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

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Item Description Universal Case Study Assumptions 4 Selected Manufacturing Processes and Operations 5 Annual Capacity Planning Volume 450,000 Units A. All operations and processes are based on existing standard/mainstream Industrial practices. 6 Supplier Manufacturing Location North America (USA or Canada) 7 OEM Manufacturing Location North America (USA or Canada) 8 Manufacturing Cost Structure Timeframe ( e.g. Material Costs, Labor Rates, Manufacturing Overhead Rates) 9 Packaging Costs 10 Shipping and Handling 11 12 Intellectual Property (IP) Cost Considerations Material Cost Reductions (MCRs) on analyzed hardware 13 Operating and End-of Life Costs 14 Stranded Capital or ED&T expenses B. No additional allowance is included in the incremental direct manufacturing cost for manufacturing learning. Application of a learning curve to the developed incremental direct manufacturing cost is handled outside the scope of this analysis. 2009/2010 Production Year Rates A. Calculated on all Tier One (T1) supplier level components. B. For Tier 2/3 (T2/T3) supplier level components, packaging costs are included in T1 mark-up of incoming T2/T3 incoming goods. A. T1 supplier shipping costs covered through application of the Indirect Cost Multiplier (ICM) discussed above. B. T2/T3 to T1 supplier shipping costs are accounted for via T1 markup on incoming T2/T3 goods. Where applicable IP costs are included in the analysis. Based on the assumption that the technology has reached maturity, sufficient competition would exist suggesting alternative design paths to achieve similar function and performance metrics would be available minimizing any IP cost penalty. Only incorporated on those components where it was evident that the component design and/or selected manufacturing process was chosen due to actual low production volumes (e.g. design choice made to accept high piece price to minimize tooling expense). Under this scenario, assumptions where made, and cost analyzed assuming high production volumes. No new, or modified, maintenance or end-of-life costs, were identified in the analysis. No stranded capital or non-recovered ED&T expenses were considered within the scope of this analysis. It was assumed the integration of new technology would be planned and phased in minimizing non-recoverable expenses. 18
C. Costing Methodology C.1 Teardown, Process Mapping, and Costing C.1.1 Cost Methodology Fundamentals The costing methodology employed in this analysis is based on two (2) primary processes: (1) the development of detailed production process flow charts (P-flows), and (2) the transfer and processing of key information from the P-flows into standardize quoting worksheets. Supporting these two (2) primary processes with key input data are the process cost models and the costing databases (e.g. material [price/lb], labor [$/hour], manufacturing overhead [$/hour], mark-up [% of manufacturing cost], and packaging [$/packaging type]). The costing databases are discussed in greater detail in Section C.4. Process flow charts, depending on their defined function and the end user, can vary widely in the level of detail contained. They can range from simple block diagrams showing the general steps involved in the manufacturing or assembly of an item, to very detailed process flow charts breaking out each process step in fine detail capturing key manufacturing variables. For this cost analysis, detailed P-flows (which will also be referred to as process maps) are used to identify all the steps involved in manufacturing a product (e.g., assembly, machining, welding, forming), at all levels (e.g., system, subsystem, assembly and component). For example, in a high voltage traction battery scenario, process flows would exist for the following: (1) at the component level, the manufacturing of every component within the battery pack sensing module (unless considered a purchase part); (2) at the assembly level, the assembly of all the individual components to produce the battery pack sensing module; (3) at the sub-subsystem level, the assembly of the battery pack sensing module onto the battery pack; and (4) at the subsystem level, the assembly of the high voltage traction battery into the vehicle. In this example, the high voltage traction battery is one of several subsystems (e.g., service battery subsystem, alternator subsystem, voltage converter-inverter subsystem) making up the electrical power supply system. Each subsystem, if costed in the analysis, would have its own process map broken out using this same process methodology. In addition to detailing pictorially the process steps involved for a given manufacturing process, having key information (e.g., equipment type, material type and usage, cycle times, handling precautions, number of operators) associated with each step is imperative. Understanding the steps and the key process parameters together creates the costing roadmap for any particular manufacturing process. Due to the vast and complex nature of P-flows associated with some of the larger systems and subsystems under analysis, having specialized software which can accurately and 19
Page 1 and 2: Light Duty Technology Cost Analysis
Page 3 and 4: Contents A. EXECUTIVE SUMMARY......
Page 5 and 6: Figures FIGURE A-1: POWER-SPLIT SYS
Page 7 and 8: FIGURE D-90: HIGH VOLTAGE HARNESS C
Page 9 and 10: A. Executive Summary Light-Duty Tec
Page 11 and 12: Internal Combustion Engine (ICE) Ot
Page 13 and 14: Table A-1: Net Incremental, Direct
Page 15 and 16: Table A-2: P2 Vehicle Segment Mass
Page 17 and 18: Table A-4 and Table A-5 provide add
Page 19 and 20: B. Introduction B.1 Objectives The
Page 21 and 22: B.2 Process Flow and Key Supporting
Page 23 and 24: Step 6: Phase 2 (component/assembly
Page 25: Table B-1: Summary of Universal Cos
Page 29 and 30: An example of a custom complex mode
Page 31 and 32: For a component which has a serial
Page 33 and 34: C.2 Cost Model Overview The cost pa
Page 35 and 36: Lastly, the “Net Incremental Dire
Page 37 and 38: considered. For example, forged com
Page 39 and 40: part, while “buy” indicates an
Page 41 and 42: C.4.3.3 Contributors to Labor Rate
Page 43 and 44: sided part, CNC turning, auto bar f
Page 45 and 46: The Primary Process Equipment secti
Page 47 and 48: For this cost analysis study, four
Page 49 and 50: very difficult to predict and are v
Page 51 and 52: C.4.6.2 Types of Packaging and Sele
Page 53 and 54: capture additional quote details an
Page 55 and 56: Project Process Requirement Minimum
Page 57 and 58: information from both technology co
Page 59 and 60: and transit lead times. This equate
Page 61 and 62: study. These vehicles provided a ve
Page 63 and 64: Table D-1: Vehicle Specification Su
Page 65 and 66: D.1.2 Direct Manufacturing Cost Dif
Page 67 and 68: D.2 Engine System and Cost Summary
Page 69 and 70: D.3 Transmission System and Cost Su
Page 71 and 72: D.3.1.2 Gear Train Subsystem The po
Page 73 and 74: The generator stator (Figure D-10)
Page 75 and 76: The traction motor stator (Figure D
Page 77 and 78:
The generator control unit (Figure
Page 79 and 80:
The CVT control circuit board (Figu
Page 81 and 82:
The speed sensor for the traction m
Page 83 and 84:
D.3.1.4 Transmission Cooling System
Page 85 and 86:
The electric pump (Figure D-30 ) is
Page 87 and 88:
technology adaptation (i.e., driven
Page 89 and 90:
Item Table D-5: Net Incremental Dir
Page 91 and 92:
Item Table D-6: eCVT Motor and Cont
Page 93 and 94:
Figure D-34: HEV Fusion, Under Engi
Page 95 and 96:
ase to the body. The seat cover is
Page 97 and 98:
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
Page 121 and 122:
The traction battery assembly is mo
Page 123 and 124:
During dormant periods the BEC (Fig
Page 125 and 126:
D.7.2 Electrical Power Supply Cost
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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
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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 and 150:
Table H-2: Primary Component Sizing
Page 151 and 152:
Costing Databases: the five (5) cor
Page 153:
Surrogate part: a part similar in f
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