Tesla Model 3 Considered “Car of the Decade”

Wheels 24 recently posted an article discussing why the Tesla Model 3 is the absolute ‘car of the decade.’ According to author Lance Branquinho, “it is a vehicle of strange contradictions. By the time Tesla had finally managed to deliver its Model 3 to customers in late 2017, the market for mid-size sedan cars had shrunk dramatically. Despite this, Tesla’s Model 3 has proven boundlessly popular, with surging global demand.”

According to Branquinho, its popularity is due to the vehicle’s “unrivalled” fundamental engineering. “Not even the most technically regarded German brands have managed to produce something with comparable performance or originality of design in terms of powertrain. Tesla’s batteries might be Panasonic’s doing, as part of a joint venture, but the electric motors are their own design and absolute genius.”

The article goes on to use Munro’s assessment of the Model 3 to further his assertion: “Engineers who have dissembled the Model 3, most notably American powertrain specialist, Sandy Munro, quickly discovered that although the bodywork design was poor, everything else is decades ahead. Much like a smartphone, almost any issue with a Model 3 can be diagnosed and remedied by over-the-air updates, which completely revolutionizes the convenience of ownership. You don’t need to seek a dealership to plug-in for diagnostics or wait for an afternoon to hear what the fault code is.”

Check out the full article here: https://www.wheels24.co.za/News/Guides_and_Lists/heres-why-this-is-the-absolute-car-of-the-decade-20191231

Tearing Down Tesla Segment 3: Suspension Costs – Premium vs. Standard

One of the primary ways the Tesla Model 3 distinguishes itself from its competitors, such as the BMW i3 and Chevy Bolt, is the superior handling performance. It shows that even though Tesla is competing on a similar pricing level, they are willing to spend a significant amount more on the suspension on the vehicle to impress their customers.

Background: Every OEM spends its money differently on systems throughout the vehicle. Some spend more on interior trim or seats or NVH control. In the Model 3, Tesla spends its extra money on the suspension. 

Data: The Tesla Model 3 spends $924 on its suspension versus the BMW i3 at $731 and Chevy Bolt at $642. Part of the cost in the suspension is due to the heavier weight of the Model 3, but the main difference is in the design of the rear suspension. The Chevy Bolt offers the simplest rear suspension with a fixed twist beam structure. Both the Model 3 and i3 have five link suspensions, but the i3 mounts the linkages to support structures on the frame, while the Model 3 has a full cradle with a stabilizer bar.

Methodology: The Munro team removed the front and rear suspension modules from each of the vehicles, and mapped the final assembly time and cost using Munro’s Design Profit® software. The modules were then torn down so the assembly process time and cost could be calculated. Lastly, each part was analyzed to determine the fabrication steps involved to create the parts for the suspension, all of which was documented in Design profit.

Breaking Down Munro’s Wall Process®

On time and on budget – these are the goals of every product launch team everywhere – yet how many actually achieve this goal?

With more than 30 years of experience that cuts across virtually every segment of the manufacturing industry, Munro & Associates has consistently saved companies billions of dollars.

One of the reasons for Munro’s success is its ability to attack the root cause of all producibility inefficiencies – the product design – with its proprietary Wall Process®.

The Munro Wall Process® is an advanced visual project and risk management tool that unites design, engineering, manufacturing, and finance to help new projects and redesigns deliver on time and on cost by identifying and solving root cause problems before they fester throughout the product development process. The simple color coding system and score cards makes for instant and unapologetic pinpointing of current pressing issues; making for fast and comprehensive executive overview.

Due to the Wall Process’ visual nature, it prevents different departments hiding or hoarding information critical to planning and development while creating a knowledge sharing system that is vastly superior than what exists in many manufacturing companies today.

Wonder how it can help with your project? Chick here for more information about Munro’s Wall Process and other project management solutions: https://leandesign.com/program-management/.

