Door modules - Just-Auto.com

Door modules: market
trends, suppliers and
forecasts to 2010
2004 edition

Page i
Door modules: market trends,
suppliers and forecasts to 2010
2 nd edition
by Matthew Beecham
August 2004
Published by
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Page iii
Table of contents
Single-user licence edition............................................................................................................. ii
Copyright statement.................................................................................................................. ii
Table of contents ........................................................................................................................... iii
List of tables ................................................................................................................................... iv
List of figures .................................................................................................................................. v
Acknowledgements ....................................................................................................................... vi
just-auto.com’s research portfolio ..............................................................................................vii
Incredible ROI for your budget – single and multi-user licences..............................................vii
just-auto.com membership ......................................................................................................... viii
Chapter 1 Introduction.................................................................................................................... 1
What is a door module? ............................................................................................................ 1
Report coverage........................................................................................................................ 2
Chapter 2 The market ..................................................................................................................... 3
Market players........................................................................................................................... 3
Market shares ........................................................................................................................... 4
Market size................................................................................Error! Bookmark not defined.
Market value..............................................................................Error! Bookmark not defined.
Chapter 3 Manufacturers....................................................................Error! Bookmark not defined.
ArvinMeritor...............................................................................Error! Bookmark not defined.
Brose.........................................................................................Error! Bookmark not defined.
Delphi........................................................................................Error! Bookmark not defined.
Dura Automotive .......................................................................Error! Bookmark not defined.
Faurecia ....................................................................................Error! Bookmark not defined.
Grupo Antolin ............................................................................Error! Bookmark not defined.
Intier Automotive .......................................................................Error! Bookmark not defined.
Wagon.......................................................................................Error! Bookmark not defined.
Online sources of information ....................................................................................................... 8
Free email newsletters.............................................................................................................. 8
Other research reports.............................................................................................................. 8
Global news and feature articles...............................................................................................8
Search the web ......................................................................................................................... 8
Your feedback ................................................................................................................................. 9
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Page iv
List of tables
Table 1: Door module manufacturers’ product range........................................................................ 3
Table 2: Market fitment rate of door module cassettes for passenger cars and light trucks, 2001 -
2010 (% installation rate)............................................Error! Bookmark not defined.
Table 3: Market volume of door module cassettes for passenger cars and light trucks, 2001 - 2010
(‘000s units) ¹..............................................................Error! Bookmark not defined.
Table 4: Market value of door module cassettes for passenger cars and light trucks, 2001 - 2010
(€ millions) ¹ ................................................................Error! Bookmark not defined.
Table 5: Dura Automotive’s facilities worldwide ................................Error! Bookmark not defined.
© 2004 All content copyright Aroq Ltd. All rights reserved.

Page v
List of figures
Figure 1: European market shares of door modules, 2003 (% of volume)........................................ 4
Figure 2: Grupo Antolin’s Door Trim Module.....................................................................................6
Figure 3: Global market shares of door modules, 2003 (% of volume)............................................. 7
Figure 4: Average wholesale cost of a door module, 2004 (% of total cost per module).......... Error!
Bookmark not defined.
Figure 5: The door panel of the BMW X5 is manufactured at the Faurecia Fontain Inn site, US
....................................................................................Error! Bookmark not defined.
Figure 6: Preparation of the Renault Laguna door panel at Faurecia's Sandouville site, France
....................................................................................Error! Bookmark not defined.
© 2004 All content copyright Aroq Ltd. All rights reserved.

Page vi
Acknowledgements
The publishers would especially like to thank ArvinMeritor, Brose, Delphi, Dura
Automotive, Faurecia, and Grupo Antolin for their assistance in compiling this
report.
© 2004 All content copyright Aroq Ltd. All rights reserved.

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Chapter 1 Introduction Page 1
Chapter 1 Introduction
What is a door module?
A door module typically consists of a rubber-sealed carrier made from plastic
or metal. Aluminium and magnesium are also being considered by
manufacturers to reduce the weight of the carrier still further. A variety of door
components are then fitted onto the carrier, forming a ‘cassette’, such as the
window lift mechanism, locks, electric motor to operate the wing mirror, wiring
harness, various switches, loud speaker and a cable that connects the latch to
the inner release handle. The carrier plate is then tested and sealed to the
outer door.
The level of componentry however, can vary immensely from one trim level to
the next. Manufacturers typically carry 90 different part numbers for each of
the four doors. Whereas one model may offer a manual latch with central
locking, another may include an electric latch with super-locking. There are five
different types of latch offered for the Golf, for example. There are more than
200 front door module combinations alone, ranging from all-manual to allelectronic.
While the majority of door modules use a steel carrier, plastic solutions are
becoming increasingly popular. Over the past few years, there have been a
number of arguments ‘for’ and ‘against’ the use of plastic over steel carriers.
Delphi’s Superplug, for example, was a well-publicised effort to use a plastic
carrier. Klaus Caspers, programme manager for Delphi’s door modules, said:
“The technological advancement in new resins and manufacturing processes
for plastic carriers has evolved to the point where plastic is being more
favourably received as an alternative to steel. With the volatility of steel prices
in the market, OEMs are searching for alternative materials, and plastics is one
material that is being considered more favourably. More OEMs are considering
plastics and are not as quick to dismiss it as an alternative material to steel.”
The trend in both Europe and the US is toward increasing complexity of the
door componentry, adding more electronic functions and, in some cases, the
glass itself. VW and Porsche are arguably furthest down that route. Developed
by Brose, the door modules for the VW Touareg and Porsche Cayenne show
© 2004 All content copyright Aroq Ltd. All rights reserved.

