Light Duty Technology Cost Analysis, Power - US Environmental ...

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In Table A-3, a summary of the net incremental, direct manufacturing costs to add P2 HEV technology to a range of vehicle segments are presented on a system level. Table A-4 and Table A-5 provide additional cost details, at the component and subsystem level, for the integrated electric motor/generator and clutch assembly system and the high voltage traction battery, respectively. These subsystems account for approximately 80% of the net cost impact for adding the P2 technology configuration. I. Glossary of Terms Assembly: a group of interdependent components joined together to perform a defined function (e.g., turbocharger assembly, high pressure fuel pump assembly, high pressure fuel injector assembly). Buy: the components or assemblies a manufacturer would purchase versus manufacture. All designated “buy” parts, within the analysis, only have a net component cost presented. These types of parts are typically considered commodity purchase parts having industry established pricing. CBOM (Comparison Bill of Materials): a system bill of materials, identifying all the subsystems, assemblies, and components associated with the technology configurations under evaluation. The CBOM records all the high-level details of the technology configurations under study, identifies those items which have cost implication as a result of the new versus base technology differences, documents the study assumptions, and is the primary document for capturing input from the cross-functional team. Component: the lowest level part within the cost analysis. An assembly is typically made up of several components acting together to perform a function (e.g., the turbine wheel in a turbocharger assembly). However, in some cases, a component can independently perform a function within a sub-subsystem or subsystem (e.g., exhaust manifold within the exhaust subsystem). Cost Estimating Models: cost estimating tools, external to the Design Profit® software, used to calculate operation and process parameters for primary manufacturing processes (e.g., injection molding, die casting, metal stamping, forging). Key information calculated from the costing estimating tools (e.g., cycle times, raw material usage, equipment size) is inputted into the Lean Design® process maps supporting the cost analysis. The Excel base cost estimating models are developed and validated by Munro & Associates. 142
Costing Databases: the five (5) core databases that contain all the cost rates for the analysis. (1) The material database lists all the materials used throughout the analysis along with the estimated price/pound for each. (2) The labor database captures various automotive, direct labor, manufacturing jobs (supplier and OEM), along with the associated mean hourly labor rates. (3) The manufacturing overhead rate database contains the cost/hour for the various pieces of manufacturing equipment assumed in the analysis. (4) A mark-up database assigns a percentage of mark-up for each of the four (4) main mark-up categories (i.e., end-item scrap, SG&A, profit, and ED&T), based on the industry, supplier size, and complexity classification. (5) The packaging database, contains packaging options and costs for each case. Lean Design® (a module within the Design Profit® software): is used to create detailed process flow charts/process maps. Lean Design® uses a series of standardized symbols, with each base symbol representing a group of similar manufacturing procedures (e.g., fastening, material modifications, inspection). For each group, a Lean Design® library/database exists containing standardized operations along with the associated manufacturing information and specifications for each operation. The information and specifications are used to generate a net operation cycle time. Each operation on a process flow chart is represented by a base symbol, operation description, and operation time, all linked to a Lean Design® library/database. Make: terminology used to identify those components or assemblies a manufacturer would produce internally versus purchase. All parts designated as a “make” part, within the analysis, are costed in full detail. MAQS (Manufacturing Assumption and Quote Summary) worksheet: standardized template used in the analysis to calculate the mass production manufacturing cost, including supplier mark-up, for each system, subsystem, and assembly quoted in the analysis. Every component and assembly costed in the analysis will have a MAQS worksheet. The worksheet is based on a standard OEM (original equipment manufacturer) quote sheet modified for improved costing transparency and flexibility in sensitivity studies. The main feeder documents to the MAQS worksheets are process maps and the costing databases. MCRs (Material Cost Reductions): a process employed to identify and capture potential design and/or manufacturing optimization ideas with the hardware under evaluation. These savings could potentially reduce or increase the differential costs between the new and base technology configurations, depending on whether an MCR idea is for the new or the base technology. Net Component/Assembly Cost Impact to OEM: the net manufacturing cost impact per unit to the OEM for a defined component, assembly, subsystem, or system. For components produced by the supplier base, the net manufacturing cost impact to the OEM 143
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Light Duty Technology Cost Analysis
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Contents A. EXECUTIVE SUMMARY......