Tearing Down Tesla Segment 2: Tesla Model 3 vs. BMW i3 with REx System

What costs more? An electric vehicle with an extended range system or a full electric vehicle? How does OEM assembly time factor in?

Background: The supplier component costs for a full battery electric vehicle, like the Tesla Model 3, are often more expensive than an electric vehicle with a range extender, like the BMW i3. However, for the OEM, an electric vehicle with a range extender (or any type of hybrid vehicle) will drive more OEM assembly costs. Additional assembly workstations are required to build a range extender system (often in a spur line), then more stations must be added to the main final assembly line in the vehicle assembly plant.

Side note: this does not include the cost to assemble the engine, which could be supplier or OEM assembly costs.

Data: The BMW i3 REx system can be estimated to drive approximately $45.61 in OEM assembly costs for installation and assembly of the system components into the REx module. This drives the need for approximately 35-40 more workstations in the assembly plant.

Methodology: Munro’s Design Profit® software has a built-in scoring system that allows users to analyze handling and interaction times when assembling parts. Munro uses this scoring system, along with a library of industry standard fastening and operation times, to generate an estimated time and motion study for the assembled parts and work cells that are required. Then, in order to generate assembly costs, that assembly time is matched with a work cell rate for the require operator and equipment.

Munro Talks Tesla Cybertruck, SpaceX Tech, Bulletproof Windows, Crash Safety and Battery Magic with All Things EV

All Things EV’s Sean Mitchell was back at Munro & Associates for a great discussion with CEO Sandy Munro. Check out the in-depth discussion that covers a variety of topics, including:

  • What do you think about the Cybertruck and did you order one? 00:30
  • Does the Cybertruck have stealth properties? 03:01
  • Is there a difference between a uni-body and exoskeleton? 04:07
  • Why is body-on-frame such a popular way to build trucks? 06:56
  • What type of chassis did the DeLorean have? 09:15
  • How can Tesla pull from SpaceX technology? 10:12
  • Will the Cybertruck be more cost effective to produce than their other vehicles? 19:43
  • How will the Cybertruck do in a crash? 22:05
  • Does this new manufacturing approach address some of your Tesla build quality concerns? 24:12
  • Is there some magic behind a $40,000 Cybertruck? 27:26
  • What are some things that appeal to you about the off-road capabilities? 34:21
  • What are Ford, GM, and Chrysler saying about the Cybertruck in their boardrooms? 37:03

Sandy brings a lot to the discussion – including bullets! – when discussing the skin of the Cybertruck. Here’s a link to the full video: https://youtu.be/koNaFUuIjk4.

Sandy Munro Discussed the Tesla Cybertruck with E for Electric

Munro & Associates CEO Sandy Munro recently shared his first impression of Tesla’s Cybertruck with E for Electric after watching the abridged version of it’s unveiling in the following video: https://www.youtube.com/watch?v=zLwjAj53PL0.

Check out the 15-minute segment for interesting insights about the Cybertruck, including:

  1. His first impression of the vehicle;
  2. Why it should be easy to manufacture;
  3. The feasibility of making it actually bulletproof;
  4. How bulletproofing will impact the vehicle’s weight;
  5. If Tesla is ready with its battery technology; and
  6. Will he tear one down?

The video also announces that Sandy has committed to being a once-a-month guest speaker for E for Electric. Stay tuned for future segments!

Fast Fact: Average ROI for Munro Customers is More than 10 Fold in One Year

Did you know that the average ROI for Munro customers is more than 10 fold in one year and the average payback period is just three months?

It’s true.

Since 1988, Munro & Associates has consistently saved companies billions of dollars spanning the gamut of manufacturing industries from aerospace, defense, automotive, marine, medical, heavy industries, MTDM, consumer electronics and more.

The company has a proven track record of helping companies reduce “time to market,” R&D, engineering and manufacturing costs, while increasing the quality of products, processes and systems. This has resulted in customers not only realizing higher profit margins, but also significantly increasing market share … or achieving market dominance.

How does Munro do it?

