EuroCarBody 201315th Global Car Body Benchmarking Conference

Car body benchmarking data summary

PLEASE RETURN THIS WORD-FILE WITH YOUR DATA INPUT BY 16 AUGUST 2013!

0. General vehicle data

OEM brand:

______________________________

Presented car model

______________________________

0. General vehicle data, dimensions

Generation No.: ____

Internal OEM denomination: _______

SOP (month/year): _________/______

Vehicle segment according to European Commission 2002:(A, B, C, D, E, F, S, M, J) ___

Vehicle dimensions:Length: ___,_______ mWidth: ___,_______ mHeight: ___,_______ m

Track, front: ___,_______ mTrack, rear: ___,_______ mWheelbase: ___,_______ m

Contact area= (Track, front + Track, rear)/2 x wheelbase __,______ m2

1

1. Weights

Total weight body-in-white: _______ kg

Defined as the total weight of the car body including doors and closures, as well as all parts that are fitted in the body shop (e.g. integrated bumper beams), excluding paint.

Corresponding exploded view:(The colour scheme of the parts shown should make use of the RGB colour code suggested for the material classification, see section 2.)

2

If applicable as extra parts:Weights of separate subframes, front end modules, etc.

Part description Corresponding view Weight

__________________: ______ kg

__________________: ______ kg

_________________: ______ kg

__________________: ______ kg

Body-in-white weights of doors, closures and fendersFront doors (both): ______ kgRear doors (both): ______ kgHood: ______ kgTailgate/Liftgate/Decklid: ______ kgFront fenders (both): ______ kgFront end modules: ______ kg

3

Total weight body-in-white without doors, closures and fenders: ______ kg

2. Material mix in the body-in-white including doors and closuresBased on metallurgical/chemical material classes

Materials: corresponding metallurgical classes RGB colour code %

Stee

ls

Low Strength Steels: Mild steels R 153, G 204, B 255

High Strength Steels (HSS):High Strength Interstitial-free Steels (HSIF), Bake Hardening Steels (BH), High Strength Low Alloy Steels (HSLA)

R 051, G 102, B 255

Advanced High Strength Steels (AHSS):Dual Phase Steels (DP), Transformation Induced Plasticity Steels (TRIP)

R 255, G 153, B 204

Stainless steels: Austenitic stainless steels R 051, G 051, B 153

Ultra High Strength Steels (UHSS):Complex Phase Steels (CP), Martensitic Steels (MS)

R 204, G 153, B 255

Press Hardened Steels (PHS) R 128, G 000, B 128

Alum

iniu

m

Aluminium sheets: 7xxx series R 051, G 204, B 153

Aluminium sheets: 6xxx series R 000, G 255, B 000

Aluminium sheets: 5xxx series R 204, G 255, B 204

Aluminium extrusion profiles R 153, G 204, B 000

Cast aluminium R 051, G 153, B 102

Magnesium R 255, G 255, B 000

Plas

tics

Fibre reinforced plastics R 255, G 000, B 000

Duroplastics, including Sheet Molding Compound (SMC)

R 255, G 153, B 000

Thermoplastics R 153, G 051, B 000

Other materials, namely:_________________________________________________

R 192, G 192, B 192

Corresponding view of the body-in-white using the colour scheme explained in the table:

4

Example: Current Audi A3

The following graph may serve as a guide to locate the properties of the metallurgical steel classes:

0

400

800

1.200

1.600

2.000

0 200 400 600 800 1.000 1.200 1.400

Tens

ile S

tren

gth

/MPa

Yield Strength /MPa

HSLABH

Low Strength Steel

High Strength Steel

Ultra HighStrength Steel

Advanced HighStrength Steel

CP

MS

PHS

Press Hardened Steel

Mild

TRIP

DP

HSIF

3. Stiffness data

Measured / Calculated1st Eigenfrequency trimmed body: ______Hz

2nd Eigenfrequency trimmed body: ______Hz

1st Eigenfrequency body*: ______Hz

2nd Eigenfrequency body*: ______Hz

*Parts included in the measurement/calculation of the body frequencies:________________________________________________________________________________________________________________________________________________

Static torsional stiffness _______________ Nm/°5

Static bend stiffness _______________ Nm/mm

6

4. Joining processesused in the body shop, including all bought-in parts and sub-assemblies

Joining technique Number of joints Weldspot Calculationor length of seamsequivalents

