BMW i3 Teardown and Benchmarking Study: Reports Summary
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BMW i3 Teardown and Benchmarking Study: Reports Summary
BMW i3 Teardown and Benchmarking Study
Study Overview
In 2014 Munro & Associates, a global leader in manufacturing costing and benchmarking, is
producing an industry exclusive teardown and benchmark study of the revolutionary BMW i3.
Using proprietary advanced design, quality and costing software, Design Profit®, Munro will
disassemble and analyze the entire vehicle, system by system, at its world class benchmarking
facility in Michigan.
Report Overview
Munro & Associates will be releasing a series of reports on the i3 in the fourth quarter of 2014 as
various phases of the vehicle teardown and analysis are completed. The initial report
scheduled for release is a Fit, Finish and Quality report. Following in succession will be a series
of reports covering ten designated vehicle zones. Zone reports will be made available
individually and will also be packaged into larger reports to provide all information pertinent
to five key vehicle systems:
1. Body
2. Rolling Chassis
3. Battery and Heat Exchange (HEX)
4. Powertrain
5. Interiors
An Original Equipment Manufacturer (OEM) level Master Report covering all aspects of the
vehicle, including all five systems and total vehicle assembly hours, will also be made
available shortly after completion of the teardown and benchmark process. Delivery is
currently slated for late December 2014 or early 2015.
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BMW i3 Teardown and Benchmarking Study
Study Highlights
The BMW i3 is notable for being the first mass produced electric vehicle to extensively feature
carbon fiber. The cost and methodologies related to the assembly and fabrication process,
especially those of the carbon fiber life module, are of high interest. In addition, the i3 utilizes
the newest battery technologies featuring an innovative modular design. Combined with an
optional range extending engine (REx), the system sets new industry standards. Munro’s
unique methodology, Design Profit®, allows us to provide detailed engineering, processing
and financial insights into these and other key areas of interest.
Carbon Fiber Life Module: Carbon Fiber Life Module components,
materials and processes are disassembled, analyzed, documented,
cost modeled and summarized. Detailed information regarding the
cutting, forming and molding of carbon fiber sheets as well as their
assembly into single body structural units will be provided. In addition
both the materials and costs for adhesive fastening of the body
structure to the frame will be provided including the number and size of
joints, adhesive types, and the types of machines used for adhesive
application.
Battery: The high voltage battery pack, battery management
electronics housed within the battery pack, battery cells, and cables,
assemblies, and sensing wire harness are all disassembled, analyzed,
documented, cost modeled and summarized. Fastener types,
properties and fastening techniques are all analyzed, documented,
cost modeled and summarized. All internal components of the battery
are analyzed and cost modeled including the electrolytes and active
materials used in the electrodes. Full detail of the electrode
manufacturing process, including mixing of active materials, coating,
drying, slitting and compaction is provided. In addition, all related
electronic control modules and printed circuit boards are analyzed.
REx System: The REx system is completely disassembled, analyzed,
documented, cost modeled, and summarized. The study includes the
removal and disassembly of the REx engine, electric generator
harnesses and mounting hardware. The engine, fuel and exhaust
systems as well as the engine accessory components are fully reviewed
for cost of materials, fabrication and the assembly and fastening
processes. Complete engineering, processing and cost information on
related electronic system control modules and harness components
are provided, as is full detail on the materials and installation of any
associated noise abatement components.
Electronics: Integrated vehicle electronics are disassembled, analyzed,
documented, cost modeled and summarized. Identification of leading
integrated circuit designs, analysis of the circuit structure and circuit
board layout, and detailed Bill of Materials costing is provided on all
electronic systems. Key areas of focus include the infotainment system
and instrument cluster, the Advanced Driver Assistance Systems (ADAS),
power train systems, and body control systems.
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BMW i3 Teardown and Benchmarking Study
Report Contents
All reports (Master/OEM, System and Zone) will contain comprehensive information including
the following:
• Videos of the disassembly process with modules highlighting key features and
functions
• Detailed vehicle specifications including all weights and dimensions through
fully descriptive and pictorial reports
• Complete cost, assembly and materials-analysis for all parts specific to a zone
or system
• A complimentary edition of the vehicle Fit, Finish and Quality Audit (FFQ) report
Audit
• A complimentary single license of Munro’s proprietary Design Profit® software
which provides the purchaser the ability to print Cost Maps®, indented Costed
Bill Of Materials (CBOM) and more.
• Copies of, or links to, any known BMW public domain articles and videos.
Report Delivery
All reports and accompanying deliverables will be made available for easy access through a
secure File Transfer Protocol FTP site. A user-friendly format will help ensure that subscribers can
easily locate a wide range of materials in addition to the reports, including a host of relevant
video and media content. The reports themselves utilize hyperlinks within a table of contents
to facilitate the ability to easily navigate throughout the contents and quickly find specific
data and information to meet user needs.
