Global market review of vehicle electrical wiring systems forecasts to edition

Transcription

1 Global market review of vehicle electrical wiring systems forecasts to edition

2 Page i Global market review of vehicle electrical wiring systems forecasts to edition By Matthew Beecham December 2007 Published by Aroq Limited Seneca House Buntsford Park Road Bromsgrove Worcestershire B60 3DX United Kingdom Tel: +44 (0) Fax: +44 (0) Web: Registered in England no:

3 Page ii Single-user licence edition This report is provided for individual use only. If you would like to share this report with your colleagues, please order additional copies or sign up for a multi-user licence by contacting: Holly Nash Research manager, just-auto.com Tel: +44 (0) holly.nash@just-auto.com Copyright statement 2007 All content copyright Aroq Limited. All rights reserved. This publication, or any part of it, may not be copied, reproduced, stored in a retrieval system, or be transmitted in any form by any means electronic, mechanical, photocopying, recording or otherwise without the prior written permission of Aroq Limited. This report is the product of extensive research work. It is protected by copyright under the Copyright, Designs and Patents Act The authors of Aroq Limited s research reports are drawn from a wide range of professional and academic disciplines. The facts within this report are believed to be correct at the time of publication but cannot be guaranteed. All information within this study has been reasonably verified to the author s and publisher s ability, but neither accept responsibility for loss arising from decisions based on this report. Incredible ROI for your budget single and multi-user licences We understand the pressure your research budget is under and price our reports realistically. You won t find our reports with four, or even five-figure price tags, but you will find that they make some of the competition look expensive. Each title is available to you on a single-user basis, supplied on the strict understanding that each title is not to be copied or shared. Alternatively, titles can be shared within departments or entire corporations via a costeffective multi-user licence. Multi-user licences can also save you money by avoiding unnecessary order duplication. To further add value, all multi-user

4 Page iii copies are hosted on a password protected extranet for your department or company saving you time, resources and effort when sharing research with your colleagues. To find out more about multi-user pricing, please contact Holly Nash. just-auto.com membership From just GBP99/US$195/EUR155* a year you will gain access to a growing portfolio of exclusive management briefing reports, and also receive 12 new briefings for each year you are a member. As well as this impressive list of members only reports, you also gain one year s access to a constantlyupdated stream of news, feature articles and analysis. Established in 1999, just-auto has rapidly evolved into the premier source of global automotive news, analysis and data for busy senior executives. For details of the current special joining offer visit: *Prices correct at time of publication.

5 Page iv Table of contents Table of contents Single-user licence edition... ii Copyright statement... ii Incredible ROI for your budget single and multi-user licences... ii just-auto.com membership...iii Table of contents... iv List of figures... vi List of tables... vii Preface... viii Research methodology...viii Report coverage...viii The author...viii Chapter 1 Introduction... 1 Chapter 2 The market... 2 Market trends... 2 Market players... 6 Alcoa Electrical and Electronic Solutions... 6 Delphi Corp... 7 INTEDIS... 7 Lear Corp... 7 Leoni... 8 Sumitomo Wiring Systems... 8 Yazaki Corp... 9 Emerging markets... 9 Market shares Global market Western European market North American market Japanese market Korean market Market forecasts Chapter 3 Technical review Defining the elements Recent innovations Q&A with BERU F1 Systems Chapter 4 Manufacturers Alcoa Electrical and Electronic Solutions... 26

6 Page v Table of contents Delphi Corp Lear Corp Leoni Sumitomo Wiring Systems Yazaki Corp... 39

7 Page vi List of figures List of figures Figure 1: Global market shares for vehicle wire harnesses, 2006 (% of volume) Figure 2: Western European market shares for vehicle wire harnesses, 2006 (% of volume) Figure 3: North American market shares for vehicle wire harnesses, 2006 (% of volume) Figure 4: Japanese market shares for vehicle wire harnesses, 2006 (% of volume) Figure 5: Market value of wire harness by application, 2007 (% of total value)... 14

