Introduction

Topics of Analysis
Body-in-white Designs
Materials
Architectures
Technologies
Part Fabrication
Assembly
Analysis Tools
Manufacturing Cost Models
Assembly Cost Model

Massachusetts Institute of Technology

Cambridge, Massachusetts

Body-in-White Assembly Model

Assembly Sequence
Realism
Specification of Subassembly Composition, Lengths, Methods
Joining Methods
Modification of Joining Methods
Addition of New Methods
Methods Specific to Material, Mode of Application

Massachusetts Institute of Technology

Cambridge, Massachusetts

Previous Assembly Model

Quarter-Pan
Parts

Quarter-Pan
"Group"

Door
Parts

Door
"Group"

Roof
Parts

Roof
"Group"

Floor
Parts

Floor "Group"

Final Assembly

Massachusetts Institute of Technology

Cambridge, Massachusetts

New Assembly Model

Part A
Part B

Part H
Part I
Part F
Part G

Subassembly
One

Subassembly
Three

FINAL
ASSEMBLY

Part C
Part D
Part E

Subassembly
Two

Subassembly
Four

Massachusetts Institute of Technology

Cambridge, Massachusetts

Modeling of Subassemblies
Total BIW Assembly Cost
400

31 Groups

350

300

5 Groups
250

1 Group
200

150

100
100,000

120000

140,000

160000

180,000 200000 220,000

Annual Production Volume
31 SA

5 SA

240000

260,000

280000

300,000

1 SA

Massachusetts Institute of Technology

Cambridge, Massachusetts

Joining Technologies
Model Methods
RS W (robot)(S)
RS W (robot)(A)
RS W (manual)(S )
RS W (manual)(A)
Tack-RS W (robot)(S )
Tack-RS W (robot)(A)
W eldbond (robot)(S)
W eldbond (robot)(A)
W eldbond (manual)(S )
W eldbond (manual)(A)

MIG Weld (robot)(S)

MIG Weld (robot)(A)
MIG Weld (manual)(S)
MIG Weld (manual)(A)

Massachusetts Institute of Technology

Cambridge, Massachusetts

Riveting (robot)(S)
Riveting (robot)(A)
Riveting (manual)(S)
Riveting (manual)(A)
Riv-bond(manual)(S)
Riv-bond(manual)(A)
Riv-bond(robot)(S)
Riv-bond(robot)(A)
6kW
6kW
6kW
6kW
3kW
3kW
3kW
3kW
3kW
3kW

AB(1comp-robot)(S)
AB(1comp-robot)(A)
AB(2comp-robot)(S)
AB(2comp-robot)(A)
AB (1comp-manual)(S)
AB (1comp-manual)(A)
AB (2comp-manual)(S)
AB (2comp-manual)(A)

CO2 LBW (r)(S)

CO2 LBW (r)(A)
CO2 LBW (g)(S )
CO2 LBW (g)(A )
CO2 LBW (r)(S)
CO2 LBW (r)(A)
CO2 LBW (g)(S )
CO2 LBW (g)(A )
Nd:YAG LBW (r)(S)
Nd:YAG LBW (r)(A)

Overall Costs @ 100,000 Vehicles/Year

Ultralight
Aluminum

Aluminum
Unibody

ULSAB

Steel
Unibody

Number of
Parts
Weight

82

167

82

167

120 kg

151 kg

208 kg

280 kg

Material

$570

$770

$250

$370

Parts
Fabrication
Assembly

$460

$700

$430

$650

$350

$380

$330

$360

Total

$1380

$1850

$1010

$1380

Massachusetts Institute of Technology

Cambridge, Massachusetts

Unibody Production Volume Sensitivity

$400

Steel Unibody
Aluminum Unibody
Tota l BIW Assembly Cost

$350

$300

$250

$200

$150
50,000

100,000

150,000

200,000

250,000

300,000

350,000

Annual Production Volume

Massachusetts Institute of Technology

Cambridge, Massachusetts

Unibody Assembly Cost Breakdown

Assembly @100,000

Amount of Joining

Fixed Costs
Variable Costs

(31.2%)

~69%
~31%

Line-Related Equipment ~50%

(59.8%)
(5.6%)
(3.5%)

Joining Methods

~50%

Joining Equipment ~18% (total)

Labor
~30% (total)
Material
~1-2%(total)

RSW(robot)(S)

RSW(manual)(S)

MIG Weld(robot)(S)

Tack-RSW(robot)(S)

Massachusetts Institute of Technology

Cambridge, Massachusetts

Unibody Joining Costs

$200

Steel Unibody

Total Joining Cost (US$)

RSW
(robotic)

Aluminum Unibody

$150

$100

$50

RSW
(manual)

MIG
Welding
(robotic)

Tack
RSW
(robotic)

$0

Joining Technology
Massachusetts Institute of Technology
Cambridge, Massachusetts

