BMW I3 Teardown Analysis Study - Munro & Associates

BMW i3 TeardownAnalysis Study:Reports Summary and Pricing DetailMunro & Associates IncUSA Operations1140 Centre RdAuburn Hills, MI, 48326 USAPhone: 1-248-362-5110Fax: 1-248-362-5117www.LeanDesign.com

Pricing: Master Report, Zone Reports and System BundlesNote: These prices represent a limited time pricing for those whohave shown an interest previously in the reports.MASTER Report 60,000Includes All ZonesSYSTEM ReportsSystem 1: BodyIncludes Zones 1 & 2 21,500System 2: Rolling ChassisIncludes Zones 3 & 5 25,700System 3: Battery & Heat Exch (HEX)Includes Zones 4 & 6 17,150System 4: PowertrainIncludes Zones 5 – 8 42,850System 5: InteriorsIncludes Zones 5,9 & 10 21,500ZONE ReportsZone 1BODY Life ModuleFront ClipGlassClosuresLatches &Hardware Seals Adhesives ChemicalsZone 6COOLING PACK & HVAC Cooling(Battery/Engine) Radiator HVAC Evap.Condenser CompressorZone 2EXTERIOR Rear QuarterPanels Fascias Cladding Badging Fenders Door Exterior WindshieldWipers Headlamp/Taillamp/Fog lamps CHMSLZone 7DRIVELINEZone 3ROLLING CHASSIS FrameCrush ZonesSuspensionBrakesElect. Pkg BrakeBrake Lines Elect. PwrSteering Wheels & TiresZone 8REx SYSTEM REx System Motor Engine / Mounts Half shafts Battery Pack DC/DCConverter Power ModuleZone 5ELECTRONICS SystemElectronics Infotainment 12V battery Body ControlModule Battery Harness Fuse Box Charger SealantKit/Pump Driveline Gear BoxZone 4BATTERY SYSTEM Generator Fuel and tank Exhaust / Shields Engine Dress &Harness ElectronicControl UnitZone 9IP & INTERIOR TRIM IP & Harness Cross Car Beam Floor Console /Shifter Door Trim Headliner Carpet/Mats Trunk Trim Pedal Box Steering WheelZone 10SEATS Seats Restraints Air bag Safety

BMW i3 Teardown Analysis StudyReport Detail and PricingMaster OEM ReportThe Master OEM report is a comprehensive analysis ofall aspects of the vehicle and includes the completefindings of the study. This report contains full descriptiveand pictorial detail on every facet of the vehicle – fromassembly sequence to costing, labor, quality projectionsand, in general, every phase of the manufacturing of theproduct.This report is highly advantageous for Original EquipmentManufacturers or Tier Suppliers looking to effectivelyexpand and compete in new markets.Sale Price: 150,000Vehicle Zone ReportsIn order to best accommodate the needs of both larger and smaller manufacturers, Munro is providing bothfull OEM reports of all Zones as well as individual Zone reports.Zone reports provide an opportunity for more specializedmanufacturers to obtain data specifically related to thecomponents they produce. In addition to this, we haveadded System Bundle reports to provide a cost effectiveway for larger manufacturers (Tier 1 and 2) to obtaincriticalcompetitive data on multiple Zones that tend to beinterrelated.These reports will be extremely valuable in assistingsuppliers of all sizes in internally benchmarking theirassemblies or parts against potential future materials andprocessing trends that impact product planning anddevelopment.The following page has detailed pricing lists that also break down the individual zones into their specificparts and content.Note: In certain cases, Munro may provide interested customers customized module pricing based onfeasibility.

BMW i3 Teardown Analysis StudyStudy HighlightsThe BMW i3 is celebrated for being the first mass produced electric vehicle to extensively feature carbonfiber. The cost and methodologies related to the assembly and fabrication process, especially those of thecarbon fiber life module, are of high interest. In addition, the BMW i3 utilizes the state-of-the-art batterytechnologies featuring an innovative modular design. Combined with an optional range extending engine(REx), the system sets new industry standards. Munro’s unique software methodology, Design Profit ,allows us to provide detailed assembly, processing and financial insights into these and other key areas ofinterest.Carbon Fiber Life Module: Carbon Fiber Life Module components, materials andprocesses are disassembled, analyzed, documented, cost modeled andsummarized. Detailed information regarding the cutting, forming and molding ofcarbon fiber sheets as well as their assembly into single body structural units willbe provided. In addition both the materials and costs for adhesive fastening of thebody structure to the frame will be provided including the number and size ofjoints, adhesive types, and the types of machines used for adhesive application.Battery: The high voltage battery pack, battery management electronics housedwithin the battery pack, battery cells, and cables, assemblies, and sensing wireharness are all disassembled, analyzed, documented, cost modeled andsummarized. Fastener types, properties and fastening techniques are allanalyzed, documented, cost modeled and summarized. All internal components ofthe battery are analyzed and cost modeled including the electrolytes and activematerials used in the electrodes. Full detail of the electrode manufacturingprocess, including mixing of active materials, coating, drying, slitting andcompaction is provided. In addition, all related electronic control modules andprinted circuit boards are analyzed.REx System: The REx system is completely disassembled, analyzed,documented, cost modeled, and summarized. The study includes the removal anddisassembly of the REx engine, electric generator harnesses and mountinghardware. The engine, fuel and exhaust systems as well as the engine accessorycomponents are fully reviewed for cost of materials, fabrication and the assemblyand fastening processes. Complete engineering, processing and cost informationon related electronic system control modules and harness components areprovided, as is full detail on the materials and installation of any associated noiseabatement components.Electronics: Integrated vehicle electronics are disassembled, analyzed,documented, cost modeled and summarized. TechInsights Teardown.comworkedwith Munro & Associates to identify, cost and document circuit designs, analyzethe structure and board layout, and provide detailed Bill of Materials for over 70boards found in the i3. Key areas of focus include the infotainment system andinstrument cluster, the Advanced Driver Assistance Systems (ADAS), power trainsystems, and body control systems.

