This article presents a design for manufacturing and assembly (DFMA) methodology for estimating the capital costs of new, emerging energy technologies built at varying rates of mass-production. The methodology consists of four major steps: (1) System Conceptual Design, (2) System Physical Design, (3) Cost Modeling, and (4) Continuous Improvement to Reduce Cost. The article describes the application of this methodology to a specific case study of automotive fuel cell systems (FCSs). Because any alternative automotive technology must compete with the very mature and widespread gasoline internal combustion engine, it is vitally important to identify the performance, design, and manufacturing conditions needed to reduce automotive FCS costs. Thus, a DFMA-style analysis is applied to the cost to manufacture a polymer electrolyte membrane (PEM) FCS for cars, at varying rates of production (between 1,000 and 500,000 vehicles per year). The results of this kind of DFMA-style analysis can be used to elucidate key cost drivers at varying levels of production for new energy technologies.

References

References
1.
2.
Jacobson
,
M. Z.
,
Colella
,
W. G.
, and
Golden
,
D. M.
,
2005
, “
Cleaning the Air and Improving Health With Hydrogen Fuel Cell Vehicles
,”
Science
,
308
(
5730
), pp.
1901
1905
.10.1126/science.1109157
3.
Colella
,
W. G.
,
Jacobson
,
M. Z.
, and
Golden
,
D. M.
,
2005
, “
Switching to a U.S. Hydrogen Fuel Cell Vehicle Fleet: The Resultant Change in Energy Use, Emissions, and Global Warming Gases
,”
J. Power Sources
,
150
, pp.
150
181
.10.1016/j.jpowsour.2005.05.092
4.
Blake
,
G. D.
,
2010
, “
Solid Oxide Fuel Cell Development for Transportation and Stationary Applications: Overview & Status Update
,”
2010 Advanced Energy Conference
.
5.
“Japan Railway on Track to Test Pollution-Free Fuel Cell
,” New York Times, April 14th, 2006.
6.
Colella
,
W. G.
,
2000
, “
Market Prospects, Design Features, and Performance of a Fuel Cell Powered Scooter
,”
J. Power Sources
,
86
, pp.
255
260
.10.1016/S0378-7753(99)00486-3
7.
Colella
,
W. G.
,
2010
, “
Designing Energy Supply Chains Based on Hydrogen
,”
Climate Change Science and Policy
,
S. H.
Schneider
,
A.
Rosencranz
, and
M. D.
Mastrandrea
, eds.,
2nd ed.
,
Island Press
,
Washington, D.C.
, pp.
456
466
.
8.
Boothroyd
,
G.
,
Dewhurst
,
P.
, and
Knight
,
W.
,
2011
,
Product Design for Manufacture and Assembly
,
3rd ed.
,
CRC Press and Taylor & Francis Group LLC
,
Boca Raton, FL
.
9.
James
,
B. D.
, and
Spisak
,
A. B.
,
2012
, “
Mass Production Cost Estimation of Direct H2 PEM Fuel Cell Systems for Transportation Applications: 2012 Update
,” report by Strategic Analysis, Inc., under Award Number DE-EE0005236 for the US Department of Energy, 18 Oct. 2012.
10.
James
,
B. D.
,
Moton
,
J. M.
,
Colella
,
W. G.
,
2013
, “
Fuel Cell Transportation Cost Analysis,
” U.S. DOE's 2013 Annual Merit Review and Peer Evaluation Meeting (AMR) for the Hydrogen and Fuel Cells Program, Arlington, VA, May 13–17.
11.
Ross
,
S.
,
Westerfield
,
R.
,
Jaffe
,
J.
,
Jordan
,
B. D.
,
2010
,
Corporate Finance: Core Principles and Application
,
McGraw-Hill Inc.
,
New York
.
You do not currently have access to this content.