ULSAB & Aluminum Alternative Production Volume Sensitivity

$400

ULSAB
Aluminum Alternative
Total BIW Assem bly Cost

$350

$300

$250

$200
50,000

100,000

150,000

200,000

250,000

300,000

Annual Production Volum e

Massachusetts Institute of Technology

Cambridge, Massachusetts

ULSAB & Al Alternative Assembly Cost Breakdown

Assembly @100,000

Amount of Joining

Fixed Costs
Variable Costs

(21.9%)

(45.9%)

~69%
~31%

Line-Related Equipment

~50%

Joining Methods

~50%

(7.2%)

Joining Equipment ~18% (total)

Labor
~30% (total)
Material
~1-2%(total)

(12.1%)
(7.7%)

(5.2%)

RSW(robot)(S)

RSW(manual)(S)

Rivet-Bonding(S)

WeldBonding(S)

3kWCO2 LBW(g)(S)

Tack-RSW(robot)(S)

Massachusetts Institute of Technology

Cambridge, Massachusetts

ULSAB and Al Alternative Joining Costs

$100

RSW
(robotic)

ULSAB

3kW CO2 (g)

Laser Welding

$80

Total Joining Cost

ULAAB

$60

$40

RSW
(manual)

Rivbonding

Weldbonding

Tack
RSW
(robotic)

$20

$0

Joining Technology
Massachusetts Institute of Technology
Cambridge, Massachusetts

Production Volume Sensitivity

$400

ULSAB
ULAAB
Steel Unibody
Alum inum Unibody

Total BIW Asse mbly Cost

$350

$300

$250

$200
50,000

100,000

150,000

200,000

250,000

300,000

Annual Production Volum e

Massachusetts Institute of Technology

Cambridge, Massachusetts

Analysis of Joining Technologies

Cost Comparison of Various Technologies
Discontinuous processes
Continuous processes
Hybrid processes

Scenario: Cost per Meter for Fully Utilized Equipment

One part - one large subassembly
Long, straight joint
Approximately 100m of joining
50mm welding segments

Massachusetts Institute of Technology

Cambridge, Massachusetts

Cost per Meter - Steel Technologies

C ost pe r m e te r o f join ing (U S $)
$ 0 .0 0

$ 1 .0 0

$ 2 .0 0

$ 3 .0 0

$ 4 .0 0

Join ing M e th od (S te e l Te ch nolo gie s)

RS W - r obot ic
RS W - m a nual
SP Rive ting - r obotic
SP Rive ting - m a nua l
W e ldbonding - r obotic
W e ldbonding - m a nua l
Riv-bonding - r obotic
Riv-bonding - m a nua l
AB 2 c om p. - r obotic
AB 2 c om p. - m a nua l
M IG w e lding - r obotic
M IG w e lding - m a nua l
6 k W CO 2 la se r - r obotic
6 k W CO 2 la se r - ga nt ry
3 k W CO 2 la se r - r obotic
3 k W CO 2 la se r - ga nt ry
3 k W Nd:YAG la se r

Massachusetts Institute of Technology

Cambridge, Massachusetts

Steel & Aluminum Cost per Meter Comparison

ost per meter of joining (US$)

$2.00

$3.00

$4.00

Steel Methods
Cost/meter
$1.24
RSW - robotic
$2.37
RSW - manual
$1.12
Riveting - robotic
$1.77
Riveting - manual
$1.54
MIG welding - robotic
$3.04
MIG welding - manual
$0.71
AB 1comp. - robotic
$1.18
AB 1comp. - manual
$0.84
AB 2comp. - robotic
$1.31
AB 2comp. - manual
$1.71
Weldbonding - robotic
$2.98
Weldbonding - manual
$1.57
Riv-bonding - robotic
$2.52
Riv-bonding - manual
6kW CO2 laser - robotic $3.20
$8.77
6kW CO2 laser - gantry
3kW CO2 laser - robotic $2.60
$8.51
3kW CO2 laser - gantry
$2.21
3kW Nd:YAG laser

Aluminum Methods Cost/meter

$1.37
RSW - robotic
$2.64
RSW - manual
$1.23
Riveting - robotic
$1.89
Riveting - manual
$1.54
MIG welding - robotic
$3.06
MIG welding - manual
$0.74
AB 1comp. - robotic
$1.22
AB 1comp. - manual
$0.87
AB 2comp. - robotic
$1.34
AB 2comp. - manual
$1.86
Weldbonding - robotic
$3.20
Weldbonding - manual
$1.67
Riv-bonding - robotic
$2.64
Riv-bonding - manual
6kW CO2 laser - robotic $3.03
$8.78
6kW CO2 laser - gantry
3kW CO2 laser - robotic $2.43
$8.53
3kW CO2 laser - gantry
$2.61
3kW Nd:YAG laser

Difference % Greater
$0.13
10.83%
$0.27
11.21%
$0.11
9.87%
$0.11
6.43%
$0.01
0.46%
$0.02
0.53%
$0.03
4.38%
$0.03
2.70%
$0.03
3.78%
$0.03
2.45%
$0.15
8.65%
$0.22
7.45%
$0.10
6.32%
$0.12
4.68%
($0.17)
-5.38%
$0.01
0.10%
($0.17)
-6.53%
$0.01
0.16%
$0.41
18.37%

