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The ability to make accurate decisions concerning early body-in-white architectures is critical to an automaker since these decisions often have long term cost and weight impacts. We address this need with a methodology which can be used to assist in body architecture decisions using process-based technical cost modeling (TCM) as a filter to evaluate alternate designs. Despite the data limitations of early design concepts, TCM can be used to identify key trends for cost-effectiveness between design variants. A compact body-in-white architecture will be used as a case study to illustrate this technique. The baseline steel structure will be compared to several alternate aluminum intensive structures in the context of production volume.

One of the many challenges facing electronic 1 system architects is how to provide a cost estimate related to design decisions over the entire life-cycle and product line of the architecture. Various cost modeling techniques may be used to perform this estimation. However, the estimation is often done in an ad-hoc manner, based on specific design scenarios or business assumptions. This situation may yield an unfair comparison of architectural alternatives due to the limited scope of the evaluation. A preferred estimation method would involve rigorous cost modeling based on architectural design cost drivers similar to those used in the manufacturing (e.g. process-based technical cost modeling) or in the enterprise software domain (e.g. COCOMO). This paper describes an initial study of a cost model associated with automotive electronic system architecture.