15Th Global Car Body Benchmarking Conference

15Th Global Car Body Benchmarking Conference

EuroCarBody 2013

15th Global Car Body Benchmarking Conference

Car body benchmarking data summary


0. General vehicle data

OEM brand:


Presented car model


0. General vehicle data, dimensions

Generation No.:____

Internal OEM denomination:______

SOP (month/year):______/______

Vehicle segment according to European Commission 2002:
(A, B, C, D, E, F, S, M, J)___

Vehicle dimensions:

Length: ___,______m



Track, front:___,______m

Track, rear:___,______m


Contact area

= (Track, front + Track, rear)/2 x wheelbase__,______m2

1. Weights

Total weight body-in-white: ______kg

Defined as the total weight of the car body including doors and closures, as well as all parts that are fitted in the body shop (e.g. integrated bumper beams), excluding paint.

Corresponding exploded view:

(The colour scheme of the parts shown should make use of the RGB colour code suggested for the material classification, see section 2.)

If applicable as extra parts:

Weights of separate subframes, front end modules, etc.

Part descriptionCorresponding viewWeight





Body-in-white weights of doors, closures and fenders

Front doors (both):______kg

Rear doors (both):______kg



Front fenders (both):______kg

Front end modules: ______kg

Total weight body-in-white without doors, closures and fenders: ______kg

2. Material mix in the body-in-white including doors and closures

Based on metallurgical/chemical material classes

Materials: corresponding metallurgical classes / RGB colour code / %
Steels / Low Strength Steels: Mild steels / R 153, G 204, B 255
High Strength Steels (HSS):
High Strength Interstitial-free Steels (HSIF), Bake Hardening Steels (BH), High Strength Low Alloy Steels (HSLA) / R 051, G 102, B 255
Advanced High Strength Steels (AHSS):
Dual Phase Steels (DP), Transformation Induced Plasticity Steels (TRIP) / R 255, G 153, B 204
Stainless steels: Austenitic stainless steels / R 051, G 051, B 153
Ultra High Strength Steels (UHSS):
Complex Phase Steels (CP), Martensitic Steels (MS) / R 204, G 153, B 255
Press Hardened Steels (PHS) / R 128, G 000, B 128
Aluminium / Aluminium sheets: 7xxx series / R 051, G 204, B 153
Aluminium sheets: 6xxx series / R 000, G 255, B 000
Aluminium sheets: 5xxx series / R 204, G 255, B 204
Aluminium extrusion profiles / R 153, G 204, B 000
Cast aluminium / R 051, G 153, B 102
Magnesium / R 255, G 255, B 000
Plastics / Fibre reinforced plastics / R 255, G 000, B 000
Duroplastics, including Sheet Molding Compound (SMC) / R 255, G 153, B 000
Thermoplastics / R 153, G 051, B 000
Other materials, namely:____________/ R 192, G 192, B 192

Corresponding view of the body-in-white using the colour scheme explained in the table:

Current Audi A3

The following graph may serve as a guide to locate the properties of the metallurgical steel classes:

3. Stiffness data

Measured / Calculated

1st Eigenfrequency trimmed body:______Hz

2nd Eigenfrequency trimmed body:______Hz

1st Eigenfrequency body*:______Hz

2nd Eigenfrequency body*:______Hz

*Parts included in the measurement/calculation of the body frequencies:



Static torsional stiffness______Nm/°

Static bend stiffness______Nm/mm

4. Joining processes

used in the body shop, including all bought-in parts and sub-assemblies

Joining techniqueNumber of joints WeldspotCalculation

or length of seamsequivalents


Spot welds______1:1

Arc welding_____.___ m______20 mm = 1 WSE

Friction stir welding_____.___ m______20 mm = 1 WSE

Laser welding_____.___ m______15 mm = 1 WSE

Conventional brazing_____.___ m______20 mm = 1 WSE

Laser brazing_____.___ m______30 mm = 1 WSE

Adhesive joining (total)_____.___ m______50 mm = 1 WSE


structural adhesive_____.___ m______

supporting adhesive_____.___ m______

hemming adhesive_____.___ m______

sealing adhesive_____.___ m______

Rivets______1 joint = 1 WSE

Clinch-spots______1 joint = 1 WSE

Friction stir spot welds_____.___ m______1 joint = 1 WSE

Screws (incl. flow drills)______1 joint = 1 WSE

Total WSE______

5. Production concept

Process stability/availability:______%

= total up-time in the body shop

Re-tooling or re-use factor:______%

= [1 – Project investment excluding operational costs / “all new“] x 100

with „all new“ = Value of the total installed investment

Degree of mechanisation:______%

= Automated Work Content* / Total Work Content*

* Work Content refers to the sum of Standardized Work Contents in the Body Shop, calculated according to the Harbour Report system, excluding lay-in operations, handling of parts, logistic operations

Bodyshop-Index BSI______[€ x hour/car unit /WSE]

* as calculated in section 5

No. of production sites:______
namely in: ______


Intended production volume:______units/year

Car body production lead time:______.__ minutes
= the time spent by the unit in the body shop, from the start of the first underbody parts to the handing over of the body-in-white to the paint shop, including
car body interim storage**

** More accurate definition (Harbour):

  • Start counting when work begins at the first station of the underbody (motor compartment or rear floor, whichever station begins first).
  • The end of the measurement is the beginning of the delivery from body in white to the paint shop. If the vehicle changes skids or pallets, the process ends as soon as the vehicle leaves the original pallet. If the vehicle is going on a lift to transfer to the paint shop, the process ends as soon as the body in white is in final position to begin transfer.

Cycle time (mainline bodyshop):______seconds

Degree of material utilisation: ______%

= 100% - scrap rate

(Sheet only, inhouse parts only, not including laser welded blanks)

Total number of parts in the BIW:______

Number of parts, including external parts, in weight classes

< 100 g:______

100 g - 1 kg:______

1 kg - 5 kg:______

> 5 kg:______

(all assemblies broken down into their component parts)

6. Targeted market regions and origin of build…

….of the vehicle presented at the EuroCarBody:

Targeted market region(s):______

Origin of build:______

7. Development strategies / initial propositions

Specific aims of the development:




Specific improvements reached compared to the predecessor (e.g. in weight, in stiffness):




8. Damage and repair strategy

Qualitative description of the repair strategy:



Engine variantInsurance classification





RCAR basket of parts*:



* Parts to be repaired after a standardised RCAR low speed (15 km/h) offset insurance crash (front and rear, respectively). See
If other tests (e.g. special in-house tests) are referred to, please specify them.

9. Additional information:

Crash performance data (if available at the time of the presentation):


No. of stars_____

Total percentage_____ %

Adult_____ Pts. =_____ %

Front _____ Pts. =_____ %

Side_____ Pts. =_____ %

Pole_____ Pts. =_____ %

Rear_____ Pts. =_____ %

Child_____ Pts. =_____ %

Pedestrian_____ Pts. =_____ %

Safety Assist_____ Pts. =_____ %

Other test results:


Development time: ______months

= time from design freeze to SOP/job one