Fiat-Chrysler The Challenges of Global Powertrain Engineering University of Michigan 07/25/12 Chris Cowland Advanced and SRT Powertrain Chrysler Group LLC Advanced Powertrain Engineering
History – Industrial Partnerships July 11, 1899: Fiat company charter “Societa 1920-1924: Walter P Chrysler teams with Anonima Fabbrica Italiana Automobili Torino” Fred Zeder, Owen Skelton and Carl Breer, signed. Led by Gianni Agnelli from 1966 – 2003. to design a revolutionary new car. 1925 Chrysler founded. 1928 partners with the Dodge brothers. MHI DSM 1928 1958-78 1964 1967 1969-93 1988 1989 1992 1998- 2003 2009 2010 1984 1985 1925 Dodge 2007 Chrysler Founded 2000-05 1969 1975 1979 1986 1993 2011 1899 1934-71 1974 1991 1999 Fiat Advanced Powertrain Engineering Founded
Fiat-Chrysler What are we trying to achieve together? - True global producer of passenger vehicles - Full spectrum of vehicles (A-F class) - Multiple Brand approach - Existing and emerging markets - Capitalize on synergies - Combine/develop best practices e.g. WCM X What are the challenges? Y - Global market regulatory/requirement differences - Managing portfolio complexity without duplication - Cultural differences - Learn from previous collaborations/ownerships Advanced Powertrain Engineering
Fiat-Chrysler Global Powertrain Bielsko Biala Auburn Hills (R&D) (Mfg) Chelsea (R&D) Trenton (Mfg x 2) Mack (Mfg) Dundee (Mfg) Kokomo (Mfg x 3) Toledo (Mfg) Orbassano (R&D) Kokomo Cast (Mfg) Conner (Mfg) Mirafiori (R&D) Windsor (R&D) Verrone (Mfg) Yucca (R&D) Balocco (R&D) Etobicoke Cast (Mfg) Satillo (Mfg x 2) Pomigliano (R&D) Shanghai (R&D) Pratola Serra (Mfg) Termoli (Mfg) Santa Fe (R&D) Ranjangaon Jiading (R&D) (R&D, Mfg) Chennai (R&D) Pune (R&D) Cordoba Betim (Mfg) (R&D,Mfg) Engine/Transmission Research and Development 8 7 Engine/Transmission Manufacturing 7 13 Advanced Powertrain Engineering
Fiat-Chrysler Vehicle Brands Differentiate via : • Technology level • Brand sound engineering • Transient response/feel • Underhood appearance • Power/torque ratings • Torque curve shaping • Transmission type • Shift strategy and feel Need to achieve brand differentiation at the powertrain level without excessive part proliferation Advanced Powertrain Engineering
Global CO 2 Emission Regulations US-LDV EU US 2025: 107 Proposed Targets EU 2020: 95 CO 2 legislation is core driver in all regions for the foreseeable future – EU leads but absolute limits converging Advanced Powertrain Engineering
Global Emissions Regulations US PM Standards US Standard 2017-2025 =3 mg/mi (1.9 mg/km) SULEV30 Emissions legislation is core driver in all regions for the foreseeable future – US leads but absolute limits converging Advanced Powertrain Engineering
Fuel Economy/Emissions Test Procedures US Drive Cycle US FTP Euro NEDC Japan Undefined European Drive Cycle Chrysler - EPA(Combined) Fiat 500 - Different test procedures have a huge cost/resource impact EPA(Combined) Chrysler - without tangible benefit to local air quality/global warming NEDC(Combined) Average vehicle demand energy (Jeep Patriot - AWD) FTP Combined = 10.34 MJ NEDC Combined = 6.06 MJ Advanced Powertrain Engineering
Fuels and Lubricants lower value = refinery average, upper value = refinery cap (retail values will be higher). Gasoline Sulphur Levels Region Fuel Lubricant Service Interval NAFTA 89-100 RON GF 4 or 5 5-10K miles EAEM ACEA 12.5-18.6K miles Regional differences in fuel and lubricants result in Western Europe 95-98 RON or considerable additional work to implement global powertrains Eastern Europe 90-98 RON OEM Spec LATAM 93-98 RON API or OEM Spec 6-9.3K miles around the world APAC* 88-98 RON ILSAC or OEM Spec Usage Specific * Manganese and methanol added to increase octane Advanced Powertrain Engineering adversely affecting aftertreatment robustness
Fuel/Vehicle Pricing – Cost of Ownership US Europe $46,875 $72,502* 225 hp (168 kW), AWD 201 hp (150 kW), AWD 3.0L Turbo Diesel 3.0L Turbo Diesel * 19% VAT,duties, foreign exchange, distribution Cost of vehicle ownership is significantly higher outside the US resulting in different vehicle attribute preferences Oil change in US Oil change in Europe $30 Generic oil $60 Minimum generic oil $80 Synthetic oil (higher at OEM) $160 Typical cost (higher at OEM) $160 High end (synthetic) $300 High end Advanced Powertrain Engineering
