Engineering & Design Harald J. Wester April 21, 2010 Fiat Investor Day 1
The product development challenge Targeting best-in-class players In a fierce worldwide competition, to develop products with excellence in speed, cost, quality and innovation April 21, 2010 Fiat Investor Day 2
Group Engineering Product development at Group level Fiat Group Automobiles BRAZIL Customization Local applications Excellence in body design Low-cost development center GROUP ENGINEERING & DESIGN Know-how, standard methods, tools, product concept Component, technical solution & architecture standardization Series development / main applications Excellence in safety, noise & vibration, weight, consumption TURKEY Customization Local applications Low-cost development center CHINA Customization Low-cost development center Research Center Innovation Methodologies Intellectual property management INDIA Customization Local applications Low-cost development center April 21, 2010 Fiat Investor Day 3
Group Engineering Global synergies between FGA & Chrysler Group Fiat Group Automobiles Synergies April 21, 2010 Fiat Investor Day 4
Product development process FROM... Kick-off Briefing Start of series development Technical validation Job 1 Model launch...to Product concept Execution & realization Pre-series Ramp-up April 21, 2010 Fiat Investor Day 5
Product development process Breaking-through new frontiers Kick-off Briefing Start of series development Technical validation Job 1 Model launch 1 2 3 4 5 6 7 8 9 9.5 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Months Stilo 15 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 Months 500 Bravo MiTo 1 13 Months 2 3 4 5 6 7 8 9 10 11 12 14 15 Giulietta Significant changes in process organization in order to allow parallel phases of activities Integrated approach to marketing, engineering & manufacturing from earliest stage of development Early involvement of suppliers April 21, 2010 Fiat Investor Day 6
Product development process Best practice across Group Sectors 24 14 15 16 17 18 19 20 21 22 23 Months 28 29 30 31 32 33 34 35 36 Months 40 14 15 16 Months Case IH Small Frame Magnum 16-month development from program approval vs. previous standard of 24 months 28 29 30 Months Small Gasoline Engine Current average competitor development time about 36-40 months April 21, 2010 Fiat Investor Day 7
Standardization strategy Towards best practice in standardization Total vehicle cost Investment Development costs Time-to-Market Vehicle specific components (model/brand differentiation) Powertrain 25-30% 25-30% Upperbody & closures Interior trims, seat trim Exterior trims Dashboard Front & rear lamps Windows... Engine Transmission Hot exhaust system Gear shift Economies of scale Quality & Reliability Additional common components Modular architecture 10-15% 30-35% Airbags Lighting Brake disks Instruments Hinges Locks Sensors... Front & rear floors Front & rear suspensions Braking system Steering system HVAC Front-seat structure... April 21, 2010 Fiat Investor Day 8
Worldwide architecture standardization strategy 38 38 32 19 11 5 2006 2010E 2014E Total models Total architectures # of models Architectures Volumes (incl. partner vehicles) Architectures 1.7 3.5 7.6 150k 205k 800k April 21, 2010 Fiat Investor Day 9
Worldwide architecture standardization strategy The 3 key modular worldwide architectures Mini Small Compact April 21, 2010 Fiat Investor Day 10
Modularity of architectures Sedan / Linea Common Modular Interchangeable April 21, 2010 Fiat Investor Day 11
Different Architecture Same Architecture Standardization strategy A strategy managed at Group level across regions and brands 2006 2010 2014 Synergies mainly within FGA segments Strong synergies within and across architecture Extension of synergies to Chrysler Group segments 10-15% 55-65% >70% 3-6% 15-25% >35% % of common components vs. vehicle cost April 21, 2010 Fiat Investor Day 12
Architectures standardization strategy Cost benefits in C-Segment Maximizing standardization of components Fiat Stilo (2001) New architecture New upperbody & interiors Integration of new powertrains Fiat Bravo (2007) Architecture carry-over Fully new upperbody & interiors R&D and Capex product-related spending (index) 100 Giulietta (2010) New architecture New upperbody & interiors Integration of new powertrains Lancia Delta (2008) Architecture carry-over Fully new upperbody Partial carry-over of interiors 50 41 32 April 21, 2010 Fiat Investor Day 13
Architecture sharing opportunities with Chrysler Segment architecture LCVs Mini Small Compact Architecture origin Fiat Group Large Chrysler Group MPV SUV Pick-up April 21, 2010 Fiat Investor Day 14
Worldwide architectures standardization strategy FGA worldwide + Chrysler Group Mini Small Compact 1 million units Each of the 3 main architectures exceeding 1mn unit mark by 2014 Fiat Group Chrysler Group April 21, 2010 Fiat Investor Day 15
Subsystems standardization HVAC example In 2006 we said 100% 80% 60% 40% 20% 0% Reduction in tooling and R&D expenditure through family standardization Now at 8 families and expect to step down to 4 by 2014 Grande Punto N. Doblò MiTo Punto EVO April 21, 2010 Fiat Investor Day 16
Common platform approach for next generation telematics Easy to scale with different contents, with ability to customize according each brand values, available worldwide Level A0 A B C D E G/H Brands High Mid Base + Entry April 21, 2010 Fiat Investor Day 17
Sub-system standardization Fiat Group Automobiles Number of families -37% -51% Average benefits 2010 vs. 2006 2014 vs. 2006 Variable costs - 4% - 6% Investments - 30% - 35% R&D - 55% - 65% April 21, 2010 Fiat Investor Day 18
Archetypes standardization Side doors example Inner panel FeP05 0.7mm Pillar reinforcement FEE275-1.5mm Inner panel FeP05 0.7mm Pillar reinforcement FEE275 1.5mm Inner panel in a single component FeP05 0.67mm / FEE 210 IF 1.3mm Inner panel FeP05 0.67mm Upper hinge reinforcement FEE340F 1.0mm Lower hinge reinforcement FEE340F 1.5mm Front door Front door Rear door Rear door Cost saving ( ) Investment saving ( ) Weight reduction (Kg) -6% -16% -8% April 21, 2010 Fiat Investor Day 19
Archetypes standardization Number of body archetypes 25 15 3 2006 2010E 2014E Average benefits 2010E vs. 2006 2014E vs. 2006 Savings on total body cost -2% -3% Savings on total body investments -4% -6% Body weight reduction -20 kg -30 kg April 21, 2010 Fiat Investor Day 20
Evolution to lighter vehicles while same performance -3% 4% -5% Weight reduction vs. previous standard 7% -9% 16% -12% 16% Hot pressed HSS April 21, 2010 Fiat Investor Day 21
Fiat product development: conclusions Synergies with Chrysler Group By 2014 Sharing of standardized architectures, components and sub-systems Sharing of know-how, best practices, tools in product development process Common innovation programs, particularly in area of alternative propulsion systems Clear division of roles and responsibilities to optimize capital expenses Total economic benefit coming from Fiat-Chrysler engineering synergies = 600mn Widespread adoption of modern standard and modular architectures Foster the convergence to 3 proprietary modular architectures (Mini, Small, Compact) Pursue standardization of sub-systems/systems pertaining to architecture perimeter More than 3mn cars on the 3 key architectures Only 2 additional architectures for LCVs and low cost cars Achieve maximum level of standardization on cross-architecture sub-systems /systems Further reduction by 20% of current number of different modules families Maximize volumes leverage through sourcing strategy Reduction vs. 2006 65% R&D costs 35% investments 6% variable costs April 21, 2010 Fiat Investor Day 22