Fiat-Chrysler The Challenges Of Global Powertrain Engineering
Transcript of Fiat-Chrysler The Challenges Of Global Powertrain Engineering
Advanced Powertrain Engineering
Chris Cowland Advanced and SRT Powertrain Chrysler Group LLC
Fiat-Chrysler The Challenges of Global Powertrain Engineering University of Michigan 07/25/12
History – Industrial Partnerships
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1920-1924: Walter P Chrysler teams with Fred Zeder, Owen Skelton and Carl Breer, to design a revolutionary new car. 1925 Chrysler founded. 1928 partners with the Dodge brothers.
July 11, 1899: Fiat company charter “Societa Anonima Fabbrica Italiana Automobili Torino” signed. Led by Gianni Agnelli from 1966 – 2003.
1899 Fiat
Founded
1925 ChryslerFounded
1928 Dodge
1934-71
1958-78 1964 1967 1969-93 1984 1985 MHI DSM
1989 1998-2007
2003 2009 1992 2010
2000-05 1979 1969 1986 1993
1988
1975 2011 1974 1991 1999
Fiat-Chrysler
What are we trying to achieve together?
- True global producer of passenger vehicles - Full spectrum of vehicles (A-F class) - Multiple Brand approach - Existing and emerging markets - Capitalize on synergies - Combine/develop best practices e.g. WCM
What are the challenges?
- Global market regulatory/requirement differences - Managing portfolio complexity without duplication - Cultural differences - Learn from previous collaborations/ownerships
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X
Y
Fiat-Chrysler Global Powertrain
Advanced Powertrain Engineering
Engine/Transmission Research and Development 8 7 Engine/Transmission Manufacturing 7 13
Jiading (R&D) Ranjangaon (R&D, Mfg)
Bielsko Biala (Mfg)
Orbassano (R&D) Mirafiori (R&D) Verrone (Mfg) Balocco (R&D)
Betim (R&D,Mfg)
Cordoba (Mfg)
Pomigliano (R&D) Pratola Serra (Mfg)
Termoli (Mfg)
Auburn Hills (R&D) Chelsea (R&D) Trenton (Mfg x 2) Mack (Mfg) Dundee (Mfg) Toledo (Mfg) Conner (Mfg) Windsor (R&D)
Kokomo (Mfg x 3) Kokomo Cast (Mfg)
Satillo (Mfg x 2)
Etobicoke Cast (Mfg) Yucca (R&D)
Santa Fe (R&D)
Shanghai (R&D)
Pune (R&D) Chennai (R&D)
Fiat-Chrysler Vehicle Brands
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Need to achieve brand differentiation at the powertrain level without excessive part proliferation
Differentiate via : • Technology level • Brand sound engineering • Transient response/feel • Underhood appearance • Power/torque ratings • Torque curve shaping • Transmission type • Shift strategy and feel
Global CO2 Emission Regulations
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Proposed Targets
US 2025: 107
EU 2020: 95
US-LDV
EU
CO2 legislation is core driver in all regions for the foreseeable future – EU leads but absolute limits converging
Global Emissions Regulations
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SULEV30
US PM Standards 2017-2025 =3 mg/mi (1.9 mg/km)
US
Sta
ndar
d
Emissions legislation is core driver in all regions for the foreseeable future – US leads but absolute limits converging
Fuel Economy/Emissions Test Procedures
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Average vehicle demand energy (Jeep Patriot - AWD) FTP Combined = 10.34 MJ NEDC Combined = 6.06 MJ
US Drive Cycle
European Drive Cycle
US FTP Euro NEDC Japan Undefined
Chrysler - EPA(Combined)
Fiat 500 - EPA(Combined)
Chrysler - NEDC(Combined)
Different test procedures have a huge cost/resource impact without tangible benefit to local air quality/global warming
Fuels and Lubricants
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Gasoline Sulphur Levels
lower value = refinery average, upper value = refinery cap (retail values will be higher).