Chapter 1 Introduction Page 2
the greatest extent of integration to date. These modules integrate xx% of all
door functions. Brose supplies these modules just-in-sequence to VW and
Porsche in up to 2,000 variants. Only the patented door outer shell is supplied
by the OEM.
There are still some significant hurdles to cross before the industry sees the
complete door in volume production. Manufacturers forecast that the demand
for complete door modules will gain greater application as soon as the inherent
paint, fit and finish problems are resolved as well as the problems in supplier
participation in unionised OEM plants.
The slick way in which the door systems are assembled and despatched
masks some heavily intricate planning on the part of suppliers. For example, at
Brose, orders for the door system variants are sent from Ford’s assembly site
in Saarlouis, Germany, then sent electronically to the supplier’s nearby plant in
Saarwellingen. At each of the four production lines in Saarwellingen, a
computer prints an order for each new door system. This order sheet
accompanies the product throughout the entire assembly process. Barcode
scanning and picture recognition ensure that the correct components are
assembled depending on the variant required. The functionality of every single
door system is tested at the inspection station at the end of the assembly line.
Once packed in special containers, the products are loaded via an automated
system onto the trucks and subsequently transported to the Ford plant.
Report coverage
In this second edition reviewing the key market for door modules, we extend
our forecasts to 2010, providing market fitment, volume and value data for this
fast-growing sector. Chapter two also identifies the main players in the door
module market, and their market shares in Europe and North America.
Chapter three provides brief profiles of the major door module manufacturers,
namely ArvinMeritor, Brose, Delphi, Dura Automotive, Faurecia, Intier and
Wagon.
© 2004 All content copyright Aroq Ltd. All rights reserved.

Chapter 2 The market Page 3
Chapter 2 The market
Market players
Most of the major suppliers pitching for door module business have their
origins in either window regulators or plastic interior trim. Brose, Kuester,
Grupo Antolin, Dura, Lames and ArvinMeritor all have a strong tradition in the
window regulator business.
Brose began expanding its window regulator business into door modules in the
1980s. Today, the group has a xx% share of the world market for window
regulators and a xx% share of the European market. It also has a xx% share of
the European power seat adjuster market. In the US, Brose has a xx% share
of the window regulator and xx% share of the door system markets.
Table 1 indicates the main products offered by the various market participants.
Table 1: Door module manufacturers’ product range
Manufacturer
ArvinMeritor
Brose
Delphi
Dura Automotive
Faurecia
Grupo Antolin
Intier
Wagon
Door module offering
Door modules feature power double-lift window regulators with anti-squeeze and super-locking
actuators.
Since 2002, Brose has been supplying door systems with the frame, glass, seal and a part of
the door structure.
Delphi’s modular door systems feature integrated sub-systems, which make up the entire door
system. Major door system components include the trim elements, moveable side glass,
window lift, electrics and electronics, latching, switches and climate control features.
Dura’s structural door module products include aluminum and steel body-in-white door
modules, side impact beams, power and manual window lift systems, anti-pinch window lift
systems.
Faurecia's door modules include a variety of electrical and electronic elements, including
locking systems, airbags, lateral shock absorbers, cables and loudspeakers.
Grupo Antolin’s door functions include door panels, window regulators, and accessories.
Intier’s closures product expertise includes complete door systems; system module
technologies including mid-doors, sliding doors, electro-mechanical systems, window regulator
systems and latching systems.
Wagon’s door system range includes doorframe modules (in aluminium or steel), door
structures and sliding doors. Wagon also supplies complete or semi-complete door structures,
which are assembled as part of the car body at the trackside.
Source: just-auto.com
© 2004 All content copyright Aroq Ltd. All rights reserved.

