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

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Costing Databases Support Process Mapping and Quote Worksheet Phases of Cost Analysis Five (5) Databases store rates for all eight cost elements used within the cost analysis: Material, Labor, Burden, Mark-up (End-item Scrap, SG&A, Profit, and ED&T) and Packaging 1. Select Component Assembly, Subsystem, and /or System, for cost analysis 4. Populate Standardized Quote Worksheets - Two Main Functional Sections (Also referred to as Manufacturing Assumption and Quote Summary (MAQS) worksheet) 3. Develop Process Flow Charts/ Process Maps using Design Profit Software® During the teardown process, process flow charts capturing every manufacturing operation are generated, including all key part input data and part specific manufacturing data. 5. Market Place Cross- Check on Selected Assemblies through solicitation of Industry Experts Quote Summary (Sections B,C,E & F) Manufacturing Assumptions (Section D of MAQS) 2. Conduct Controlled Teardown Process Using the data generated in the Manufacturing Assumption Section of the MAQS, along with data from the Costing Databases, a net component/assembly cost impact is calculated. Using the data captured in the Process Flow Charts, multiple calculations are performed establishing the mass production manufacturing assumptions. For simpler processes, process parameter models are setup within the Design Profit ® Software to calculate part manufacturing data based on entered part data. For more complex operations and processes, external process parameter models are used. 6. Roll Up costs from MAQS Assembly Worksheets into Net Incremental Subsystem Costs Information used in final calculations includes the following: > Calculated pieces/hour > Material specification, quantity, and price/pound > Labor Classification, number of operators, and cost/hour > Burden Classification, number of machines, and cost/hour > OEM/Supplier Classification, percent of total manufacturing costs > Packaging Container, cost per container, number of parts per container 7. Roll Up each Incremental Subsystem Cost into a Net Incremental System Costs followed by a Net Incremental Vehicle Cost Examples included the following: > OEM and Supplier classifications are selected, based on component type and processes, establishing the applicable mark-up rates > Serial operations are combined into parallel operations where applicable > Operations, both serial and/or parallel, are grouped into high volume parallel processes where applicable. > Equipment numbers calculated to support capacity requirements > Final equipment selection and associated burden rates are established > Number of operators required to support defined manufacturing process calculated > Piece per hours calculated External Process Parameter Models Using process parameter models developed in Microsoft Excel, part input parameters (material specifications, mass, volume, part geometery, part features, etc) are fed into the process parameter models generating key output parameters (e.g. equipment type, equipment size, operation cycle times, material usage, etc). Figure C-1: Fundamental Steps in Costing Process The calculated manufacturing process data is then fed back into the Process Maps 24
C.2 Cost Model Overview The cost parameters considered in determining the net incremental component/assembly impact to the OEM for new technologies are discussed in detail following. Unit Cost is the sum of total manufacturing cost (TMC), mark-up costs, and packaging cost associated with producing a component/assembly. It is the net component/assembly cost impact to the OEM (generally, the automobile manufacturer). Figure C-2 shows all the factors contributing to unit cost for supplier manufactured components. Additional details on the subcategories are discussed in the sections that follow. Total Manufacturing Cost + = Material + Labor Raw Material + Packaging In-process Scrap Purchased Part Commodity Parts Net Component/Assembly Cost Impact To OEM = Mark-up Cost = End Item Scrap + Sell, General & Administrative Costs Direct Labor Indirect Labor + Maintenance, Fringe Repair, Other Profit + + Quality Defects Shipping Damage Manufacturing Primary Equipment Process Supporting Equip. Engineering, Design Project Support ED&T Overhead/ Burden General Plant & Office Equip. Facilities and Testing/R&D Corporate R&D Utilities Plant Salary Destruct Tests Corporate Overhead: personnel functions, finance/accounting, systems data processing, sales/marketing, purchasing, public relations, legal staff, training, warranty, etc Supplier compensation for the assumption of investment risk in supplying a part to a customer. Cost Figure C-2: Unit Cost Model – Costing Factors Included in Analysis For OEM manufactured components/assemblies, the unit cost is calculated in the same way, except that mark-up is addressed outside the scope of this study through application of indirect cost (IC) multipliers. The IC multiplier assigned is based on the technology complexity level and timeframe in the market place. See Section C.3 for additional details. The full report, “Automobile Industry Retail Price Equivalent and Indirect Cost 25
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 and 30: An example of a custom complex mode
Page 31: For a component which has a serial
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
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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
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D.4.2 Body System Cost Impact As sh
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Figure D-49: Key Components of Brak
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D.5.1.2 Power Brake Subsystem D.5.1
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Figure D-56: Actuator Solenoid and
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Table D-8: Net Incremental Direct M
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D.6.1.2 Refrigeration/Air Condition
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The two (2) main housings and both
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Figure D-67: Main Housing and Elect
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The rotor shaft is mounted to an in
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D.7 Electrical Power Supply System
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Circuit connections between packs a
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The traction battery assembly is mo
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During dormant periods the BEC (Fig
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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
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The HV connectors (Figure D-91) are
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Item Table D-12: Net Incremental Di
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F. Power-Split Scaling Cost Analysi
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vehicle class was determined. Also
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G. 2010 Hyundai Avante Lithium Poly
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Figure G-3: Li Ion Battery Modules
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Figure G-6: Cell Covers in Module,
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Figure G-9: The Battery Pack Discon
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Table G-2: 2010 Hyundai Avante Lith
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Table H-1: Baseline Powertrain and
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Table H-2: Primary Component Sizing
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Costing Databases: the five (5) cor
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Surrogate part: a part similar in f
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