By evolving the way companies manufacture. From the executive level (program cost reduction and management, consolidation, risk assessment) down through engineering, costing, supply chain and manufacturing, Munro offers a suite of exclusive, time-tested tools and methodologies that are the envy of the industry.

Don’t just take our word for it. Click here and we’ll sent you a case study relevant to your industry: https://leandesign.com/case-study-signup.php?industry=automotive

Tearing Down Tesla: Comparing Secrets of Tesla and Other Leading EVs

Calling all automotive engineers looking for objective technical information about today’s leading electric vehicles (EVs).

This post kicks off a series of articles that will compare notable aspects of leading EVs. From OEM assembly time to suspension and from battery cooling systems to HVAC ducting and venting, this series will cover a lot of ground. Most importantly, it aims to offer knowledge that’s interesting and valuable to today’s engineers … with data points that support our findings.

We used our proprietary Design Profit software for all of our teardown analysis. It enables the teardown team to document each part, how it is installed in the vehicle, as well as how it’s assembled in each subassembly. With this data, we’re able to reverse engineer the assembly process for the given vehicle. More information about the software can be found here: https://designprofit.com/

With that said, here’s the first post ….

Did you know that the BMW i3 has a serviceable battery pack while the Tesla Model 3 doesn’t?

Background: The BMW i3 has a serviceable battery that can be lowered from the vehicle by removing the pack’s mount bolts located on the exterior of vehicle. Individual sub-packs can be replaced after removal of the cover and sub-pack fasteners.

The Tesla Model 3 battery pack was designed not to be serviced. It requires the removal of bolts in the interior and exterior of the vehicle to drop out the battery pack, as well as the removal of the vehicle’s seats and carpeting (to access bolts). The battery pack uses structural adhesives to seal and mount its cover and sub-packs, which does not allow service to open and easily remove modules for repair.

Insight: The advantage of the Tesla Model 3 non-serviceable battery pack is that it reduces the final assembly cost of the battery pack. The disadvantage is that if significant cell damage happens in the pack, then it requires a full swap of the battery pack.

Side note: based on the range for the Tesla Model 3 battery pack vs the BMW i3, in order to equalize, the BMW i3 assembly costs would be considerably higher than the current cost analysis.

Data:  The Tesla Model 3 uses three lines of structure adhesive bead and 78 fasteners, with a final assembly cost of $36.87 to mount the sub-packs and install the battery pack cover. The BMW i3 battery pack uses 120 fasteners, with a final assembly cost of $41.39.

Munro on Tesla’s Motors: “They’ve Got Magic!”

After watching numerous interviews of Munro, it is apparent that it takes a lot to impress him, and Tesla does exactly that. When talking about Tesla’s innovation, he is as happy as a kid in a candy store. Like anyone, Munro wants to make money, but like many engineers, he is intrinsically obsessed with his work and you can tell he really loves this technology.”Kurt Lowder, CleanTechnica

Does anyone else remember when Sandy Munro said that Tesla’s motors have magic? If you missed it, this CleanTechnica article offers a nice recap of how Sandy explains Tesla’s motor magic.

According to the article, Tesla’s newer permanent magnet motors are superior to the competition for a number of reasons. This article focused on one of those reasons: magnets. Per the article:

“Tesla was able to take advantage of what is referred to as the Halbach array. Tesla’s new permanent magnet motors are an improved design that first appeared in the Model 3. Only recently have the Model S and Model X been upgraded to this new technology.

Magnets within these motors are engineered to create a more optimal magnetic field. Four carefully designed, small magnets that oppose each other are actually glued together to create a stronger — or rather, a more optimized — magnetic field that makes the permanent magnet motor more powerful and more efficient. There are several of these magnets within the motor.

This crucial aspect of the motor is one of the main reasons why Tesla vehicles get more range than competing vehicles that have the same size battery packs.”

Interested in learning more? Then head over to the full article with more details: https://cleantechnica.com/2019/04/28/industry-expert-on-teslas-motors-theyve-got-magic/