An Assessment of Mass Reduction Opportunities for a 2017 – 2020 Model Year Vehicle Program Prepared by: Lotus Engineering Inc. Submitted to: The International Council on Clean Transportation March 2010 Rev 006A Table of Contents 1. EXECUTIVE SUMMARY....................................................................................................................6 2. NOMENCLATURE...............................................................................................................................9 3. INTRODUCTION................................................................................................................................20 4. WORKSCOPE .....................................................................................................................................22 4.1. Methodology .............................................................................................................22 5. BODY STRUCTURE ..........................................................................................................................26 5.1. Overview...................................................................................................................26 5.2. Trends.......................................................................................................................26 5.3. Benchmarking...........................................................................................................30 5.4. Analysis.....................................................................................................................31 5.4.1. Baseline Body...........................................................................................................31 5.4.2. Low Development .....................................................................................................34 5.4.3. High Development ....................................................................................................36 5.5. Results......................................................................................................................46 5.5.1. Low Development .....................................................................................................46 5.5.2. High Development Summary....................................................................................46 5.5.3. Body Structure Mass Distribution by Material...........................................................48 6. CLOSURES..........................................................................................................................................50 6.1. Closures (Doors, Hood, Liftgate) Overview..............................................................50 6.2. Trends.......................................................................................................................50 6.3. Benchmarking...........................................................................................................51 6.4. Analysis.....................................................................................................................55 6.4.1. Low Development .....................................................................................................55 6.4.2. High Development ....................................................................................................59 6.5. Results......................................................................................................................63 6.5.1. Low Development .....................................................................................................63 6.5.2. High Development ....................................................................................................65 6.5.3. Closure Mass Distribution by Material ......................................................................67 7. FRONT AND REAR BUMPERS .......................................................................................................71 7.1. Overview...................................................................................................................71 7.2. Trends.......................................................................................................................71 7.3. Benchmarking...........................................................................................................71 7.4. Analysis.....................................................................................................................73 7.5. Results......................................................................................................................73 8. GLAZING (WINDSHIELD, BACKLIGHT, DOORS, SUNROOF, FIXED) ................................74 8.1. Overview...................................................................................................................74 8.2. Trends.......................................................................................................................74 8.3. Benchmarking...........................................................................................................74 8.4. Analysis.....................................................................................................................74 8.4.1. Low Development .....................................................................................................74 8.4.2. High Development ....................................................................................................75 8.5. Results......................................................................................................................75 8.5.1. Low and High Development .....................................................................................75 9. INTERIOR ...........................................................................................................................................76 9.1. Overview...................................................................................................................76 9.2. Seats.........................................................................................................................79 2 9.2.1. Seat Trends ..............................................................................................................79 9.2.2. Seat Benchmarking ..................................................................................................91 9.2.3. Seat Analysis ............................................................................................................93 9.2.4. Seat Results ...........................................................................................................103 9.2.4.1. Low Development Drivers Seat ..............................................................................103 9.2.4.2. High Development Drivers Seat .............................................................................104 9.2.4.3. Low Development Front Passenger Seat...............................................................105 9.2.4.4. High Development Front Passenger Seat ..............................................................106 9.2.4.5. Low Development Rear Seat..................................................................................107 9.2.4.6. High Development Rear Seat.................................................................................108 9.3. Instrument Panel, Console and Insulation..............................................................109 9.3.1. Instrument Panel, Console and Insulation Trends .................................................109 9.3.2 Instrument Panel | Console | Insulation Benchmarking..........................................122 9.3.3 Instrument Panel, Console and Insulation Analysis ...............................................124 9.3.4 Instrument Panel, Console and Insulation Results.................................................138 9.3.4.1 Low Development Instrument Panel, Console and Insulation................................138 9.3.4.2 High Development Instrument Panel, Console and Insulation...............................140 9.3.4.3 Low Development Center Console.........................................................................141 9.3.4.4 High Development Center Console ........................................................................141 9.3.4.5 Low and High Development Noise Insulation.........................................................142 9.4. Interior Trim ............................................................................................................143 9.4.1 Interior Trim Trends ................................................................................................143 9.4.2 Hard Trim Benchmarking........................................................................................145 9.4.3 Interior Trim Analysis ..............................................................................................147 9.4.4 Interior Trim Results ...............................................................................................153 9.4.4.1 Low Development Interior Trim ..............................................................................153 9.4.4.2 High Development Interior Trim..............................................................................155 9.5. Control Systems .....................................................................................................156 9.5.1 Control System Trends...........................................................................................156