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Figures FIGURE A-1: POWER-SPLIT SYS
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FIGURE D-90: HIGH VOLTAGE HARNESS C
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A. Executive Summary Light-Duty Tec
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Internal Combustion Engine (ICE) Ot
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Table A-1: Net Incremental, Direct
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Table A-2: P2 Vehicle Segment Mass
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Table A-4 and Table A-5 provide add
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B. Introduction B.1 Objectives The
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B.2 Process Flow and Key Supporting
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Step 6: Phase 2 (component/assembly
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Table B-1: Summary of Universal Cos
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C. Costing Methodology C.1 Teardown
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An example of a custom complex mode
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For a component which has a serial
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C.2 Cost Model Overview The cost pa
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Lastly, the “Net Incremental Dire
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considered. For example, forged com
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part, while “buy” indicates an
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C.4.3.3 Contributors to Labor Rate
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sided part, CNC turning, auto bar f
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The Primary Process Equipment secti
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For this cost analysis study, four
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very difficult to predict and are v
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C.4.6.2 Types of Packaging and Sele
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capture additional quote details an
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Project Process Requirement Minimum
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information from both technology co
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and transit lead times. This equate
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study. These vehicles provided a ve
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Table D-1: Vehicle Specification Su
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D.1.2 Direct Manufacturing Cost Dif
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D.2 Engine System and Cost Summary
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D.3 Transmission System and Cost Su
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D.3.1.2 Gear Train Subsystem The po
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The generator stator (Figure D-10)
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The traction motor stator (Figure D
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The generator control unit (Figure
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The CVT control circuit board (Figu
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The speed sensor for the traction m
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D.3.1.4 Transmission Cooling System
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The electric pump (Figure D-30 ) is
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technology adaptation (i.e., driven
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Item Table D-5: Net Incremental Dir
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Item Table D-6: eCVT Motor and Cont
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Figure D-34: HEV Fusion, Under Engi
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ase to the body. The seat cover is
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Figure D-43: Expanded Polypropylene
Page 99 and 100: D.4.2 Body System Cost Impact As sh
Page 101 and 102: Figure D-49: Key Components of Brak
Page 103 and 104: D.5.1.2 Power Brake Subsystem D.5.1
Page 105 and 106: Figure D-56: Actuator Solenoid and
Page 107 and 108: Table D-8: Net Incremental Direct M
Page 109 and 110: D.6.1.2 Refrigeration/Air Condition
Page 111 and 112: The two (2) main housings and both
Page 113 and 114: Figure D-67: Main Housing and Elect
Page 115 and 116: The rotor shaft is mounted to an in
Page 117 and 118: D.7 Electrical Power Supply System
Page 119 and 120: Circuit connections between packs a
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Page 123 and 124: During dormant periods the BEC (Fig
Page 125 and 126: D.7.2 Electrical Power Supply Cost
Page 127 and 128: Item 1 2 3 4 5 6 7 8 9 10 11 12 13
Page 129 and 130: The HV connectors (Figure D-91) are
Page 131 and 132: Item Table D-12: Net Incremental Di
Page 133 and 134: F. Power-Split Scaling Cost Analysi
Page 135 and 136: vehicle class was determined. Also
Page 137 and 138: G. 2010 Hyundai Avante Lithium Poly
Page 139 and 140: Figure G-3: Li Ion Battery Modules
Page 141 and 142: Figure G-6: Cell Covers in Module,
Page 143 and 144: Figure G-9: The Battery Pack Discon
Page 145 and 146: Table G-2: 2010 Hyundai Avante Lith
Page 147 and 148: Table H-1: Baseline Powertrain and
Page 149: Table H-2: Primary Component Sizing
Page 153: Surrogate part: a part similar in f
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