Foresight Vehicle Technology Roadmap - Institute for Manufacturing

4.5 Design and Manufacturing ProcessesScopeThe design and manufacturing processes (DMaP) technology theme is broad, covering the full lifecycle of road vehicles, with strong links to the other technology themes: Design, engineering, prototyping, manufacturing, assembly, use and recycling / regeneration Other business processes, including supply chain management, marketing, logistics, distributionand retailMarket and industry trends and drivers that are particularly relevant to this technology theme include:SocialEconomicEnvironmentalTechnologicalPoliticalDemands for greater mobility and changing patterns of working and living, together withdemographic changes.Competitive pressure to reduce development and manufacturing cycle times and costs, andto improve responsiveness, agility, flexibility, durability, efficiency and quality, in order toachieve greater profitability and return on capital, together with changes to industrystructure (consolidation, globalisation, supply chain, etc.).Requirement to reduce energy consumption, material waste and emissions of CO 2 andother harmful substances, during manufacture and use of vehicles.Competition to develop innovative solutions in the areas of vehicle design andmanufacture, considering all aspects of the vehicle life cycle.UK Government, European and international policy, regulation and legislation concerningtransport, energy, CO 2 , safety and waste management.Development of design and manufacturing process technologies, together with associated researchchallenges, have been explored in an expert workshop that identified and considered the followingthemes, summarised below and detailed in Appendix C:LifecycleManufacturingIntegrationTechnology directionsLifecycleThe development of sustainable road transport, in terms of meeting social, economic and environmentalneeds, requires consideration of the full life cycle of vehicles, including design, production, distribution, useand end-of-life (re-use, recycling and disposal). Substantial reductions in total system material and energyconsumption are required, together with reduced pollution and waste, whilst at the same time increasingeconomic performance in a globally competitive market. There are substantial challenges involved withmigrating to more sustainable modes of vehicle production and use, which will require social, economic,environmental, technological, political and infrastructural change. A range of actions will result in moderateprogress towards these goals, based on evolution of existing technology and approaches. However, in thelonger term there is a requirement for improved understanding of the scale and type of change required, at asystem level, and the associated implications for technology, industry and society.< 10 years 10 – 20 years > 20 years Supply for demand (reduce stock) Increased use of information technology (throughoutlifecycle) Simulation technologies for customer education andmarket research Trend towards ‘full service contracts’ Near zero landfill: strategies for existing fleetand new vehicles End of life disassembly: materials separationand fluid handling Energy recovery Increasing customisation and diversity of Substantial (50%)reduction in energyconsumption andemissions35