their production processes, components and systems, modular manufacturing can help foster innovation. Audi reports incorporating VR into its component design at Ingolstadt, which allows designers to iterate rapidly without wasting materials.
Modular manufacturing will undoubtedly play a significant role in the automotive industry’s evolution over the next decade and beyond. Are you ready?
To discover how to incorporate modular manufacturing into your conventional vehicle or EV production workflow, speak to Dalroad’s independent automotive engineers today.
