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Global market review of vehicleelectrical wiring systems – forecasts to 2013

2008 edition

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Global market review of vehicle electrical wiring systems – forecasts to 2013 2008 edition

By Matthew Beecham

December 2007

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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 ......................................................................................................................... 10

Global market ................................................................................................................. 10 Western European market.............................................................................................. 10 North American market................................................................................................... 11 Japanese market ............................................................................................................ 12 Korean market ................................................................................................................ 12

Market forecasts...................................................................................................................... 13

Chapter 3 Technical review.......................................................................................................... 19 Defining the elements ............................................................................................................. 19 Recent innovations.................................................................................................................. 20

Q&A with BERU F1 Systems.......................................................................................... 22

Chapter 4 Manufacturers.............................................................................................................. 26 Alcoa Electrical and Electronic Solutions................................................................................ 26


Page v Table of contents

Delphi Corp ............................................................................................................................. 28 Lear Corp ................................................................................................................................ 30 Leoni ....................................................................................................................................... 32 Sumitomo Wiring Systems...................................................................................................... 34 Yazaki Corp............................................................................................................................. 39


Page vi List of figures

List of figures

Figure 1: Global market shares for vehicle wire harnesses, 2006 (% of volume)........................... 10

Figure 2: Western European market shares for vehicle wire harnesses, 2006 (% of volume) ....... 11

Figure 3: North American market shares for vehicle wire harnesses, 2006 (% of volume) ............ 12

Figure 4: Japanese market shares for vehicle wire harnesses, 2006 (% of volume)...................... 12

Figure 5: Market value of wire harness by application, 2007 (% of total value).............................. 14


Page vii List of tables

List of tables

Table 1: Market value of wire harness by application, Europe, North America, Japan and China,

2003-2013 (EUR‘000s)............................................................................................. 15

Table 2: Alcoa Electrical and Electronic Solutions’ facilities worldwide .......................................... 26

Table 3: Lear Corp’s electrical and electronic production facilities ................................................. 31

Table 4: Sumitomo Wiring Systems’ automotive wire harness facilities worldwide ........................ 35

Table 5: Yazaki’s wire harness operations worldwide..................................................................... 39


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 2013. 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,


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.


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.


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


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 centrally-

located 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.


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


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