EU vs US Market Differences Market Quartiles: US vs EU A/B/C D E F egment $3.80/gal. CAFE Equivalent 34% 22% 22% 22% 27.1 – 31.8 23.7 – 27.0 < 23.6 mpg > 31.8 mpg 89% 6% 4% 1% $7.80/gal. Vehicle footprint correlates to disposable income Advanced Powertrain Engineering
Powertrain Portfolio - Engines Advanced Powertrain Engineering
Powertrain Portfolio - Engines Fiat Sales Mix Chrysler Sales Mix (Euro Market) (US Market) Cummins RAM Truck Maserati Gasoline Diesel Chrysler Fiat Gasoline – Fiat = small displacement/lower output Chrysler = larger displacement Diesel – Fiat = significant in-house portfolio Chrysler = 100% purchased Advanced Powertrain Engineering
Powertrain Portfolio - Transmissions Chrysler Sales Mix (US Market) Automatic Manual Chrysler Fiat Fiat Sales Mix (Euro Market) FWD options similar for Fiat and Chrysler AMT/DCT transmissions more prevalent outside the US Chrysler has larger capacity RWD transmissions Advanced Powertrain Engineering
Design/Validation Boundary Conditions Fiat Chrysler Combined Cycle Individual Tests • Coolant Temperature = 100 °C • Coolant Temperature = 90 °C • Oil Temperature = 100 °C • Oil Temperature = Floats • Fuel Energy (LHV) = 43.05 MJ/kg • Fuel Energy (LHV) = 42.5 MJ/kg • Electrical Loads = None • Electrical Loads = Loaded • Accessory Drive = Fully equipped • Accessory Drive = Various levels Opportunity to rationalize future test procedures Advanced Powertrain Engineering
World Class Manufacturing (WCM) WCM is …. Goals: Zero Accidents, Zero Waste, Zero Breakdowns, Zero Inventories A system based on the systematic reduction of all types of waste and loss through the contribution of everyone and the rigorous use of methods and standards Deliverables: Continuous improvement Applies its’ principles to all aspects of the plant Waste organization, from quality to maintenance, cost control to logistics, in a culture of continuous improvement Time Was born of the collaboration between Fiat and Two result examples from Fiat: the best European and Japanese experts, with the aim to develop a recognized, world class production standard Energy Efficiency Improvement - 1,700 projects introduced in 2011 Safety - 80% energy savings increment over 2010 Huge opportunities for efficiency improvements and waste Deployment - €38 million savings Cost reduction over very large global manufacturing footprint Workplace Logistics Quality Maintenance Organization Waste Reduction - 1,900 projects introduced in 2011 - €50 million savings
Key Technology/Powertrain Transfer Examples MultiAir DDCT CNG Small I4 Gas Engines Hybrid/Electric Axle Disconnect (4wd) Diesel Engines V6 Gas Engines Cylinder Deactivation Multispeed ATX Advanced Powertrain Engineering
Social/Cultural Leisure time Racing Start early vs work late “Football?” Advanced Powertrain Engineering
Key Conclusions • Minimal Overlap within Powertrain portfolios but still need rationalization • CO 2 driving downsized engines in all regions • Joint entity has key technical capabilities in all necessary technologies for future – diesel emissions, advanced valvetrain, high efficiency transmissions, cylinder de-activation, pressure charging, advanced fuel systems • Lack of harmonization in worldwide legislation is a vast waste of money and effort – but little hope of change • Fundamental differences in engineering practices, books of knowledge etc already narrowing – good opportunity to question the paradigms • Customer requirements/perceptions around the world are widely different but MAY start to converge if fuel prices increase dramatically in the US • World Class Manufacturing is a cultural change with huge savings opportunity • Out of phase economy highs and lows (US and Europe) allow some resource opportunities • Joint R & D offers significant technical and financial benefits • Global purchasing leverage benefits considerable Truly a Marriage of Equals??? Advanced Powertrain Engineering
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