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All content copyright © 2003 Aroq Limited

The global market for automotive door modules: forecasts to 2005 - SAMPLE

Author: Matthew Beecham

Published February 2003

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The global market for automotive door modules: forecasts to 2005


Table of Contents

Table of Contents ................................................................................................................................................................... i

List of Tables ......................................................................................................................................................................... ii

List of Figures....................................................................................................................................................................... iii

Chapter 1 Introduction .......................................................................................................................................................... 1 Report coverage ...................................................................................................................................................................... 2

Chapter 2 The market............................................................................................................................................................ 3 Market overview ...................................................................................................................................................................... 3 Market trends........................................................................................................................................................................... 7 As one door closes― .............................................................................................................................................................. 9 ―another one opens ............................................................................................................................................................. 10 Market size ............................................................................................................................................................................ 10 Market shares........................................................................................................................................................................ 12 Interior door module market .................................................................................................................................................. 12 A foot in the door ................................................................................................................................................................... 12 Structural door module market .............................................................................................................................................. 15 Window regulators................................................................................................................................................................. 16

Chapter 3 Manufacturers .................................................................................................................................................... 19 ArvinMeritor ........................................................................................................................................................................... 19 Brose .......................................................................................................................................Error! Bookmark not defined. Delphi ......................................................................................................................................Error! Bookmark not defined. Dura Automotive......................................................................................................................Error! Bookmark not defined. Faurecia...................................................................................................................................Error! Bookmark not defined. Magna......................................................................................................................................Error! Bookmark not defined. Wagon .....................................................................................................................................Error! Bookmark not defined.



List of Tables

Table 1: Cost comparison of the ULSAC door and ‘state-of-the-art’ door ($) ......................................................................... 5

Table 2: Market penetration of interior door module¹ for passenger cars, 1999 - 2005 (% of car production)...................... 10



List of Figures

Figure 1: Delphi’s integrated door module .............................................................................................................................. 9

Figure 2: Delphi’s power sliding door concept.........................................................................Error! Bookmark not defined.

Figure 3: Global market shares of interior door modules, 2002 ............................................................................................ 14

Figure 4: Average wholesale cost of a complete door module, 2002.................................................................................... 15

Figure 5: Global outsourced structural door module market shares, 2002 ........................................................................... 16

Figure 6: North American window lift regulator market, 2002 ............................................................................................... 17

Figure 7: European window lift regulator market, 2002 (% of volume).................................................................................. 18

Figure 8: ArvinMeritor’s door module featuring a power double-lift window regulator with anti-trap and latch with

superlocking actuator and multiplexing ..........................................................................Error! Bookmark not defined.

Figure 9: Door panel for the BMW X5, manufactured at Faurecia’s facility in Fountain Inn, US............Error! Bookmark not defined.

Figure 10: Door panel for the Mercedes-Benz CLK, manufactured at Faurecia’s facility in Sheuerefeld, Germany....... Error! Bookmark not defined.


All content copyright © 2003 Aroq Limited Chapter 1 Introduction

Chapter 1 Introduction Opening doors to new markets It may not look like it, but the door is the second most complex system on a

vehicle, the most complex system being the cockpit. It must look good,

incorporate crash stability and, above all, be fit to open and close more than

50,000 times during the vehicle’s life. It also hides a myriad of functional

componentry such as the window lift mechanism, locks, electric motor to

operate the wing mirror, wiring harness, various switches, loud speaker and a

cable that connects the latch to the inner release handle.

However, the assembly of all of these parts by hand is expensive and time

consuming. In the mid-1980s, the Volkswagen Group was among the early

adopters of outsourcing the ‘door module’ or cassette, trimming in-house

assembly costs in the process. Global market leader Brose produced its first

door module for the Audi Coupé in 1987. A decade later, Brose won its first

major order for door modules from Volkswagen, supplying units for the Passat.

Production commenced in 1997 and Brose’s door module business almost

doubled in 1998. Door modules now account for Brose’s fastest growing

component segment.

