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Door modules - Just-Auto.com

Door modules: market

trends, suppliers and

forecasts to 2010

2004 edition


Page i

Door modules: market trends,

suppliers and forecasts to 2010

2 nd edition

by Matthew Beecham

August 2004

Published by

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Page ii

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Page iii

Table of contents

Single-user licence edition............................................................................................................. ii

Copyright statement.................................................................................................................. ii

Table of contents ........................................................................................................................... iii

List of tables ................................................................................................................................... iv

List of figures .................................................................................................................................. v

Acknowledgements ....................................................................................................................... vi

just-auto.com’s research portfolio ..............................................................................................vii

Incredible ROI for your budget – single and multi-user licences..............................................vii

just-auto.com membership ......................................................................................................... viii

Chapter 1 Introduction.................................................................................................................... 1

What is a door module? ............................................................................................................ 1

Report coverage........................................................................................................................ 2

Chapter 2 The market ..................................................................................................................... 3

Market players........................................................................................................................... 3

Market shares ........................................................................................................................... 4

Market size................................................................................Error! Bookmark not defined.

Market value..............................................................................Error! Bookmark not defined.

Chapter 3 Manufacturers....................................................................Error! Bookmark not defined.

ArvinMeritor...............................................................................Error! Bookmark not defined.

Brose.........................................................................................Error! Bookmark not defined.

Delphi........................................................................................Error! Bookmark not defined.

Dura Automotive .......................................................................Error! Bookmark not defined.

Faurecia ....................................................................................Error! Bookmark not defined.

Grupo Antolin ............................................................................Error! Bookmark not defined.

Intier Automotive .......................................................................Error! Bookmark not defined.

Wagon.......................................................................................Error! Bookmark not defined.

Online sources of information ....................................................................................................... 8

Free email newsletters.............................................................................................................. 8

Other research reports.............................................................................................................. 8

Global news and feature articles...............................................................................................8

Search the web ......................................................................................................................... 8

Your feedback ................................................................................................................................. 9

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Page iv

List of tables

Table 1: Door module manufacturers’ product range........................................................................ 3

Table 2: Market fitment rate of door module cassettes for passenger cars and light trucks, 2001 -

2010 (% installation rate)............................................Error! Bookmark not defined.

Table 3: Market volume of door module cassettes for passenger cars and light trucks, 2001 - 2010

(‘000s units) ¹..............................................................Error! Bookmark not defined.

Table 4: Market value of door module cassettes for passenger cars and light trucks, 2001 - 2010

(€ millions) ¹ ................................................................Error! Bookmark not defined.

Table 5: Dura Automotive’s facilities worldwide ................................Error! Bookmark not defined.

© 2004 All content copyright Aroq Ltd. All rights reserved.


Page v

List of figures

Figure 1: European market shares of door modules, 2003 (% of volume)........................................ 4

Figure 2: Grupo Antolin’s Door Trim Module.....................................................................................6

Figure 3: Global market shares of door modules, 2003 (% of volume)............................................. 7

Figure 4: Average wholesale cost of a door module, 2004 (% of total cost per module).......... Error!

Bookmark not defined.

Figure 5: The door panel of the BMW X5 is manufactured at the Faurecia Fontain Inn site, US

....................................................................................Error! Bookmark not defined.

Figure 6: Preparation of the Renault Laguna door panel at Faurecia's Sandouville site, France

....................................................................................Error! Bookmark not defined.

© 2004 All content copyright Aroq Ltd. All rights reserved.


Page vi

Acknowledgements

The publishers would especially like to thank ArvinMeritor, Brose, Delphi, Dura

Automotive, Faurecia, and Grupo Antolin for their assistance in compiling this

report.

© 2004 All content copyright Aroq Ltd. All rights reserved.


Page vii

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Chapter 1 Introduction Page 1

Chapter 1 Introduction

What is a door module?

A door module typically consists of a rubber-sealed carrier made from plastic

or metal. Aluminium and magnesium are also being considered by

manufacturers to reduce the weight of the carrier still further. A variety of door

components are then fitted onto the carrier, forming a ‘cassette’, such as the

window lift mechanism, locks, electric motor to operate the wing mirror, wiring

harness, various switches, loud speaker and a cable that connects the latch to

the inner release handle. The carrier plate is then tested and sealed to the

outer door.

The level of componentry however, can vary immensely from one trim level to

the next. Manufacturers typically carry 90 different part numbers for each of

the four doors. Whereas one model may offer a manual latch with central

locking, another may include an electric latch with super-locking. There are five

different types of latch offered for the Golf, for example. There are more than

200 front door module combinations alone, ranging from all-manual to allelectronic.

