Full Text - University of Michigan Transportation Research Institute

Fiat-Chrysler
The Challenges of Global Powertrain Engineering
University of Michigan
07/25/12
Chris Cowland
Advanced and SRT Powertrain
Chrysler Group LLC
Advanced Powertrain Engineering
History – Industrial Partnerships
July 11, 1899: Fiat company charter “Societa
Anonima Fabbrica Italiana Automobili Torino”
signed. Led by Gianni Agnelli from 1966 – 2003.
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.
MHI
1928
1925 Dodge
Chrysler
Founded
1899
Fiat
Founded
DSM
1958-78 1964 1967 1969-93
1934-71
1988 1989
1984 1985
1969 1975 1979
1974
1986
Advanced Powertrain Engineering
1992
19982007
2003
2000-05
1993
1991
1999
2009 2010
2011
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
X
What are the challenges?
Y
- Global market regulatory/requirement differences
- Managing portfolio complexity without duplication
- Cultural differences
- Learn from previous collaborations/ownerships
Advanced Powertrain Engineering
Fiat-Chrysler Global Powertrain
Kokomo (Mfg x 3)
Kokomo Cast (Mfg)
Auburn Hills (R&D)
Chelsea (R&D)
Trenton (Mfg x 2)
Mack (Mfg)
Dundee (Mfg)
Toledo (Mfg)
Conner (Mfg)
Windsor (R&D)
Bielsko Biala
(Mfg)
Orbassano (R&D)
Mirafiori (R&D)
Verrone (Mfg)
Balocco (R&D)
Yucca (R&D)
Etobicoke Cast (Mfg)
Satillo (Mfg x 2)
Pomigliano (R&D)
Pratola Serra (Mfg)
Termoli (Mfg)
Shanghai (R&D)
Santa Fe (R&D)
Ranjangaon
(R&D, Mfg)
Jiading (R&D)
Chennai (R&D)
Pune (R&D)
Cordoba
(Mfg)
Betim
(R&D,Mfg)
Engine/Transmission Research and Development
Engine/Transmission Manufacturing
8
7
Advanced Powertrain Engineering
7
13
Fiat-Chrysler Vehicle Brands
Differentiate via :
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Technology level
Brand sound engineering
Transient response/feel
Underhood appearance
Power/torque ratings
Torque curve shaping
Transmission type
Shift strategy and feel
Need to achieve brand differentiation at the powertrain
level without excessive part proliferation
Advanced Powertrain Engineering
Global CO2 Emission Regulations
US-LDV
EU
US 2025: 107
Proposed
Targets
EU 2020: 95
CO2 legislation is core driver in all regions for the foreseeable
future – EU leads but absolute limits converging
Advanced Powertrain Engineering
US Standard
Global Emissions Regulations
US PM Standards
2017-2025 =3 mg/mi
(1.9 mg/km)
SULEV30
Emissions legislation is core driver in all regions for the
foreseeable future – US leads but absolute limits converging
Advanced Powertrain Engineering
Fuel Economy/Emissions Test Procedures
US Drive Cycle
US FTP
Euro NEDC
Japan
Undefined
European Drive Cycle
Chrysler EPA(Combined)
Fiat 500 -
EPA(Combined) impact
Different test procedures have a huge
cost/resource
Chrysler NEDC(Combined)
without tangible benefit to local air
quality/global warming
Average vehicle demand energy
(Jeep Patriot - AWD)
FTP Combined = 10.34 MJ
NEDC Combined = 6.06 MJ
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Fuels and Lubricants
lower value = refinery
average, upper value =
refinery cap (retail values
will be higher).
Gasoline Sulphur Levels
Region
Fuel
Lubricant
Service Interval
NAFTA
89-100 RON
GF 4 or 5
5-10K miles
EAEM
ACEA
12.5-18.6K miles
Regional
differences
in
fuel
and
lubricants
result in
Western Europe
95-98 RON
or
Eastern Europe additional
90-98 RON
OEM Spec
considerable
work to implement
global powertrains
LATAM
93-98 RON
or OEM Spec
6-9.3K miles
around theAPIworld
APAC*
88-98 RON
ILSAC or OEM Spec
Advanced Powertrain Engineering
Usage Specific
* Manganese and methanol added to increase octane
adversely affecting aftertreatment robustness
Fuel/Vehicle Pricing – Cost of Ownership
US
Europe
$46,875
225 hp (168 kW), AWD
3.0L Turbo Diesel
$72,502*
201 hp (150 kW), AWD
3.0L Turbo Diesel
* 19% VAT,duties, foreign exchange, distribution
Cost of vehicle ownership is significantly higher outside the
US resulting in different vehicle attribute preferences
Oil change in US
$30 Generic oil
$80 Synthetic oil (higher at OEM)
$160 High end (synthetic)
Oil change in Europe
$60 Minimum generic oil
$160 Typical cost (higher at OEM)
$300 High end
Advanced Powertrain Engineering
EU vs US Market Differences
Market Quartiles: US vs EU
D
E
F
34%
22%
22%
22%
> 31.8 mpg
27.1 – 31.8
23.7 – 27.0
< 23.6 mpg
89%
6%
4%
1%
$7.80/gal.
CAFE Equivalent
$3.80/gal.
A/B/C
egment
Vehicle footprint correlates to disposable income
Advanced Powertrain Engineering
Powertrain Portfolio - Engines
Advanced Powertrain Engineering
Powertrain Portfolio - Engines
Fiat Sales Mix
(Euro Market)
Chrysler Sales Mix
(US Market)
Cummins
RAM Truck
Maserati
Gasoline
Diesel
Chrysler
Fiat
Gasoline – Fiat = small displacement/lower output
Chrysler = larger displacement
Diesel – Fiat = significant in-house portfolio
Chrysler = 100% purchased
Advanced Powertrain Engineering
Powertrain Portfolio - Transmissions
Chrysler Sales Mix
(US Market)
Automatic
Manual
Chrysler
Fiat
Fiat Sales Mix
(Euro Market)
FWD options similar for Fiat and Chrysler
AMT/DCT transmissions more prevalent outside the US
Chrysler has larger capacity RWD transmissions
Advanced Powertrain Engineering
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
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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
Advanced Powertrain Engineering
World Class Manufacturing (WCM)
WCM is ….
Goals:
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
Cost
Deployment
Safety
Deliverables: Continuous improvement
Waste
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
Zero Accidents, Zero Waste, Zero Breakdowns,
Zero Inventories
Time
Two result examples from Fiat:
Energy Efficiency Improvement
- 1,700 projects introduced in 2011
- 80% energy savings increment over 2010
- €38 million savings
Huge opportunities for efficiency improvements and waste
Workplace
reduction
over
very large
Logistics global manufacturing footprint
Maintenance
Quality
Organization
Waste Reduction
- 1,900 projects introduced in 2011
- €50 million savings
Key Technology/Powertrain Transfer Examples
MultiAir
Small I4 Gas Engines
CNG
DDCT
Hybrid/Electric
Axle Disconnect (4wd)
Diesel Engines
V6 Gas Engines
Cylinder Deactivation
Multispeed ATX
Advanced Powertrain Engineering
Social/Cultural
Leisure time
Racing
Start early vs
work late
“Football?”
Advanced Powertrain Engineering
Key Conclusions
• 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
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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
Truly a Marriage of Equals???
Advanced Powertrain Engineering