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In our comprehensive cost analysis, FEV delved into the intricacies of NMC and LFP battery packs. Beyond technical aspects like energy density, we meticulously compared costs across all variants. Our findings provide actionable insights and strategic recommendations for your next steps in battery development.

In an increasingly competitive market, our client is looking to improve the cost structure of its battery management systems (BMS). FEV Consulting’s comprehensive study dissects not only the client’s BMS, but also those of two competitors. From tear-down reports to granular cost analysis, we examine functions, features, and potential cost reduction strategies.

FEV specializes in developing comprehensive cost models to drive critical decisions for future production. Our capabilities include scenario calculations for different battery applications, multiple cell configurations and production locations. We analyze manufacturing costs across specific regions, compare boundary conditions, and consider essential location factors such as CO2 footprint and subsidies.

FEV Consulting collaborated closely with the client to develop an innovative stationary energy storage system. Our approach included targeted cost analysis, design workshops, and continuous cost forecasting. By identifying and evaluating cost reduction ideas, we achieved significant results for our client’s energy storage solution.

FEV conducted a comprehensive benchmark of four light commercial vehicles, focusing on cost reduction and design enhancements. Our structured approach included complete teardowns, interdisciplinary design-to-value workshops, and detailed analysis across key criteria. The result: 241 actionable cost reduction ideas, including technical impact, implementation effort, risk assessment, and variable savings potential.

FEV Consulting conducted a target cost analysis for DC/DC converters to help our client obtain better pricing from their suppliers. Our analysis covered the entire converter, as well as the key components, such as the housing, the power board, and the control board. We also performed a scenario analysis with different production volume assumptions to help our clients optimize their budget. Our project helped our clients gain more insight into the true cost of their DC/DC converters and improve their negotiation power.

Our client wanted to offer the best value proposition for their new powertrain. To do this, they needed to understand how much customers valued different aspects of vehicle performance. We conducted a comprehensive study that measured customer preferences and willingness to pay for each performance indicator. We identified customer segments and relevant ranges for each indicator. We crafted a customized questionnaire that translated technical specifications into customer-friendly questions. The data was used to generate willingness-to-pay curves for each indicator.

We helped our client design a cost-effective drive system for textile machines to conquer the Asian market. We generated and evaluated dozens of innovative ideas, considering various aspects such as power, efficiency, durability, and cost. We delivered the best solution that met the client’s expectations and budget.

Our client wanted to understand the cost structure of a benchmark engine in their industry. We conducted a comprehensive teardown and technical analysis of the engine, involving experts from different disciplines. We provided a detailed report with high quality images and cost breakdowns for each component and subcomponent. We also identified key cost drivers and proposed design solutions to reduce costs for a new generation of engines.

Our client was developing a new global family of tractors, but was challenged to meet cost targets. We supported them with a holistic cost reduction and value improvement tool that tracked and analyzed over 500 actions across 6 representative vehicles. We also facilitated weekly workshops with over 50 participants from across the organization, resulting in validated bottom-up cost estimates and significant value improvements.

Our value improvement workshop series transformed the development of a global tractor family, resulting in cost savings of over 20%. Using holistic cost reduction tools, bottom-up cost estimates, and weekly meetings, we defined, tracked, and analyzed over 500 actions and engaged over 50 participants across the organization.

Our interdisciplinary team of experts conducted a sprint of cost reduction workshops for a manufacturer of commercial electric vehicle charging stations. We identified and evaluated redesign, technology, manufacturing, and sourcing opportunities that resulted in significant cost savings. Our collaboration with the client’s team of experts led to the prioritization of key ideas and defined next steps.

FEV Consulting’s client embarked on the development of a new battery electric vehicle, with target costing and cost monitoring as crucial components to achieve their goals. Our approach included an initial cost estimation for the entire vehicle, a breakdown of cost forecasts to sub-systems, and consideration of different system specifications and equipment features. We ensured the success of the project through continuous refinement, monitoring and regular cost reduction loops.

The FEV Consulting team performed a cost estimate for a Class 8 HD truck electric motor and inverter, providing the client with a better understanding of fair market value, cost drivers, and competitiveness. Through a teardown and analysis of the electric motor and inverter, we provided target costs, technology competitiveness assessments, and recommended cost reduction ideas.

FEV Consulting conducted a should-cost analysis and identified more than 20 cost reduction ideas for a state-of-the-art high-voltage traction inverter, helping the client reach their target cost. Ideas were classified into quick wins, mid-term, and long-term, with a qualitative assessment of savings potential, implementation effort, and risk.

Our team conducted a target cost estimation and gap analysis for a global tier-1 automotive supplier’s new EDU portfolio. We provided detailed should-cost and market-optimized costing, design assessment, and recommended technology selection strategies for each subsystem, resulting in leading insights and cost optimization.

FEV Consulting optimized the design of agricultural sprayers to meet stringent cost reduction targets. Through pre-analysis, idea generation workshops, and structured investigations, we generated 261 cost reduction and value improvement ideas. 20 top ideas were selected for technical and economic detailing, resulting in significant savings for the customer.