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

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As discussed, the intent of a process flow chart is to capture all the individual operations and details required to manufacture a part (e.g., component, subassembly, assembly). This often results in a string of serial operations, generating a serial process, which requires additional analysis to develop a mainstream mass production process (i.e., inclusion of parallel operations and processing). The Manufacturing Assumption section of the MAQS worksheet is where the base assumptions for converting serial operations and processes into mass production operations and processes, is captured. For example, assume “Assembly M” requires fifteen (15) operations to assembly all of its parts. Each operation on average taking approximately ten (10) seconds to complete. In a serial process (analogous to single, standalone work cell, manned by a single operator) consisting of fifteen (15) serial operations, the total process time would be 150 seconds to produce each part (15 operations x 10 second average/station). By taking this serial assembly process and converting it into a mass production parallel process, the following scenarios could be evaluated (Note: rates and assumptions applied below are assumed for this example only): Scenario #1: 15 serial operation stations, all manned, each performing a single parallel operation. � Process Time 10 seconds/part, 360 parts/hour @ 100% efficiency � Labor Cost/Part = [(15 Direct Laborers)*(Labor Rate $30/hour )]/360 parts/hour = $1.25/part � Burden Cost/Part = [(15 Stations)*(Burden Rate Average (Low Complexity Line) $15/hour/station)]/360 parts/hour = $0.625/part � Labor + Burden Costs = $1.875/part Scenario #2: 15 serial operations combined into 10 stations, 5 with 2 parallel automated operations, 5 serial manual operations. � Process Time 10 seconds/part, 360 parts/hour @ 100% efficiency, � Labor Cost/Part = [(5 Direct Laborers)*(Labor Rate $30/hour )]/360 parts/hour = $0.42/part � Burden Cost/Part = [(10 Stations)*(Burden Rate Average (Moderate Complexity Line) $30/hour/station)]/360 parts/hour = $0.83/part � Labor + Burden Costs = $1.25/part Assuming a high production volume and a North America manufacturing base (two key study assumptions), Scenario #2 would have been automatically chosen, with the higher level of automation offsetting higher manual assembly costs. 22
For a component which has a serial process as its typical mass production process (e.g., injection molding, stamping, die casting, selected screw machining), the manufacturing assumption section of the MAQS worksheet requires far less consideration. Analysis is usually limited to determining the total number of equipment pieces required for the defined volume. Figure C-1 illustrates the fundamental steps incorporated into the cost methodology. 23
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 and 26: Table B-1: Summary of Universal Cos
Page 27 and 28: C. Costing Methodology C.1 Teardown
Page 29: An example of a custom complex mode
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
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 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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