While the majority of door modules use a steel carrier, plastic solutions are

becoming increasingly popular. Over the past few years, there have been a

number of arguments ‘for’ and ‘against’ the use of plastic over steel carriers.

Delphi’s Superplug, for example, was a well-publicised effort to use a plastic

carrier. Klaus Caspers, programme manager for Delphi’s door modules, said:

“The technological advancement in new resins and manufacturing processes

for plastic carriers has evolved to the point where plastic is being more

favourably received as an alternative to steel. With the volatility of steel prices

in the market, OEMs are searching for alternative materials, and plastics is one

material that is being considered more favourably. More OEMs are considering

plastics and are not as quick to dismiss it as an alternative material to steel.”

The trend in both Europe and the US is toward increasing complexity of the

door componentry, adding more electronic functions and, in some cases, the

glass itself. VW and Porsche are arguably furthest down that route. Developed

by Brose, the door modules for the VW Touareg and Porsche Cayenne show

© 2004 All content copyright Aroq Ltd. All rights reserved.


Chapter 1 Introduction Page 2

the greatest extent of integration to date. These modules integrate xx% of all

door functions. Brose supplies these modules just-in-sequence to VW and

Porsche in up to 2,000 variants. Only the patented door outer shell is supplied

by the OEM.

There are still some significant hurdles to cross before the industry sees the

complete door in volume production. Manufacturers forecast that the demand

for complete door modules will gain greater application as soon as the inherent

paint, fit and finish problems are resolved as well as the problems in supplier

participation in unionised OEM plants.

The slick way in which the door systems are assembled and despatched

masks some heavily intricate planning on the part of suppliers. For example, at

Brose, orders for the door system variants are sent from Ford’s assembly site

in Saarlouis, Germany, then sent electronically to the supplier’s nearby plant in

Saarwellingen. At each of the four production lines in Saarwellingen, a

computer prints an order for each new door system. This order sheet

accompanies the product throughout the entire assembly process. Barcode

scanning and picture recognition ensure that the correct components are

assembled depending on the variant required. The functionality of every single

door system is tested at the inspection station at the end of the assembly line.

Once packed in special containers, the products are loaded via an automated

system onto the trucks and subsequently transported to the Ford plant.

Report coverage

In this second edition reviewing the key market for door modules, we extend

our forecasts to 2010, providing market fitment, volume and value data for this

fast-growing sector. Chapter two also identifies the main players in the door

module market, and their market shares in Europe and North America.

Chapter three provides brief profiles of the major door module manufacturers,

namely ArvinMeritor, Brose, Delphi, Dura Automotive, Faurecia, Intier and

Wagon.

© 2004 All content copyright Aroq Ltd. All rights reserved.


Chapter 2 The market Page 3

Chapter 2 The market

Market players

Most of the major suppliers pitching for door module business have their

origins in either window regulators or plastic interior trim. Brose, Kuester,

Grupo Antolin, Dura, Lames and ArvinMeritor all have a strong tradition in the

window regulator business.

Brose began expanding its window regulator business into door modules in the

1980s. Today, the group has a xx% share of the world market for window

regulators and a xx% share of the European market. It also has a xx% share of

the European power seat adjuster market. In the US, Brose has a xx% share

of the window regulator and xx% share of the door system markets.

Table 1 indicates the main products offered by the various market participants.

Table 1: Door module manufacturers’ product range

Manufacturer

ArvinMeritor

Brose

Delphi

Dura Automotive

Faurecia

Grupo Antolin

Intier

Wagon

Door module offering

Door modules feature power double-lift window regulators with anti-squeeze and super-locking

actuators.

Since 2002, Brose has been supplying door systems with the frame, glass, seal and a part of

the door structure.

Delphi’s modular door systems feature integrated sub-systems, which make up the entire door

system. Major door system components include the trim elements, moveable side glass,

window lift, electrics and electronics, latching, switches and climate control features.

Dura’s structural door module products include aluminum and steel body-in-white door

modules, side impact beams, power and manual window lift systems, anti-pinch window lift

systems.

Faurecia's door modules include a variety of electrical and electronic elements, including

locking systems, airbags, lateral shock absorbers, cables and loudspeakers.

Grupo Antolin’s door functions include door panels, window regulators, and accessories.

Intier’s closures product expertise includes complete door systems; system module

technologies including mid-doors, sliding doors, electro-mechanical systems, window regulator

systems and latching systems.

Wagon’s door system range includes doorframe modules (in aluminium or steel), door

structures and sliding doors. Wagon also supplies complete or semi-complete door structures,

which are assembled as part of the car body at the trackside.

Source: just-auto.com

© 2004 All content copyright Aroq Ltd. All rights reserved.