(WSE)Spot welds ___________ ___________ 1:1Arc welding _____.___ m ___________ 20 mm = 1 WSEFriction stir welding _____.___ m ___________ 20 mm = 1 WSELaser welding _____.___ m ___________ 15 mm = 1 WSEConventional brazing _____.___ m ___________ 20 mm = 1 WSELaser brazing _____.___ m ___________ 30 mm = 1 WSEAdhesive joining (total) _____.___ m ___________ 50 mm = 1 WSE

thereofstructural adhesive _____.___ m ___________supporting adhesive _____.___ m ___________hemming adhesive _____.___ m ___________sealing adhesive _____.___ m ___________

Rivets ___________ ___________ 1 joint = 1 WSEClinch-spots ___________ ___________ 1 joint = 1 WSEFriction stir spot welds _____.___ m ___________ 1 joint = 1 WSEScrews (incl. flow drills) ___________ ___________ 1 joint = 1 WSE

Total WSE ___________

5. Production conceptProcess stability/availability: _______ %= total up-time in the body shop

Re-tooling or re-use factor: _________ %= [1 – Project investment excluding operational costs / “all new“] x 100

with „all new“ = Value of the total installed investment

Degree of mechanisation: _________ %= Automated Work Content* / Total Work Content** Work Content refers to the sum of Standardized Work Contents in the Body Shop, calculated according to the Harbour Report system, excluding lay-in operations, handling of parts, logistic operations

Bodyshop-Index BSI _________ [€ x hour/car unit /WSE]

= project investment,architecture [ € ]+ additional investment for the specific model [ € ]net production of the model [car units/hour ] ×Total WSE of the model*

* as calculated in section 5

No. of production sites: _________namely in: ________________________________________________________

________________________________________________________7

Intended production volume: _________ units/year

8

Car body production lead time: _______.__ minutes= the time spent by the unit in the body shop, from the start of the first underbody parts to the handing over of the body-in-white to the paint shop, including car body interim storage**** More accurate definition (Harbour):

Start counting when work begins at the first station of the underbody (motor compartment or rear floor, whichever station begins first).

The end of the measurement is the beginning of the delivery from body in white to the paint shop. If the vehicle changes skids or pallets, the process ends as soon as the vehicle leaves the original pallet. If the vehicle is going on a lift to transfer to the paint shop, the process ends as soon as the body in white is in final position to begin transfer.

Cycle time (mainline bodyshop): _________ seconds

Degree of material utilisation: _________ %= 100% - scrap rate(Sheet only, inhouse parts only, not including laser welded blanks)

Total number of parts in the BIW: _________ Number of parts, including external parts, in weight classes

< 100 g: _________100 g - 1 kg: _________

1 kg - 5 kg: _________> 5 kg: _________

(all assemblies broken down into their component parts)

6. Targeted market regions and origin of build…….of the vehicle presented at the EuroCarBody:

Targeted market region(s): ___________________________________________

Origin of build: ___________________________________________

7. Development strategies / initial propositions

Specific aims of the development: ________________________________________________________________________________________________________________________________________________________________________________________________________________________

Specific improvements reached compared to the predecessor (e.g. in weight, in stiffness):________________________________________________________________________________________________________________________________________________________________________________________________________________________

9

8. Damage and repair strategy

Qualitative description of the repair strategy:________________________________________________________________________________________________________________________________________________

Engine variant Insurance classification________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________

RCAR basket of parts*:Front:_________________________________________________________________________________________________________________________________________________

Rear:__________________________________________________________________________________________________________________________________________________

* Parts to be repaired after a standardised RCAR low speed (15 km/h) offset insurance crash (front and rear, respectively). See http://www.rcar.org/Papers/Procedures/rcar_test_protocol_angled_barrier.pdfIf other tests (e.g. special in-house tests) are referred to, please specify them.

9. Additional information:

Crash performance data (if available at the time of the presentation):

Euro NCAPNo. of stars _____Total percentage _____ %Adult _____ Pts. = _____ %

Front _____ Pts. = _____ %Side _____ Pts. = _____ %Pole _____ Pts. = _____ %Rear _____ Pts. = _____ %

Child _____ Pts. = _____ %Pedestrian _____ Pts. = _____ %Safety Assist _____ Pts. = _____ %

Other test results:__________________________________________________________________________________________________________________________________________

Development time: _________ months= time from design freeze to SOP/job one

10