Munro Talks Tesla Model 3 Manufacturing, Model Y Wiring, and EV Competition with All Things EVs

Munro & Associates CEO Sandy Munro and Mark Ellis, senior lead design consultant, recently sat down with Sean Mitchell of All Things EV to discuss the Tesla Model 3, EV technology and manufacturing, and the upcoming Tesla Model Y.

The discussion covers a variety of topics, nicely outlined by Sean here:

  • What does Munro & Associates do? 1:06
  • What is your technical background? 3:03
  • What are traditional automakers doing well with EVs? 5:13
  • What pending EV are you most excited about? 11:38
  • Why are we not seeing more competitive range EVs from traditional OEMs? 13:57
  • Do EV makers need to create their own cells to be competitive? 16:22
  • Will Tesla get into the battery raw materials business? 22:01
  • Why is the Model 3 over-manufactured? 26:44
  • Is a 204 mile e-tron and 235 mile I-Pace viable for the luxury EV market? 31:25
  • What do you make of Rivian’s product and will Ford take advantage of their tech? 36:41
  • What did you discover between how Tesla and others approached overall design and manufacturing? 45:36
  • You’ve compared Tesla’s hardware tech to what you see in fighter jets, can you expound on that? 52:50

Interestingly, Sandy shares that Munro has plans to acquire and tear down an early Model Y. He’s most interested to see what changes Tesla has made to the body, as well as what the wiring looks as it’s reduced from over a kilometer to a few hundred meters.

Check out the full video here: https://youtu.be/i93VJ1PEp6o

Sandy Munro Shares Thoughts on Structural Adhesives in Automotive Engineering Article

In the recent Automotive Engineering article “Stuck on Structural Adhesives” from Automotive Engineering, Munro & Associates CEO Sandy Munro shares “We’ve used adhesives forever. It’s just that the amount of confidence in them has drastically changed [in recent years].”

According to the article, as the need for lighter materials and enhanced body performance intensifies, structural adhesives are flourishing as a materials-joining solution. The widening reliance on high- and ultrahigh-strength steels and aluminum for body structures, particularly unitized bodies-in-white (BIW), to cut weight without sacrificing crash-mitigating strength or handling degrading rigidity, is the prime factor driving the expanding use of structural adhesives.

Sandy references his firm’s findings from the BMW i3 teardown and adds, “Anything you can possibly imagine, they glued together. The polyurethanes they are using are unreal.”

To read the full article, visit: http://bit.ly/2pHYsRS.

Munro & Associates Partners with Centrepolis Accelerator for Manufacturing; Celebrates Grand Opening at Lawrence Technological University

On October 4, Munro & Associates will join the Centrepolis Accelerator in celebrating the grand opening of its new manufacturing business accelerator space at Lawrence Technological University. The new Centrepolis Accelerator facility is a 6,300 square-foot, state-of-the-art business assistance center for physical product developers and manufacturing companies.

Centrepolis Accelerator clients will include manufacturing startups and existing companies looking to move up to the next level in product innovation. Services will include access to office space, co-working space, workshops, mentors, business planning services, and laboratories and equipment for digital product design and prototyping, as well as virtual reality and mixed reality labs.

Munro is offering Centrepolis Accelerator clients its Design Profit software to support product design and cost planning. Munro has previously provided formal Lean Product Design Assessments to Centrepolis Accelerator clients, which has reduced the complexity of products, reduced part count, and improved design for manufacturability and total product cost before going to market.

The Centrepolis Accelerator and Munro have also previously partnered on a series of events at Munro’s facility called “Leaning Your Product Design,” which has attracted many physical product developers and improved their product designs as a result.

For more information on the Centrepolis Accelerator, visit: http://www.centrepolisaccelerator.com/.

Munro’s Cory Steuben Shares Secrets of Tesla and Other Leading EVs at The Battery Show

Presenting to a standing room only crowd, Munro & Associates’ Cory Steuben, account director, offered automotive engineers objective technical information about today’s leading EVs during two sessions at The Battery Show North America recently held in Novi, Mich.

