Digital Revolution in Automotive Manufacturing: Audi Embraces Siemens’ Virtual Automation

Source: AUDI AG. Audi is using Siemens’ virtual controller for their car body assembly line

(IN BRIEF) Siemens and Audi are revolutionizing the automotive manufacturing landscape by implementing virtual shop floor automation using Siemens Xcelerator. This initiative involves the use of Siemens’ first entirely virtual controller, the Simatic S7-1500V, at Audi’s Neckarsulm facility, which is integrated with the company’s cloud-based production system to streamline and standardize manufacturing processes. Additionally, the deployment of an AI vision inspection system, powered by Siemens’ Industrial AI Suite and industrial PC BX-59A, allows for real-time quality control by detecting and eliminating weld spatters. This dual approach not only enhances production safety and flexibility but also boosts car body quality and overall efficiency. The project underscores the long-standing collaboration between Siemens and Audi and will be a key topic at the upcoming Hannover Messe 2025 panel discussion featuring senior leaders from both organizations.

(PRESS RELEASE) NUREMBERG, 27-Mar-2025 — /EuropaWire/ — Siemens AG (ETR: SIE) and Audi are transforming manufacturing with a groundbreaking approach to virtual shop floor automation through the Siemens Xcelerator platform. By integrating innovative virtual controllers and advanced AI-powered vision inspection, Audi is enhancing production safety, flexibility, and overall efficiency. The companies are leveraging Siemens’ Industrial AI Suite and Industrial Edge system to merge virtual and hardware control, streamlining processes and setting new standards in automotive manufacturing.

At the heart of this transformation is the implementation of Siemens’ software-defined automation. Audi has adopted the Simatic S7-1500V—the first completely virtual controller by Siemens—for its car body assembly line at the Böllinger Höfe factory in Neckarsulm, Germany. This virtual programmable logic controller (PLC) seamlessly integrates with Audi’s cloud-based Edge Cloud 4 Production, paving the way for rapid deployment across the production floor. As a result, Audi is able to standardize and optimize its operations, ensuring a more agile and responsive manufacturing environment.

Source: Siemens AG. The Simatic S7-1500V is hardware-independent and fully compatible with the TIA portfolio

In parallel, Siemens has equipped Audi with an AI-driven quality control system that utilizes the Industrial AI Suite and the Simatic industrial PC BX-59A. This system performs real-time inspections using high-resolution imaging and customer-trained AI algorithms to automatically detect and remove weld spatters. The outcome is a significant improvement in car body quality and a safer, more efficient production process.

The collaboration further extends to industry events, with a panel discussion at Hannover Messe 2025 where key figures from both companies will share insights on software-defined automation and industrial AI. Henning Löser, Head of Production Lab at AUDI AG, Sven Müller, Project Lead for Edge Cloud 4 Production at AUDI AG, and Rainer Brehm, CEO of Factory Automation at Siemens AG, will discuss the practical impacts and future potential of these innovative solutions.

Siemens Digital Industries (DI) empowers companies of all sizes within the process and discrete manufacturing industries to accelerate their digital and sustainability transformation across the entire value chain. Siemens’ cutting-edge automation and software portfolio revolutionizes the design, realization and optimization of products and production. And with Siemens Xcelerator – the open digital business platform – this process is made even easier, faster, and scalable. Together with our partners and ecosystem, Siemens Digital Industries enables customers to become a sustainable Digital Enterprise. Siemens Digital Industries has a workforce of around 70,000 people worldwide.

Siemens AG (Berlin and Munich) is a leading technology company focused on industry, infrastructure, mobility, and healthcare. The company’s purpose is to create technology to transform the everyday, for everyone. By combining the real and the digital worlds, Siemens empowers customers to accelerate their digital and sustainability transformations, making factories more efficient, cities more livable, and transportation more sustainable. Siemens also owns a majority stake in the publicly listed company Siemens Healthineers, a leading global medical technology provider pioneering breakthroughs in healthcare. For everyone. Everywhere. Sustainably.
In fiscal 2024, which ended on September 30, 2024, the Siemens Group generated revenue of €75.9 billion and net income of €9.0 billion. As of September 30, 2024, the company employed around 312,000 people worldwide on the basis of continuing operations. Further information is available on the Internet at www.siemens.com.

Media contacts:

Hannah Arnal (for trade press)
Siemens AG
+49 152 22572736
hannah.arnal@siemens.com

Jil Huber (for business press)
Siemens AG
+49 162 3474144
jil-patricia.huber@siemens.com

SOURCE: Siemens AG