Chapter 2 The market Page 4
Market shares
The main suppliers of steel and plastic door module carriers in Europe are
Brose, ArvinMeritor, Lames, Kuester, and Faurecia.
Figure 1: European market shares of door modules, 2003 (% of volume)
%
Brose
ArvinMeritor
Faurecia
Kuester
Lames
Others
Sources: just-auto.com; industry estimates.
Brose expects to report sales of €xx billion by 20xx, up from €xx billion in 2003.
By 2005, the company expects for the first time to earn more revenues from
abroad than in Germany. Over the next few years, Brose plans to pursue its
international strategy, stepping up its activities in Europe and North America.
In fact, Brose regards North America as a major growth market. The company
began its activities there in 1993 and succeeded in posting annual double-digit
growth. In 2003, the company generated sales of US$xxx million in North
America. By 20xx, Brose expects to achieve sales of US$xxx million. In order
to meet its targets, the company is investing some US$xxx million in building
© 2004 All content copyright Aroq Ltd. All rights reserved.

Chapter 2 The market Page 5
three new production sites in Chicago, Tuscaloosa and London (Canada) plus
a new headquarters in Detroit. The company already operates plants in
Queretaro and Puebla in Mexico. The company is also planning to enter the
North America seat adjuster market in 20xx. From 20xx, Brose will be
producing mechanical and power seat height adjusters at its new plant in
London, Canada. By 20xx, Brose anticipates to generate sales of US$xxx
million in this business division. Brose’s window regulator business in North
America is also growing.
Brose’s power window regulators have been offered in the US since 2000.
Today, Brose equips six American car models with these systems and is
currently working on nine customer projects involving window regulators with
an anti-trap feature. just-auto.com predicts at least xx% penetration of antipinch
windows in the North American market by 20xx. A spokesman for Brose
told us: “We see more and more cars being developed in the US with the antitrap
devices. In the long-run, we expect all cars to have those safety devices -
as it is the case in Europe, North America is a main growth market for Brose.”
Brose expects to generate sales of US$xxx million from its North American
window regulator business by 20xx.
Over the past few years, Grupo Antolin has seen a huge increase in its doortrim
module business thanks to an order to supply the new Renault Megane.
The Megane deal is its first major door module contract. In 2004, Grupo
Antolin will also supply door modules to SEAT and there are possibilities to
supply DaimlerChrysler in the US, and Ford in the US & Europe. The group is
currently promoting its DTM (Door Trim Module) concept. The module includes
the inside handle, window regulator, loudspeaker, latch, wiring harness,
sealing system and passive safety. The company believes it can cut costs by
integrating door-trim and mechanical elements to deliver. In 2003, the
company introduced three new door modules into the US market, of which two
were for Ford and one for DaimlerChrysler.
© 2004 All content copyright Aroq Ltd. All rights reserved.

Chapter 2 The market Page 6
Figure 2: Grupo Antolin’s Door Trim Module
Source: Grupo Antolin
ArvinMeritor claims an xx% share of the door system market in North America,
ranking it in third place. ArvinMeritor manufactures more than xx million
window regulators, and one million door modules annually. The company’s
Door Systems group is also a world leader in the supply of door latches. The
company produces more than xx million side door, trunk, tailgate, hood and
sliding door latches annually. The group also supplies millions of electrical
actuators for use in modular power locking latches and other automotive
applications, including electrical door releases, powered door closures and
electrical fuel flap operation.
ArvinMeritor recently won a contract to supply one million door modules
annually for two of Hyundai’s platforms, beginning production in Montgomery,
US in 2005. The finished door module will include a window regulator, latch,
motor, loudspeaker and wire harness integrated into one system that will be
© 2004 All content copyright Aroq Ltd. All rights reserved.

Chapter 2 The market Page 7
line sequenced into Hyundai’s production schedule. To ensure just-in-time
delivery, ArvinMeritor plans to open a new Customer Value Centre for final
assembly in Montgomery, Alabama, US. ArvinMeritor is currently a partner
with Pyeong Hwa Automotive to supply door modules for Hyundai’s production
of the Santa Fe, Sonata and Grandeur models in Korea.
On the global stage, Brose is reckoned to lead the market for door modules
with a 40% share, followed, by ArvinMeritor, Delphi, Intier and others.
Delphi supply door modules to a number of vehicle makers, including General
Motors, DaimlerChrysler, Isuzu and International NGV. Its modules are fitted to
a number of models, including the Chevrolet Malibu and Buick Park Avenue.
Figure 3: Global market shares of door modules, 2003 (% of volume)
%
Brose
ArvinMeritor
Delphi
Intier
Others
Sources: just-auto.com; industry estimates.
© 2004 All content copyright Aroq Ltd. All rights reserved.

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