Massachusetts Institute of Technology

Cambridge, Massachusetts

Steel & Aluminum Cost per Meter Comparison

Steel Methods
RSW - robotic

Cost/meter
$1.24

Aluminum Methods
RSW - robotic

Cost/meter
$1.37

Difference % Greater
$0.13
10.83%

Riveting - robotic

$1.12

Riveting - robotic

$1.23

$0.11

9.87%

Weldbonding - robotic

$1.71

Weldbonding - robotic

$1.86

$0.15

8.65%

Riv-bonding - robotic

$1.57

Riv-bonding - robotic

$1.67

$0.10

6.32%

AB 2comp. - robotic

$0.84

AB 2comp. - robotic

$0.87

$0.03

3.78%

MIG welding - robotic

$1.54

MIG welding - robotic

$1.54

~$0

0.00%

3kW Nd:YAG laser

3kW CO2 laser - gantry
6kW CO2 laser - gantry
6kW CO2 laser - robotic
3kW CO2 laser - robotic

$2.21
$8.51
$8.77
$3.20
$2.60

3kW Nd:YAG laser

3kW CO2 laser - gantry
6kW CO2 laser - gantry
6kW CO2 laser - robotic
3kW CO2 laser - robotic

$2.61
$8.53
$8.78
$3.03
$2.43

$0.41
~$0
~$0
($0.17)
($0.17)

18.37%
0.00%
0.00%
-5.38%
-6.53%

Massachusetts Institute of Technology

Cambridge, Massachusetts

Process Parameter Sensitivity

Resistance Spot Welding
STEEL
ALUMINUM
Spot Weld
Steel
Spot Weld Aluminum
Spa cing Cost/meter Spa cing Cost/meter
35mm
$1.24
31.5mm
$1.37
40mm
$1.07
36mm
$1.21
Spot Welding Rate
(robotic)
0.33 welds/se c
0.50 welds/se c

Steel
Aluminum
Cost/meter Cost/meter
$1.24
$1.37
$0.92
$1.03

MIG Welding
Steel
Aluminum
Cost/meter Cost/meter
$1.54
$1.54
$1.90
$1.92
$1.34
$1.34

Welding Spe ed
13mm/s
9mm/s
17mm/s
Massachusetts Institute of Technology
Cambridge, Massachusetts

Process Parameter Sensitivity

Laser Beam Welding
ALU MIN U M
P roce ss
6kW CO2 (r)
6kW CO2 (r)
6kW CO2 (r)
3kW N d:Y AG
3kW N d:Y AG
3kW N d:Y AG

E quipme nt
S te e l
Aluminum
Cost
Cost/me te r Cost/me te r
$600,000
$3.20
$3.03
$540,000
$3.05
$2.88
$450,000
$2.82
$2.67
$480,000
$432,000
$360,000

$2.21
$2.11
$1.97

STEEL

MIG Welding

$2.61
$2.50
$2.33

ALU MIN U M

P roce ss
6kW CO2 (r)
6kW CO2 (r)
6kW CO2 (r)

W e lding
S te e l
W e lding
Aluminum
S pe e d
Cost/me te r
S pe e d
Cost/me te r
100mm/ s
$3.20
150mm/ s
$3.03
90mm/s
$3.25
135mm/ s
$3.07
75mm/s
$3.36
113mm/ s
$3.14

3kW N d:Y AG
3kW N d:Y AG
3kW N d:Y AG

70mm/s
63mm/s
53mm/s

Massachusetts Institute of Technology

Cambridge, Massachusetts

$2.21
$2.27
$2.42

40mm/s
36mm/s
30mm/s

$2.61
$2.73
$2.95

Process Parameter Sensitivity

Resistance Spot Welding
S p o t W e ld
S p a cing
35m m
40m m

U LS AB
Co st
$332
$321

S p o t W e ld ing R a te
(ro b otic)
0.33 we ld s/ se c
0.50 we ld s/ se c

S p o t W e ld
S p a cing
31.5mm
36m m

U LAAB
Co st
$347
$328

U LS AB
Co st
$332
$303

U LAAB
Co st
$347
$320

MIG Welding
W e lding S pe e d
13m m/ s
9mm/ s
17m m/ s

S te e l U ni
Co st
$364
$372
$364

Alum U ni
Co st
$380
$386
$379

Massachusetts Institute of Technology

Cambridge, Massachusetts

Process Parameter Sensitivity

Laser Beam Welding
3kW CO2 (gantry)
Welding Speed
60mm/s
45mm/s
75mm/s

ULSAB
Cost
$332
$332
$332

ULAAB
Cost
$347
$347
$347

ULSAB
Cost
$332
$287
$294

ULAAB
Cost
$347
$302
$308

$290

$308

ULAAB
Cost
Laser Process
3kW CO2 (gantry)
3kW CO2 (robotic)
6kW CO2 (robotic)
3kW Nd:YAG (robotic)

Massachusetts Institute of Technology

Cambridge, Massachusetts