Region Fuel Lubricant Service Interval NAFTA 89-100 RON GF 4 or 5 5-10K miles
EAEM Western Europe Eastern Europe
95-98 RON 90-98 RON
ACEA or
OEM Spec
12.5-18.6K miles
LATAM 93-98 RON API or OEM Spec 6-9.3K miles
APAC* 88-98 RON ILSAC or OEM Spec Usage Specific
* Manganese and methanol added to increase octane adversely affecting aftertreatment robustness
Regional differences in fuel and lubricants result in considerable additional work to implement global powertrains
around the world
Fuel/Vehicle Pricing – Cost of Ownership
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Oil change in Europe $60 Minimum generic oil $160 Typical cost (higher at OEM) $300 High end
Oil change in US $30 Generic oil $80 Synthetic oil (higher at OEM) $160 High end (synthetic)
$72,502* 201 hp (150 kW), AWD 3.0L Turbo Diesel * 19% VAT,duties, foreign exchange, distribution
$46,875 225 hp (168 kW), AWD 3.0L Turbo Diesel
US Europe
Cost of vehicle ownership is significantly higher outside the US resulting in different vehicle attribute preferences
EU vs US Market Differences
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Vehicle footprint correlates to disposable income
Market Quartiles: US vs EU
A/B/C egment
D E F
4% 1% 6% 89%
23.7 – 27.0 < 23.6 mpg 27.1 – 31.8 > 31.8 mpg
$7.8
0/ga
l. $3
.80/
gal.
CAF
E Eq
uiva
lent
22% 22% 22% 34%
Powertrain Portfolio - Engines
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Cummins RAM Truck
Chrysler Sales Mix (US Market)
Fiat Sales Mix (Euro Market)
Maserati
Gasoline Diesel
Chrysler
Fiat
Gasoline – Fiat = small displacement/lower output Chrysler = larger displacement Diesel – Fiat = significant in-house portfolio Chrysler = 100% purchased
Powertrain Portfolio - Transmissions
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FWD options similar for Fiat and Chrysler AMT/DCT transmissions more prevalent outside the US
Chrysler has larger capacity RWD transmissions
Chrysler Sales Mix (US Market)
Fiat Sales Mix (Euro Market)
Automatic Manual
Chrysler
Fiat
Design/Validation Boundary Conditions
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Chrysler
Fiat
Individual Tests Combined Cycle
• Coolant Temperature = 100 °C • Oil Temperature = 100 °C • Fuel Energy (LHV) = 43.05 MJ/kg • Electrical Loads = None • Accessory Drive = Fully equipped
• Coolant Temperature = 90 °C • Oil Temperature = Floats • Fuel Energy (LHV) = 42.5 MJ/kg • Electrical Loads = Loaded • Accessory Drive = Various levels
Opportunity to rationalize future test procedures
World Class Manufacturing (WCM)
WCM is …. A system based on the systematic reduction of all types of waste and loss through the contribution of everyone and the rigorous use of methods and standards Applies its’ principles to all aspects of the plant organization, from quality to maintenance, cost control to logistics, in a culture of continuous improvement Was born of the collaboration between Fiat and the best European and Japanese experts, with the aim to develop a recognized, world class production standard
Deliverables: Continuous improvement
Safety
Workplace Organization Quality Maintenance Logistics C
ost
Dep
loym
ent
Goals: Zero Accidents, Zero Waste, Zero Breakdowns, Zero Inventories
Two result examples from Fiat: Energy Efficiency Improvement
- 1,700 projects introduced in 2011 - 80% energy savings increment over 2010 - €38 million savings
Waste Reduction
- 1,900 projects introduced in 2011 - €50 million savings
Time
Was
te
Huge opportunities for efficiency improvements and waste reduction over very large global manufacturing footprint
Key Technology/Powertrain Transfer Examples
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MultiAir DDCT
Diesel Engines V6 Gas Engines
Multispeed ATX Cylinder Deactivation
Small I4 Gas Engines Axle Disconnect (4wd) Hybrid/Electric
CNG
Social/Cultural
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Start early vs work late
Leisure time
“Football?”
Racing
• Minimal Overlap within Powertrain portfolios but still need rationalization • CO2 driving downsized engines in all regions • Joint entity has key technical capabilities in all necessary technologies for future – diesel
emissions, advanced valvetrain, high efficiency transmissions, cylinder de-activation, pressure charging, advanced fuel systems
• Lack of harmonization in worldwide legislation is a vast waste of money and effort – but little hope of change
• Fundamental differences in engineering practices, books of knowledge etc already narrowing – good opportunity to question the paradigms
• Customer requirements/perceptions around the world are widely different but MAY start to converge if fuel prices increase dramatically in the US
• World Class Manufacturing is a cultural change with huge savings opportunity • Out of phase economy highs and lows (US and Europe) allow some resource opportunities • Joint R & D offers significant technical and financial benefits • Global purchasing leverage benefits considerable
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Truly a Marriage of Equals???
Key Conclusions