During two presentations, Steuben compared EV systems integrations across car companies/vehicles and demonstrated why a vertically integrated company, such as Tesla, is leading the way and why the domestics must rethink their designs if they want to catch up.

Steuben first presented “Tesla Model 3 vs. Jaguar I-PACE Motor Insights” where he showcased two disassembled electric motors: one Tesla Model 3 internal permanent magnet (IPM); and one Jaguar I-PACE IPM.

“When it comes to motors, we see many different attempts across many manufacturers—particularly with the geometry of how they put the magnets into their internal permanent magnet motors,” said Steuben. “When you look at the ideal shape is actually very expensive to manufacture—it would be three or four sets of parabolic magnets. There is no common orientation. With the Jaguar, we see three stacked magnets, all neodymium-ferrite-born magnets which is similar to others in the magnet material. Tesla does a simple single V. We have seen six or seven variations in various forms.”

For more Steuben’s insights on Jaguar I-PACE and Tesla Model 3 motor configurations, check out this Design News article: Motors Are as Important as Batteries In The World Of EVs

Steuben also presented “Electric Vehicle System-Level Integration Trends & Thermal-Electrical Management Synergies,” where he provided a detailed report on the system-level integration advancements that are impacting the OEM-level development of thermal and electrical systems. He highlighted system integration trends from the past and present, with a focus on the Tesla Model 3 Superbottle and integrated system.

Revealing the Secrets of the Tesla Model 3, BMW i3, Chevy Bolt, and Jaguar I PACE – An Exclusive Event hosted by Munro & Associates

Get Your Tickets Now Online!

Munro is hosting an intimate Electric Vehicle conference at its headquarters in Auburn Hills, Michigan on June 21st 2019. Attendees will get a closer look at the parts and structure of these vehicles, all while being educated by Munro’s staff on their inner workings.

During the event, the Munro team will present an engineering comparison of four leading EVs: the Tesla Model 3; the BMW i3, the Chevy Bolt; and the Jaguar I-PACE.

The tour of the Munro Benchmarking Investigation, Innovation & Implementation Center will provide an Engineering deep dive of the most advanced electric vehicles and technologies in the market today. Munro will also provide an in-depth view into how we analyze products and perform Costing and Reverse Engineering.

The main focus will be on the EV “Big 3”: Motors, Batteries and Electronics; however, there will be a new technology review with insight into the engineering and designs of some of the other innovative vehicles on the road today. All the Powertrains will be compared side-by-side to highlight their strengths and weaknesses.

Unlike many “Power Point Conferences” the parts will be laid out on tables or hanging on “A Frames” with knowledgeable Munro Engineers to provide detailed description of the key take-ways along with answering all your questions.

For the Jaguar I-PACE, there will be a hoist review to discuss the I-PACE and its electric motor.

EXTRA! Munro has also invited an independent investigator from Tesloop who will share important aspects of EVs that are rarely discussed; life expectancy and maintenance of an EV. Tesloop has ALL the documentation on the durability of the Tesla product.

This is a must attend event for all EV Engineers!

$199 which includes:

  • An overview of “EV Big 3:” motors; batteries; and electronics;
  • A technology review with insight into the engineering and designs of some of the other innovative vehicles on the road today;
  • A tour of Munro’s Benchmarking Investigation, Innovation & Implementation Center
  • The opportunity to participate in an engineering deep dive of today’s most advanced EVs and technologies; and
  • An in-depth view into how Munro analyzes products and performs reverse engineering.