Report Detail and Pricing
Vehicle Fit, Finish and Quality Audit
The Fit, Finish and Quality Audit (FFQ) is a thorough yet
non-intrusive evaluation of the i3. The purpose is to
analytically document what one would see, hear and
feel when experiencing the vehicle. Vehicle weight
and key dimensions are provided. All gaps, flushness, forces and weights are assessed using
standard gauges and scales. This report also includes water ingress testing results.
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BMW i3 Teardown and Benchmarking Study
Report Detail and Pricing (continued)
Master OEM Report
The Master OEM report is a comprehensive analysis of all aspects of the vehicle and includes
the complete findings of the study. This report contains full descriptive and pictorial detail on
every aspect of the vehicle – covering everything from
assembly sequence to costing, labor, quality projections
and, in general, every aspect of the manufacturing of the
product. This report is highly advantageous for
Original equipment Manufacturers or Tier 1 suppliers looking
to effectively expand and compete in new markets.
Vehicle System and Zone Reports
In order to best accommodate the needs of both larger and smaller manufacturers, Munro is
providing both System level reports and Zone level reports. System reports essentially provide
a cost effective way for larger manufacturers (Tier 1 and 2) to obtain critical competitive data
on multiple systems that tend to be interrelated, while Zone reports provide an opportunity for
more specialized manufacturers to obtain data
specifically related to the components they produce.
These reports will be extremely valuable in assisting
suppliers of all sizes in internally benchmarking their
assemblies or parts against potential future materials
and processing trends that impact product planning
and development.BMW i3 Teardown and Benchmarking Study
Master Report, System Reports, and Zone Reports
MASTER Report
Includes All Systems & Zones $TBD
SYSTEM Reports
System 1: Body Includes Zones 1 & 2 $ TBD
System 2: Rolling Chassis Includes Zones 3 & 5 $ TBD
System 3: Battery and Heat Exchange (HEX) Includes Zones 4 & 6 $ TBD
System 4: Powertrain Includes Zones 5,6,7 & 8 $ TBD
System 5: Interiors Includes Zones 5,9 & 10 $ TBD
ZONE Reports
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5
BODY EXTERIOR ROLLING CHASSIS BATTERY SYSTEM ELECTRONICS
• Life Module • Rear Quarter • Frame • Battery Pack • System
• Front Clip Panels Electronics
• Crush Zones • DC/DC
• Glass • Fascias
• Suspension Converter • Infotainment
• Cladding
• Closures • Brakes • Power Module
• Badging • Body Control
• Latches &
• Fenders • Electronic Parking • 12V battery Module
Hardware
• Door Exterior Brake
• Seals • Battery Harness • Fuse Box
• Windshield • Brake Lines
• Adhesives • Charger
Wipers • Electronic Power
• Chemicals Steering
• Headlamp/Tail
lamp/Fog lamps • Wheels
• CHMSL • Tires
• Sealant Kit/Pump
Zone 6 Zone 7 Zone 8 Zone 9 Zone 10
COOLING PACK & HVAC DRIVELINE REx SYSTEM IP & INTERIOR TRIM SEATS
• Cooling • Driveline • REx System • IP & Harness • Seats
(Battery/Engine) • Cross Car Beam
• Motor • Engine / Mounts • Restraints
• Radiator • Floor Console /
• Gear Box • Generator Shifter • Air bag
• HVAC
• Evap. • Fuel and tank • Door Trim
• Half shafts • Safety
Condenser • Exhaust / Shields • Headliner
• Compressor • Carpet/Mats
• Engine Dress &
• Trunk Trim
Harness
• Pedal Box
• Electronic • Steering Wheel
Control Unit
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Contacts For Regional Sales
Brenan Hudgens
Sales, Munro & Associates
1749 Northwood Drive
Troy, MI 48084
USA
Phone: (248) 362 5110
Fax: (248) 362-5117
smunro@leandesign.com
Alistair Munro
Director Business Development
Lean Design Canada, Inc.
World Trade Centre Tower B
10 Queens Quay West
Suite 2505
Toronto, ON, CAN
M5J2R9
Phone: +1 (416) 848-1104
Fax: +1 (416) 619-0676
Alistair@leandesign.com
Tina Yu - Qualisys
Business Development Director
Phone: 86-0755-2699 3418
Fax: 86-0755-2699 3362
tinayu@qaulysisgroup.com
Seokhee Han
Director of Sales
3 Floor, Hyundai Etre-beau Blg,
852, Janghang, Ilsandong, Goyangi,
Gyeonggi, Korea 410-837
Phone: +011-82-03-1904-5643
Cell: +011-82-10-2384-5643
SteveHan@leandesign.com
Gary Stewart
Director
2 Benjamin Dr.
Lara Victoria, 3212, AU
Phone: +011-61-400-888-186
Fax: +011-61-352-825-761
gstewart@leandesign.comYou can also read