BMW i3 Teardown Analysis StudyReport Detail OverviewZone reports will be made available individually and willalso be packaged into larger System Bundle reports toprovide all information pertinent to the vehicle systems: Zone 1 – BODY Zone 2 – Exterior Zone 3 – Rolling Chassis Zone 4 – Battery System Zone 5 – Electronics Zone 6 – Cooling Pack and HVAC Zone 7 – Driveline Zone 8 – REx System Zone 9 – IP and Interior Trim Zone 10 – SeatsSeveral metrics, key points, eye catching features, anddetailed assembly and manufacturing steps areilluminated to the reader throughout the reports.See next page for more details:

BMW i3 Teardown Analysis StudyThe most comprehensive teardown andbenchmark analysis available of the BMW i3!While the BMW i3 has, and will continue to be, the subject of amyriad of different analyses and reports, only Munro will providedetailed findings that breakdown and detail every manufacturingcost.Munro has a long history of producing teardownbenchmarking studies for both the public sector and private clients,however the i3 study will mark the first time that these types ofreports will be made available for general distribution.The i3 study will tap into all facets of Munro’s deep knowledge oftechnologies, materials and manufacturing processes. The companyis uniquely positioned to analyze and report findings on the i3’sground breaking use of carbon fiber as well as other light-weightmaterials, metal forming and molding. Munro’s extensive experiencewith powertrain and battery technologies will also be leveraged toprovide a comprehensive analysis of the BMW i3.This study includes: A 10 Zone complete cost, assembly, and materials-analysis for allparts specific to a zone or system. Eye catching features and functions A Vehicle Fit and Finish Quality Audit (FFQ) report Audit. Comprehensive analysis of the i3's carbon fiber manufacturing andassembly process. Detailed reporting of the battery cost and construction. A complimentary single license of Munro’s proprietary DesignProfit software which provides the purchaser the ability to printCost Maps , indented Costed Bill Of Materials (CBOM). Copies of, or links to, any known BMW public domain articles andvideos.Study OverviewIn late 2014 Munro & Associates, a global leader in manufacturingcosting and benchmarking, began the monumental challenge ofproducing an industry exclusive, highly detailed, teardown andbenchmark study of the revolutionary BMW i3 Electric Vehicle.Using proprietary advanced quality, assembly process and costingsoftware, Design Profit , Munro disassembled and meticulouslyanalyzed the entire vehicle, system by system, at its world classbenchmarking facility in Auburn Hills, Michigan.

BMW i3: Complete Reverse Engineering,Manufacturing Build of Process and Costing StudyFAQ (Frequently Asked Questions) How long did the study take?The study took 11.5 man-years What was the cost to Munro?Well over 1,600,000 Why did Munro perform this study?Munro is a world class consulting company that needs tokeep up with cutting edge technology What was not analyzed?Nothing was excluded How accurate is the Costing and Manufacturing Data?The EPA says Munro costing is “Irrefutable”“Munro estimates are within 1% of our manufacturingcosts!” Chinese OEM CFO“You are 3 cents off on a part that we know costs 123.64!” Tier 2 Powertrain SupplierWOW! You are at 1,016.59 and we have a price of 1,021.15. Tier 1 supplier costing a Mexican build. How can I be sure these numbers are accurate? Who says theyare accurate?“Your numbers are too close to be estimates! Who gaveyou this data?” A BMW representative.10

BMW i3: Complete Reverse Engineering,Manufacturing Build of Process and Costing StudyFAQ (Frequently Asked Questions) How deep was Munro & Associates analysis on the unique carbonfiber reinforced polymer (CFRP) material used on the BMW i3 body.In other words, how much aluminum in proportion to carbon fiberreinforced polymer (CFRP) was used? How were the proportionscalculated – by the entire vehicle or sub-systems? Are the materialcompositions laid out in detail and specified? General information isinteresting but not beneficial to us. We must have specifics.”Our ‘deep dive’ examination into the i3 materials hassurpassed any previous analysis performed by Munro &Associates in our 29 year history. In fact, every single parthas been painstakingly investigated and detailed in theBMW i3 report including analysis on the ‘super’adhesivesused and even the chemical composition of the batteries.To date, we have upwards of 196,000 manufacturing stepsdocumented including a staggering 54,000 parts (31,000mechanical and 23,000 electronic/electric). The i3 Report is inexcess of 23,000 digital pages.But we didn’t stop there our team partnered withTeardown.com to tear into the i3’s advanced electronicsright down to the circuit component level offering you detailedimagery on what makes the BMW i3 tick.11