Post on 07-Feb-2018
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
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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.)
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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
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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:
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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
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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
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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):________________________________________________________________________________________________________________________________________________________________________________________________________________________
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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
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