Timing, Location & Agenda:

Friday, June 21st, 2019

Munro & Associates
1140 Centre Road Auburn Hills, MI 48326

8:30 a.m.Registration, Coffee & Donuts
9:00 to 9:15Welcome and logistics
9:15 to 9:45Who is Munro? How do we get our Numbers?
9:45 to 10:15Battery Debrief  
10:15 to 10:45Electronics Debrief
10:45 to 11:15Electric Motor Debrief
11:15 to 12:00Long Range Tesla Data; Full data on Tesla vehicles some with 380,000 MILES! BTW No Maintenance Issues!!!
12:00 to 1:00Lunch
13:00 to 15:30On-The-Floor, Group Breakout, Around the Parts; I PACE Hoist Review, Side by Side discussions at 5 teardown stations to discuss all the vehicle components
15:30 to 16:30Social Hour, Tours of Other Vehicles at Munro and Networking

Tickets limited to 100 guests. Purchase your tickets now by clicking here:

http://bit.ly/2HJF8dr

Latest Additions to the Team at Design Profit

Munro’s is pleased to be welcoming a few new faces to our Design Profit software development center!

Rebekah is an expert in all things communication with experience in web design, media content management, and professional writing. As we celebrate her graduation from Michigan State University with a Master’s degree in Professional Writing. Rebekah started with us in December as a part time employee and has now made the transition to full time as a technical writer in our Design Profit software development center. She has already completed work on various documents and media content for us and is looking forward to dedicating a full time schedule to ensuring that we communicate as clearly as possible!

Michael Brown, our newest addition to the development team, has spearheaded our efforts in CAD integration. Michael completed a number of impressive projects before starting here at Design Profit including—but not limited to– creating video game engines from scratch and designing games themselves! His ability to play around and bring new ideas and approaches into our development process has been essential. He also has expertise in AI and we expect to see much of his contributions in the next update of our software.

Jennifer Rodgers spent over two decades working in the insurance industry and Real Estate while simultaneously managing social media and media sales for local comedians and entertainers. Her experience is varied and it gives her a great edge as our new sales associate. Personable and professional, Jennifer has been a local in Williamston for longer than most, and it seems like she knows everyone who walks through the door! The rest of us here at Design Profit are so happy that she found a new job so close to her community, and we’re very excited for her future here.

Our numbers are rapidly growing to account for the strides we’ve made and will continue to make to guarantee that the tools of Lean Design, Click2Cost, and the rest of Design Profit, operate at peak performance. We look forward to seeing more from these talented individuals as time goes on.

Munro & Associates Forms Strategic Alliance With Hinduja Tech

Munro & Associates and Hinduja Tech have announced a strategic alliance which will bring the powerhouse of Hinduja Tech’s CAD design expertise together with Munro’s unique approach to product design through their proprietary Lean Design® Methodology, technology cross-pollination, and teardown benchmarking to create a formidable and complimentary symbiosis.

Hinduja Tech, based in Chennai, India is part of the multi-billion dollar Hinduja Group headquartered in the UK, which boasts a heritage of over 100 years in many key industry sectors. Hinduja Tech’s specific experience in Automotive design spanning across the US, Europe and Asia, brings both capability and understanding of the latest design tools in the market and proves a past healthy pedigree in that sector. Hinduja Tech is known for its “frugal engineering” approach to delivering award winning vehicle programs in emerging markets by compressing the barriers of cost, quality and time.

“We are excited to be partnering with Munro & Associates, as both companies share a passion for delivering award winning engineering services and solutions and will now offer flexibility, disrupting the automotive industry via onshore, nearshore and offshore delivery models,” said Kumar Prabhas, CEO, Hinduja Tech.

Together with Munro’s experience which spans the gamut of manufacturing sectors including Automotive, Heavy Industries, Aerospace, Medical, Consumer Electronics, and Marine to name a few, this alliance will combine both Hinduja Tech’s frugal engineering approach with the inherent cost and weight reduction techniques born from within Munro’s methodologies to provide for their mutual customers a full array of engineering services.

Founded in 1988, the Auburn Hills Michigan based Munro & Associates team has brought billions of dollars in savings to companies across the globe using it’s many services including costing, program management, sustainability, benchmarking and reverse engineering as well as the Lean Design® methodology and other Lean techniques. CEO, Sandy Munro, is excited to be working with Hinduja Tech and sees, “unlimited potential” for both companies to grow in their future endeavors.

