Fifth Annual DuPont Automotive/SAE Survey Results
2 March 1999
Fifth Annual DuPont Automotive/SAE Survey Results In ... Emissions Control, Safety Get Greater Attention as Cost Remains Top Concern
DETROIT, March 2 -- While cost reduction again topped the
list of challenges facing the automotive industry, the number of auto
engineers and designers who picked emissions and safety regulations as the top
challenge substantially increased from last year. These results come from the
fifth annual DuPont Automotive/SAE survey of automotive engineers and
designers who say they're attending the 1999 SAE International Congress and
Exposition in Detroit.
Thirty-one percent of survey respondents identified cost reduction as the
number one challenge facing the automotive design and engineering community.
Another 31 percent also identified cost as the top capability an OEM looks for
in a supplier.
The issue of cost consistently has topped this list for the past five
years. "The industry's emphasis on cost reduction has reduced vehicle prices
relative to consumer purchasing power," said Walter Fields, vice president of
automotive engineering materials, DuPont Automotive. He is referring to a
recent Comerica Bank study that reports the purchase of an average-priced new
vehicle last year required 24.6 weeks of median family income before taxes,
down 10 percent from two years ago.
"This shows how the automotive supply chain can come together to better
manage development programs and deliver real innovation that lowers final
product cost," said Fields.
"And these improvements add up to sustainable value that will keep
vehicles cost-competitive far into the future."
Regulatory issues emerge
New vehicle-emissions regulations coming onstream are of increasing
importance to engineers. Thirteen percent of those surveyed selected
emissions regulations as the number one challenge, up 62 percent from last
year.
"DuPont is committed to helping customers meet new California Air
Resources Board (CARB) evaporative-emissions regulations by providing advanced
permeation-resistant materials, such as Tefzel(R) fluoropolymer and Selar(R)
barrier resins for cost-effective applications that will effectively meet the
future needs of our customers," said Fields. These materials are used in
hoses and fuel-filler neck applications to resist permeation and resist static
build-up for greater safety.
Safety on the increase
Thirteen percent of respondents named safety regulations as the number one
challenge facing the auto industry, up 50 percent over last year. And as
automakers and government agencies explore the use of laminated safety glass
in side windows, DuPont introduced SentryGlas(R) Plus ionomeric interlayer,
which will deter vehicle thefts and allow manufacturers to meet glass-
performance standards at a reasonable cost. The FBI estimates forced entry is
responsible for $7 billion in motor vehicle theft and $1.5 billion in lost
articles. SentryGlas(R) Plus also can reduce the potential of passenger
ejection from a vehicle in an accident.
"It's time we stopped accepting the inherent fragility of glass," said
Fields. "Glass can be made stronger and safer at an excellent cost-benefit
ratio."
Innovation without cost penalty
"Systems integration, parts commonization and functional modularity are
the most effective means to drive innovation and lower costs," said Fields.
"Thermoplastics allow us to take full advantage of these design techniques."
Examples of how thermoplastics can help automotive engineers and designers
take advantage of these opportunities are on display during SAE at DuPont
Automotive booth #1700. They include:
* A power steering pump inlet, using DuPont Zytel(R) nylon for the Ford
Focus, reduces part count from 16 to one and creates significant savings.
* A Mercedes-Benz pedal-bracket plate, using Zytel(R) nylon, is common
for all nine A-Class compact models and reduces assembly and installation
costs.
* The 1999 Oldsmobile Intrigue ignition-cassette system, using DuPont
Rynite(R) PET polyester, eliminates high-voltage plug wires by integrating the
coils within the cassette. The result is significant cost savings through
simplified assembly and reduced power loss of 70 percent.
* The Generation III composite intake manifold, using Zytel(R) nylon for
GM's line-up of full-size trucks, features an integrated Helmholtz resonator,
but paves the way for further integration -- including air-cleaner elements,
throttle-body housings, fuel-rail elements, snap fits and twist locks.
* The Mercedes-Benz center-bolted rocker cover, using Zytel(R) nylon for
the Atego, Vario and Unimog, features an integrated oil separator, cutting
costs in half and weight by 40 percent compared to its predecessor.
Supplier partnering creates value
Bringing innovation to market without a cost penalty is achieved through
partnering within the various tiers that comprise the automotive supplier
community.
One example is illustrated through the development of North America's
first vibration-welded manifold, debuting on the Ford 5.4L engine. In just 14
months, a team from Ford, Montaplast of North America and DuPont was able to
develop a vibration-welded manifold using a new material -- Zytel(R) welding
enhanced nylon 66 -- which was introduced for this particular manufacturing
technique. The resulting manifold not only weighs less and performs better
than its aluminum predecessor, but also reduces cost.
Molded-in-color plastics arrives
Nearly half the survey respondents said molded-in-color plastics will be
used in more body exterior applications during the next five years.
Anticipating the need for improved products, DuPont introduced Surlyn(R)
Reflection(TM) Series supergloss alloy, which debuts on the model year 2000
Dodge and Plymouth Neon fascia. The new material complements the more
sophisticated look and feel of this new model.
With world headquarters in Troy, Mich., DuPont Automotive offers more than
100 product lines to the global automotive industry, including plastics,
advanced composites, finishes, fibers, fabricated products, refrigerants,
specialty chemicals and lubricants. DuPont worldwide automotive sales were
$4 billion in 1998.
Tefzel(R), Selar(R), SentryGlas(R) Plus, Zytel(R), Rynite(R) and Surlyn(R)
are registered trademarks of DuPont.
Reflection(TM) Series is a trademark of DuPont.