8 Page vii List of tables List of tables Table 1: Market value of wire harness by application, Europe, North America, Japan and China, (EUR 000s) Table 2: Alcoa Electrical and Electronic Solutions facilities worldwide Table 3: Lear Corp s electrical and electronic production facilities Table 4: Sumitomo Wiring Systems automotive wire harness facilities worldwide Table 5: Yazaki s wire harness operations worldwide... 39

9 Page viii Preface Preface Research methodology This report is intended to provide an overview of vehicle electrical distribution systems, providing top level market fitment, volume and value forecasts through to Our forecasts are not extrapolative but dependent on the underlying drivers of supply and demand. Our forecasts are largely based on interviews with the author s extensive international network of industry contacts. This allows us to consider and explain the meaning and implications of industry events, rather than offer simple description based on incomplete data. Our approach is divided into two distinct methodologies: qualitative interviews these are generally opinion-based, which aim to build knowledge about future vehicle electrical distribution system market trends and company strategies; and quantitative interviews typically fact-based, focused on establishing market values, shares, and volumes. Report coverage In this, the fourth edition of this report, just-auto reviews the key market drivers for vehicle electrical distribution systems, and updates the market analysis. Following our market overview in Chapter 1, just-auto s product fitment forecasts in Chapter 2 predict the market by value worldwide (and by major car-producing region) for vehicle wiring harnesses by application, e.g. engine harness, roof harness, floor harness, etc. Chapter 3 sets out a review of recent innovations in this arena while Chapter 4 provides brief profiles of the major manufacturers, namely Alcoa Electrical and Electronic Solutions, Delphi, INTEDIS, Lear, Leoni, Sumitomo Wiring Systems and Yazaki. The author Since 2000, Matthew Beecham has served as an associate editor for just-auto. He authors a range of global auto components market research reviews, including batteries, braking systems, coatings, clutches, cockpits, driver assistance systems, door modules, electric motors, engine cooling systems,

10 Page ix Preface exhaust systems, front-end modules, fuel injection, fuel tanks, glass, ignitions, interiors, lighting, mirrors, roof systems, shock absorbers, spark plugs, rotating electrics, tyre pressure monitoring systems, tyres, wheels and wipers. Matthew has also written a number of features for magazines including Car Graphic (Japan), JAMA (Japan) and Automotive Engineer (UK). He earned his PhD in automotive technology transfer at Cranfield University.

11 Page 1 Chapter 1 Introduction Chapter 1 Introduction Developing an electrical and electronic architecture starts with the physical and functional partitioning of the various sub-systems and components. It determines how many electronic controllers there will be and where they will be placed, what materials will be used, how much wiring and cable will be used, and how various components will be positioned. Electrical and electronic architecture can optimise packaging and routing of the wiring harness so that it fits in smaller or better places. In some instances, it can eliminate the need for the conduit or harness covering that wiring may be packaged in, cutting costs and labour required to produce the system as well as making it easier to separate materials and recycle components at the end of the vehicle s life.

12 Page 2 Chapter 2 The market Chapter 2 The market Market trends There are a number of forces driving the electrical and electronic distribution systems (EEDS) market, including cost pressures, safety and environmental concerns. An auto executive told us: The major driving force is the need to improve fuel consumption and cut emissions. We are seeing more and more hybrid and electric vehicles supporting this trend. Both of these trends can be only be solved by the increasing use of electronics. Lear Corp reports that the migration from conventional electrical distribution systems to electronic products and electrical distribution systems is facilitating the integration of wiring and electronic products within the overall electrical architecture of a vehicle. This migration can reduce the overall system cost and weight and improve reliability and packaging by optimising the overall system architecture and eliminating a portion of the terminals, connectors and wires normally required for a conventional electrical distribution system. Hybrid vehicles also make tough demands on the electrical and electronic distribution systems, and these have significant effects upon the architecture. For instance, the additional voltage level for the electric drive must be safely distributed between the assemblies of equipment. Furthermore, the already existing demand for weight reduction becomes far more critical when the extra weight of electro-motor and hybrid battery is considered. In today s hybrid vehicles, the conventional electrical system and the hybrid electrical system are for the most part separate. The feature content of new cars is also increasing year on year, as another auto executive told us: About xx% of electrical and electronic comfort and convenience features that are available in a modern car today were simply not around ten years ago. Features like multimedia systems, telephones, rear seat entertainment, remote keyless entry and tyre pressure monitoring systems all consume more energy. We must therefore look at novel, cost-effective ways in which to integrate those new features. On one hand, that means we must continually review the EEDS architecture and push back the technical boundaries with innovative integration solutions. On the other hand, we must