Chapter 2 The market Page 4

Market shares

The main suppliers of steel and plastic door module carriers in Europe are

Brose, ArvinMeritor, Lames, Kuester, and Faurecia.

Figure 1: European market shares of door modules, 2003 (% of volume)

%

Brose

ArvinMeritor

Faurecia

Kuester

Lames

Others

Sources: just-auto.com; industry estimates.

Brose expects to report sales of €xx billion by 20xx, up from €xx billion in 2003.

By 2005, the company expects for the first time to earn more revenues from

abroad than in Germany. Over the next few years, Brose plans to pursue its

international strategy, stepping up its activities in Europe and North America.

In fact, Brose regards North America as a major growth market. The company

began its activities there in 1993 and succeeded in posting annual double-digit

growth. In 2003, the company generated sales of US$xxx million in North

America. By 20xx, Brose expects to achieve sales of US$xxx million. In order

to meet its targets, the company is investing some US$xxx million in building

© 2004 All content copyright Aroq Ltd. All rights reserved.


Chapter 2 The market Page 5

three new production sites in Chicago, Tuscaloosa and London (Canada) plus

a new headquarters in Detroit. The company already operates plants in

Queretaro and Puebla in Mexico. The company is also planning to enter the

North America seat adjuster market in 20xx. From 20xx, Brose will be

producing mechanical and power seat height adjusters at its new plant in

London, Canada. By 20xx, Brose anticipates to generate sales of US$xxx

million in this business division. Brose’s window regulator business in North

America is also growing.

Brose’s power window regulators have been offered in the US since 2000.

Today, Brose equips six American car models with these systems and is

currently working on nine customer projects involving window regulators with

an anti-trap feature. just-auto.com predicts at least xx% penetration of antipinch

windows in the North American market by 20xx. A spokesman for Brose

told us: “We see more and more cars being developed in the US with the antitrap

devices. In the long-run, we expect all cars to have those safety devices -

as it is the case in Europe, North America is a main growth market for Brose.”

Brose expects to generate sales of US$xxx million from its North American

window regulator business by 20xx.

Over the past few years, Grupo Antolin has seen a huge increase in its doortrim

module business thanks to an order to supply the new Renault Megane.

The Megane deal is its first major door module contract. In 2004, Grupo

Antolin will also supply door modules to SEAT and there are possibilities to

supply DaimlerChrysler in the US, and Ford in the US & Europe. The group is

currently promoting its DTM (Door Trim Module) concept. The module includes

the inside handle, window regulator, loudspeaker, latch, wiring harness,

sealing system and passive safety. The company believes it can cut costs by

integrating door-trim and mechanical elements to deliver. In 2003, the

company introduced three new door modules into the US market, of which two

were for Ford and one for DaimlerChrysler.

© 2004 All content copyright Aroq Ltd. All rights reserved.


Chapter 2 The market Page 6

Figure 2: Grupo Antolin’s Door Trim Module

Source: Grupo Antolin

ArvinMeritor claims an xx% share of the door system market in North America,

ranking it in third place. ArvinMeritor manufactures more than xx million

window regulators, and one million door modules annually. The company’s

Door Systems group is also a world leader in the supply of door latches. The

company produces more than xx million side door, trunk, tailgate, hood and

sliding door latches annually. The group also supplies millions of electrical

actuators for use in modular power locking latches and other automotive

applications, including electrical door releases, powered door closures and

electrical fuel flap operation.

ArvinMeritor recently won a contract to supply one million door modules

annually for two of Hyundai’s platforms, beginning production in Montgomery,

US in 2005. The finished door module will include a window regulator, latch,

motor, loudspeaker and wire harness integrated into one system that will be

© 2004 All content copyright Aroq Ltd. All rights reserved.


Chapter 2 The market Page 7

line sequenced into Hyundai’s production schedule. To ensure just-in-time

delivery, ArvinMeritor plans to open a new Customer Value Centre for final

assembly in Montgomery, Alabama, US. ArvinMeritor is currently a partner

with Pyeong Hwa Automotive to supply door modules for Hyundai’s production

of the Santa Fe, Sonata and Grandeur models in Korea.

On the global stage, Brose is reckoned to lead the market for door modules

with a 40% share, followed, by ArvinMeritor, Delphi, Intier and others.

Delphi supply door modules to a number of vehicle makers, including General

Motors, DaimlerChrysler, Isuzu and International NGV. Its modules are fitted to

a number of models, including the Chevrolet Malibu and Buick Park Avenue.

Figure 3: Global market shares of door modules, 2003 (% of volume)

%

Brose

ArvinMeritor

Delphi

Intier

Others

Sources: just-auto.com; industry estimates.

© 2004 All content copyright Aroq Ltd. All rights reserved.


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