The trend in both Europe and the US is toward increasing complexity of the

door componentry, adding more electronic functions and, in some cases, the

glass itself. There are still some significant hurdles to cross before the industry

sees the complete door in volume production. Manufacturers forecast that the

demand for complete door modules will gain greater application as soon as the

inherent paint, fit and finish problems are resolved as well as the problems

inherent in supplier participation in unionised vehicle maker plants. Even

though many vehicle makers have proclaimed their intentions to buy more and

more systems and modules, there are still only two complete door examples in

Europe where a supplier either ships a fully assembled door, which is attached

to the car body (the Smart car), and a structural door where the OEM attaches

the inner and outer panel (VW Touareg/Porsche Cayenne). Nonetheless,

some predict the industry will begin to see the widespread shipment of

complete modular doors―consisting of structural components, glass, sealing

and the inner electrical and mechanical workings―by 2006.

The global market for automotive door modules: forecasts to 2005 1

All content copyright © 2003 Aroq Limited Chapter 1 Introduction

Report coverage

Continuing our major series of niche component market studies, this just-

auto.com report reviews the key market drivers for vehicle door modules, and

will give you important forward-looking analysis for the European, Japanese

and North American markets. In Chapter two we present you our forecasts for

product trends, fitment levels and market wholesale values for door modules

through 2005. We have also identified market shares for window regulators in

Europe and North America. Chapter three will provide you with brief profiles of

the major interior and structural door module manufacturers.


All content copyright © 2003 Aroq Limited Chapter 2 The market

Chapter 2 The market

Market overview

There are two parts to a door module: interior and exterior.

An interior door module consists of a rubber-sealed carrier made from plastic

or metal. Delphi’s Superplug was originally thermoplastic whereas Brose’s and

ArvinMeritor’s designs are metal. Aluminium and magnesium are also being

considered by manufacturers to reduce the weight of the carrier still further. A

variety of door components are then fitted onto the carrier, forming a ‘cassette’,

such as the window lift mechanism, locks, electric motor to operate the wing

mirror, wiring harness, various switches, loud speaker and a cable that

connects the latch to the inner release handle. The carrier plate is then tested

and sealed to the outer door. Brose’s solution is to seal the carrier plate to the

outer door, dividing it into ‘wet’ and ‘dry’ chambers, thereby saving money on

waterproofing. Brose claims that mounting electrical and electronic

components in the ‘dry’ chamber also increases reliability. The only difference

between the front door module and the rear is that the front cassette includes a

double guided window regulator (due to the angular shape of the front glass) to

help guide the window into the door without any shudder.

The level of componentry, however, can vary immensely from one trim level to

the next. Manufacturers typically carry xx different part numbers for each of the

four doors. Whereas one model may offer a manual latch with central locking,

another may include an electric latch with super-locking. There are five

different types of latch offered for the Golf, for example. There are more than

xxx front door module combinations alone, ranging from all-manual to all-

electronic. The door panel itself consists of several component parts that are

attached to a substrate by various methods. Specific components of Lear

Corp’s door panel include vinyl or cloth-covered appliqués, armrests, radio

speaker grilles, map pocket compartments, carpet and sound-reducing

insulation. In addition, door panels often incorporate electronic and electrical

distribution systems and products, including switches and wire harnesses for

the control of power seats, windows, mirrors and door locks.



While the interior door module market is gaining momentum, the exterior or

structural door panel market is still in its infancy. This module consists of a

pressed metal frame, impact protection and exterior skin. Although structural

doors are typically made from steel, combining extruded profiles, die cast

components and pressings, there is a notable trend toward aluminium,

particularly in the upmarket car segments. As one supplier said: “Weight

savings play a more important role in the sports-utility vehicle (SUV) segment

than in any other. The opportunities for using aluminium not only for door

structures but also in other areas of car bodies is higher with SUVs.”

Aluminium is also about xx% more expensive than steel so applications on

some cars and regions are limited, as the supplier added: “The North

American car makers are driven by cost, not weight considerations. Unlike

Europeans, they are not prepared to pay more for a lighter door. Our focus is

on Europe, with the strongly increasing number of derivatives on one line. I

think that there is a big opportunity for structural door modules being

implemented on such cars with regard to lower volumes per derivative. We see

annual growth rates in the area of xx% - xx%.” Just xx% of exterior side doors

are currently made by outside suppliers in North America.

Jaguar uses Alcan's aluminium vehicle technology to provide the new XJ

series with a unique aluminium structure. This is the first volume production

car to have a uni-body structure composed predominantly of aluminium sheet.

Compared to a conventional steel body, Jaguar claims that the new technology

will enable weight savings of around xx% while also making the car around

xx% stiffer than the previous XJ series. Bonnets, doors, bumpers and boot lids

will also be made of aluminium which will allow the kerb weight of the new XJ

to be xxxkg lighter than its predecessor, despite it being far better equipped.