13 Page 19 Chapter 3 Technical review Chapter 3 Technical review Defining the elements The modern vehicle electrical system is becoming more and more complex. During the 1960s, an average vehicle electrical system contained about xx metres of cable. Today, this amounts to about one mile. Leoni defines a wiring system as comprising all the wiring in a vehicle, which also integrates components such as mounting and sealing parts, cable channels, fuse boxes, power distributors and electronic control systems. The term cable harness, by contrast, describes the wiring of individual vehicle components such as the engine, dashboard, doors and seats. Lear Corp defines electrical distribution systems as networks of wiring and associated control devices that route electrical power and signals throughout the vehicle. Wire harness assemblies consist of raw, coiled wire, which is automatically cut to length and terminated. Lear defines wire harness assemblies as a collection of terminals, connectors and wires that connect all of the various electronic and electrical devices in the vehicle to each other and/or a power source. Terminals and connectors are components of wire harnesses and other electronic and electrical devices that connect wire harnesses and electronic and electrical devices. Fuse boxes are centrallylocated boxes in the vehicle that contain fuses and/or relays for circuit and device protection, as well as power distribution. According to Delphi, the electrical/electronic architecture is a representation of the vehicle s electrics and electronics. The increase in the number of electrically-controlled functions and in their complexity, leads to a corresponding increase in the number of electric and electronic modules and the associated communications requirements. The architectural target, says Delphi, is to determine the correct balance between the electrical and electronic costs. In this process the following marginal conditions, for instance, must be taken into account: logistics, standardisation, thermal behaviour, humidity, installation space, interface requirements and diagnostics, communication costs and network management, and system-relevant demands such as energy management.

14 Page 26 Chapter 4 Manufacturers Chapter 4 Manufacturers Alcoa Electrical and Electronic Solutions Alcoa Electrical and Electronic Solutions is organised on a regional basis across Europe, North America and South America. Alcoa Electrical and Electronic Solutions product range includes wiring looms for engine compartments, doors, boot lids, roofs and other sub-assemblies. It also supplies a variety of automotive electronic products, including bus systems, junction boxes and relays. Alcoa Electrical and Electronic Solutions customers include Ford, Subaru, Paccar, Audi, Volkswagen, GM, DaimlerChrysler, Johnson Controls, Freightliner, International Truck & Engine, Denso and Visteon. The company is also supplying Polaris Industries Inc with wire harnesses for the company s Ranger all-purpose utility vehicle. The wire harnesses are manufactured at Alcoa Electrical and Electronic Solutions facility in Acuna, Mexico and then shipped to Polaris Roseau, Minnesota and Spirit Lake, Iowa, manufacturing plants where the Ranger is produced. Alcoa Electrical and Electronic Solutions employ xxxxxx people at xx sites in xx countries, as shown in the table below. Table 2: Alcoa Electrical and Electronic Solutions facilities worldwide Country Location Operation Belgium Brussels Logistics Canada St Thomas, Ontario Logistics Czech Republic Plzen Engineering office, design Stribro Manufacturing and final assembly of integrated electrical distribution systems and wire harness assembly Germany Frickenhausen Development site, electronics production, European head office Ingolstadt Sales, prototype shop, development site