Munro and Associates Attend NDIA Banquet to Present Munro Award for Academic Excellence

On April 12th the Michigan chapter of the National Defense Industrial Association (NDIA) held their annual ROTC Awards Recognition Banquet. This event recognizes academic and leadership accomplishments of just under 100 students in the State of Michigan ROTC program. The students, made up of cadets and midshipmen, were presented with awards for their performance in their studies and their participation in ROTC. The Recognition Banquet is sponsored by the NDIA MI Chapter, supported by the Greater Michigan Armed Forces Week Committee, the Association of the United States Army, the Navy League, and a handful of corporate sponsors including Munro and Associates.

Our continued relationship with the NDIA MI chapter and the ROTC program in Michigan is just one aspect of our commitment to our local community and our relationship with defense education and industry. Pictured below David Oberholtzer and Sandy Munro present the students with their awards. The dedication shown by these individuals represents the rigor and enthusiasm our company looks for in future employees. We were very happy to be involved in their recognition this year, and expect great things from these award recipients in the coming years.

Munro & Associates’ World Class Lean Design® Certification is Changing the Industry!

Munro & Associates has long been a provider of training in various Lean methodologies, but now Munro combines its Lean Design® Methodology instruction with its Design Profit® software training into one comprehensive course.

Students will undergo training with Munro’s instructors providing them with the core basics of the Lean Design® Methodology and then proceeding into the practical applications of these new skills in the Design Profit® software. More importantly, the skills and techniques that students learn in this course can be immediately applied in their current projects at work for an immediate return on investment.

Students will learn how implementing Good Design Principals along with other Lean Design® fundamentals becomes the ultimate influencer of profitability and quality in a products life span and that neglecting these principals can result in a design that is bloated, over cost, over weight, and of poor quality. Students will learn how the different Lean Design® techniques are used to consistently remove waste from the product design itself that ultimately results in a more elegant and higher quality product. “You can never have Lean Manufacturing without Lean Design®” will become a mantra and paradigm shift for students as they explore the practical workings of this methodology which has saved companies around the globe Billions of dollars throughout the last 30+ years.

Once the methodology has been imbued in the students, the trainers move on to how to use the Design Profit® software to compile, sort, and analyze data in a visual mapping context which also helps to expedite the product design process which forces a Lean Design® to be procured, avoiding the pitfalls of poor quality drivers BEFORE they are experienced on the manufacturing floor. Students will learn the importance of creating a costed business case for all design decisions which will illuminate both student and executive as to what the best design choices should consist of.

The course ends in an exam which, upon successful completion, results in the student receiving a unique certification number. This certificate number can then be used throughout the rest of their career to prove they have been successfully trained by Munro in their industry changing techniques, garnering them professional clout that can be carried from job to job throughout anywhere in the world.


Learn more on leandesigncertification.com »

Competitive Benchmarking at Its Highest

A few months ago, Fusion TV sent the crew from their new show, “Car VS America” to investigate what they called, “One of the stealthiest little known operations in the Detroit area” to uncover one of the best kept secrets of the automotive industry – Munro’s Benchmarking Innovation Center (BIC) to see just how deep the “Competitive Benchmarking” rabbit hole goes.

Munro & Associates has been in the business of Competitive Benchmarking and Reverse Engineering for decades, tearing apart and analyzing anything from cars to tanks, consumer electronics to heavy industrial machines.  They now currently have a materials, process and new technology base rivaled by very few in the Manufacturing industry.

The presenters Michael Ballaban and Raphael Orlove, car-obsessed editors from Jalopnik, now team up in their new show to explore all the inner workings, tricks of the trade, and, in general, experience how people in the Auto Industry take their craft to the next level.

Both presenters of this show were dazzled by the secrets they got to check out and play around with at Munro & Associates.  But to find out what they saw, you will have to watch the episode.

Follow this link to watch a short clip of the program on Munro and find out for yourself.