Both performance and fuel consumption will also be enhanced. Alcan's

innovative technology combines adhesive bonding of structural sheet sections

with self-piercing rivets, the culmination of around xx years of research and

development in this area, much of it in partnership with Jaguar.

Wagon has been the pioneer in this area, having supplied aluminium door

assemblies since the mid-1980s.



Although aluminium offers weight benefits, there have been some notable

advances in producing lightweight, high-strength steels. In 2001, the US-based

xxxx revealed a higher-strength steel used with sheet hydroforming to show

the potential for further mass reduction in steel vehicle body exterior parts. To

demonstrate the benefits of high-strength steels, xxxx designed and

manufactured a door panel. Through the use of manufacturing techniques

such as tailored blanks, stamping and hydroforming, xxxx produced a

frameless door that is up to xxkg lighter than the average benchmark for

frameless doors and xx% lighter than the lightest door benchmarked. xxxx

state that this door structure, with significant weight savings and comparable

performance relative to state-of-the-art generic doors, has the potential to be

made at a rate of xxx,000 units per year without cost penalty. Their detailed

cost analysis follows:

Table 1: Cost comparison of the xxxx door and ‘state-of-the-art’ door ($) xxxx

Stamped

outer Sheet hydroformed outer State-of-the-art generic door

Parts fabrication 39.50 43.00 45.00

Materials 14.00 14.00 24.00

Stamping 7.00 3.00 8.00

Tailored blank stamping 6.00 6.00 10.00

Sheet hydroforming -- 8.00 --

Tube hydroforming 7.50 7.50 --

Purchased parts 4.50 4.50 3.50

Assembly 27.00 27.00 23.50

Total cost of door $66.50 $70.00 $69.00

SAMPLE ONLY

Note: Costs shown are for one door.

Sources: xxxxx



Renault's Ellypse concept car, which was shown at the Paris motor show in

September 2002, is designed to be lightweight and to use either recycled or

easily recyclable materials. It uses polypropylene (which has a well developed

recycling infrastructure) for the plastic body panels and interior trim and the car

can be quickly dismantled according to the types of materials used.

Polycarbonate plastic replaces conventional window glass as this is lighter and

can be recycled. Recycled steel and aluminium account for around xx% of the

vehicle's 980kg weight, steel being used mainly for chassis components while

aluminium makes up the superstructure on which the plastic panels and doors

are hung. The seating is lighter and thinner, and flooring is made from recycled

leather and NVH insulation from recycled cotton and polyester. The engine

chosen is a 16-valve turbodiesel. Renault says a full hybrid powertrain would

be only slightly more efficient than the chosen engine but much more

expensive.

Several manufacturers are currently offering the concept of a complete door

with interior trim and cassette melded into the exterior frame. However, most

(more than xx%) of the exterior door panel is still manufactured by the vehicle

maker. Outsourcing this area is happening, albeit gradually.

The trend in both Europe and the US is toward increasing complexity of the

door componentry, adding more electronic functions and, in some cases, the

glass itself. There are still some significant hurdles to cross before the industry

sees the complete door in volume production. Manufacturers forecast that the

demand for complete door modules will gain greater application as soon as the

inherent paint, fit and finish problems are resolved, as well as the problems

inherent in supplier participation in unionised vehicle maker plants.

Nonetheless, some predict the industry will begin to see the widespread

shipment of complete modular doors―consisting of structural components,

glass, sealing and the inner electrical and mechanical workings―by 2006.

SAMPLE ONLY



Market trends

As the door module increases in complexity, suppliers are forming alliances in

order to offer the necessary design and project management skills. For

example, since 1999, Johnson Controls has been working with Oxford

Automotive to develop integrated door systems. Johnson Controls defines

such systems in three levels:

• A Level 1 door system includes a door hardware cassette and door

trim assembly―which could include latch assembly, latch rods,

window regulator, glass run channels, speaker, wire harness, glass

and carrier―that are shipped to the vehicle maker and installed onto

the vehicle as separate components.

• A Level 2 door system combines the trim assembly and hardware

cassette into a single system ready for a simple electrical connection

and attachment to the door steel assembly.

• A Level 3 integrated door system is a complete door assembly―or

module―that includes trim, hardware and exterior body components,

fully finished and ready to assemble to the vehicle.

SAMPLE

The partners used the 2000 North American International Auto Show to display

their Level 2 integrated door system. Johnson Controls designed and

developed the trim and hardware module for the door while Oxford Automotive

applied its skills in door metal to optimise the exterior door structure by adding

strength and reducing weight. “We view supplying door systems as

evolutionary not revolutionary,” said Lou Kincaid, group vice president, product

and business development for Johnson Controls. “We currently supply

automakers with complete seat systems, overhead systems, cockpit systems

and door trim systems, so teaming up with a leader such as Oxford Automotive

to further develop Level 2 and Level 3 door systems is the next logical step in

this evolutionary process.”

SAMPLE



Oxford Automotive designs and makes a range of door panels and

components including closure panels, inner door panels, door assemblies,

hinges, latches, locking mechanisms and sliding door mechanisms. The

customer base for its door components includes both GM and Ford. Oxford

Automotive supplies the door, hood and underbody assemblies for the GM

Pontiac Aztec and Buick Rendezvous and the doors and structural

components and apron assembly for the Ford Focus and Escort as well as the

closure panels (doors, decklids, hoods and trunk lids) for the Saturn LS. In

early 2002, Oxford Automotive filed for protection from creditors under Chapter

11 of the US bankruptcy code.

Delphi Corp has also developed a range of modular door systems, dividing

their product offering into four levels of integration. Level 1 contains door

hardware and trim components, such as latches, connectors and trim. Level 2

sees these components integrated into multi-system door builds. At Level 3,

Delphi integrates the door structure components into the multi-system module,

based on either hardware or trim. At Level 4, Delphi takes on total

responsibility for delivering a complete door to the vehicle maker, from inner

trim to outer skin. In November 2002, Delphi announced that it will supply what

it terms its modular door to DaimlerChrysler for its new Actros heavy-duty

vehicle (see Delphi profile Chapter 3). Delphi says this module is at Level 3,

adding that there is another unnamed vehicle currently being developed that

will also feature its Level 3 door module. Delphi perceives that most of the

European market is currently at Level 2.

SAMPLE ONLY



Figure 1: Delphi’s integrated door module

SAMPLE

Source: Delphi Corp.

As one door closes―

Over the next five years, we could see some major changes in the way in

which vehicle makers source their doors, at least in Europe. We are already

seeing a strong trend towards modular and lightweight designs. In terms of

modularity and outsourcing, however, opinions are divided with regard to

whether doors could follow the same path as seats. As one auto executive of a

door module supplier said: “If you had asked me this question two years ago, I

would have said ‘yes’, it will follow seating and there is a clear trend amongst

car makers to outsource door assembly. Since then, however, we have seen a

reversal in that trend. Volkswagen, for example, has completely changed its

body-in-white technology strategy. They are going for more insourcing than

outsourcing, aiming to again source all the components for a door module

cassette rather than outsource the cassette itself.”



―another one opens

Another supplier envisages a different scenario, forecasting a blossoming

European market. He said: “The OEM is now devoid of any expertise in the

area of seats. That same progression is going to happen in the area of doors

because there is really nothing technical or commercial in the product itself

that should stop this from happening. I expect to see more alliances in the

industry. But what really needs to happen to improve the efficiency in the door

system is the interface management, whether it be product, commercial or

project management. There may be 17 or more different engineering groups

that touch the door within an OEM, such as occupant protection, metal

stamping, structure, door trim, electrical and electronics, sealing systems and

glass. But it is difficult to get 17 people to agree. Good interface management

is an absolute must.”

Market size

The global volume of door modules was around 11 million in 1999, 12 million

in 2000 and 33 million in 2002.

By 2005, we forecast that 40% of new vehicles will be built using interior door

modules, up from about 27% in 2002. In North America, there are currently

around ten vehicle platforms where Level 1 door modules are delivered to the

trackside. Although the American market is widely expected to increase its use

of door modules, the rate of acceleration will be more gradual than that which

is witnessed in Europe. In Japan, however, the market penetration for interior

as well as structural door modules is expected to remain low through this

decade due to vehicle maker’s component sourcing strategies.

SAMPLE ONLY

Table 2: Market penetration of interior door module¹ for passenger cars, 1999 - 2005 (% of car production) 1999 2000 2001 2002 2003 2004 2005

Western Europe 20 24 27 30 33 36 40

North America 14 15 16 17 18 19 20

Japan 3 3 3 4 4 4 4

¹ Here, we define a door module as combining the trim assembly and hardware cassette into a single system ready for a

simple electrical connection and attachment to the door steel assembly.

SAMPLE

Sources: Industry estimates; just-auto.com.



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Market shares

Interior door module market

Family-owned Brose leads the world market for door modules. In 2000, Brose

delivered more than six million door system pieces in-line sequence to vehicle

makers in Europe, North and South America, Africa and Asia, giving the

company a 50% global share. In 2002, Brose claimed a 45% share of the

world market and a 50% share in Europe (including a 70% share in Germany).

From its just-in-time facilities in Brazil, Mexico, Germany and China, Brose can

deliver a door module to the vehicle maker’s assembly line in three hours from

receipt of order. Brose’s competitors on the world stage include ArvinMeritor,

Delphi and Magna.

SAMPLE

A foot in the door

In addition, manufacturers with origins in seat supply, such as Lear Corp,

Johnson Controls and Magna are all attempting to gain a foothold in the door

module market in their efforts to supply complete interiors, partly through the

acquisition of window regulator and door trim manufacturers.

Valeo recently launched a new e-module concept that is intended to help

vehicle makers flexibly integrate increasingly complex electrical, electronic and

mechanical features into future vehicles. The e-module is a ‘design for

integration’ for individual components. These can later be combined into a

single sub-module with common connectors and mounting points. Although the

e-module concept will find applications in many locations in a vehicle, Valeo is

concentrating the first application of the e-module concept on tailgates and

other types of rear door openings. Car maker engineers and designers have

told key automotive supplier Valeo that feature-packed rear doors pose many

challenges when it comes to including more electronic features yet achieving

distinctive styling, standard components, build quality and

durability/performance targets, while cutting assembly costs.

SAMPLE



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Figure 2: Global market shares of interior door modules, 2002 (% of volume)

Brose45%

Delphi20%

Magna (Intier)7%

Others3%

Arvin Meritor25%

SAMPLE

%

Tolal

Sources: just-auto.com; industry estimates.



Figure 3: Average wholesale cost of a complete door module, 2002 (% of total cost per module)

Latch6%

Window regulator10%

Various other electrical parts

31%

Interior door trim panel25%

Exterior door trim panel28%

%

Latch 6

Window regulator 10

Various other electrical parts 31

Interior door trim panel 25

Exterior door trim panel 28

Total 100

SAMPLE


Structural door module market

Dura Automotive and Wagon dominate the global outsourced structural door

market with a collective 78% share, followed by the Italian supplier Emarc and

some other small local players. The vast majority of this business is in Europe.

There is no structural door business in North America, as they use pressed

metal doors. In 2001, Dura posted sales of $197.7 million for its structural door

module business, equivalent to 8% of total sales.

SAMPLE



Figure 4: Global outsourced structural door module market shares, 2002 (% of volume)

Dura Automotive40%

Wagon 38%

Emarc7%

Others15%

%

Dura Automotive 40

Wagon 38

Emarc 7

Others 15

Total 100

SAMPLE


Window regulators



Figure 5: North American window lift regulator market, 2002 (% of volume)

Magna35%

Brose15%

ArvinMeritor15%

Others35%

%

Magna 35

Brose 15

ArvinMeritor 15

Others 35

Total 100

SAMPLE


The European automotive window regulator market is led by Brose with a xx%

share, followed by xxx, xx xxx and some other, smaller and local suppliers

based in xxx and xx.



Figure 6: European window lift regulator market, 2002 (% of volume)

Brose50%

ArvinMeritor18%

Kuster15%

Others17%

%

Brose 50

ArvinMeritor 18

Kuster 15

Others 17

Total 100

SAMPLE



All content copyright © 2003 Aroq Limited Chapter 3 Manufacturers

Chapter 3 Manufacturers

ArvinMeritor

ArvinMeritor designs and manufactures a variety of modular door systems,

plus a range of manual and power electric window regulators. Its products

include a variety of window regulators and door modules such as arm and

sector (cross-arm, single-arm and divergent), drum and cable (double-lift,

single-lift and bare cable), push-pull (double-lift, single-lift and compact) and

electronically controlled motors. Its door modules feature power double-lift

window regulators with anti-squeeze and super-locking actuators. ArvinMeritor

manufactures more than 30 million window regulators and one million door

modules…

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