Efficient Modular Platform 2

The New Vehicle Platform by PSA Peugeot Citroën

Platform: definition and purpose

A platform is a modular vehicle base at the core of new model design and production.

A platform equipped with a powertrain represents 60% of a vehicle’s production cost. It comprises all functions not specific to a specific body style, including:

The underbody.
The suspension system.
The appropriate powertrain.
The core electric and electronic architecture.

From this single platform, PSA Peugeot Citroën is able to develop a wide variety of body styles across several segments that are tailored to its different global markets. These include four and five door sedans, station wagons, MPVs, notchbacks, SUVs, cabriolets and coupés.

Critical role in automobile manufacturing

The platform policy initiated by PSA Peugeot Citroën in 1998 makes it possible to produce a wide variety of models, accelerate launch schedules and optimise capacity utilisation.

Platforms play a critical role in:

Guaranteeing a competitive set of features.
Sharing and streamlining product and process design.
Speeding replacement schedules.
Diversifying the vehicle line-up to suit different markets.
Generating economies of scale.

In addition, platforms provide powerful leverage in terms of mass, consumption, quality and cost competitiveness.

PSA Peugeot Citroën’s current platforms
At present, Peugeot and Citroën brand models mainly use three PSA Peugeot Citroën proprietary platforms. This does not include the shared platforms with Fiat, Toyota or Mitsubishi developed under cooperation agreements.

Platform 1 (PF1) currently covers the B1, B2 and C entry segments (Peugeot 301 and Citroën C Elysée) and will soon cover the B-SUV segment (Peugeot 2008).
PF1 isused in Group manufacturing facilities around the world (Poissy, Mulhouse, Aulnay, Madrid, Vigo, Trnava, Buenos Aires, Porto Real and Wuhan), but remains deeply rooted in France and the rest of Europe.
Platform 2 (PF2), which focused initially on C segment sedans, has evolved to handle multiple body styles (MPVs, light commercial vehicles such as the Citroën Berlingo and Peugeot Partner, and SUVs). Most recently, it was expanded to cover the D segment with the Citroën DS5.PF2 is used at Sochaux, Vigo, Mulhouse, Mangualde, Wuhan and Buenos Aires. It has been deployed at the Kaluga plant in Russia and will soon come on stream at the Shenzhen plant in China as part of the Group's new joint venture.
Platform 3 (PF3) is dedicated to D and E segment executive models produced in Rennes for the European and Overseas market and in Wuhan for the Chinese market.

Efficient Modular Platform 2 (EMP2): a new generation modular platform

The modular EMP2 platform will allow the Group to develop a diversified worldwide product line-up

The combination of advanced modularity and broad dimensional coverage allows for completely new combinations:

Four different track widths
Five wheelbases
Two cockpit and cowl solutions
Two rear suspension architectures (deformable beam and multi-link)
A variety of rear-unit modules for different versions (short, long, five or seven seats, independent or bench seats, internal combustion engine or hybrid, etc.).
Increased manufacturing flexibility, notably at the body-in-white stage, allowing for up to six rear unit versions on a single line.

Operational in 2013, the new generation EMP2 platform is scheduled to gradually replace PF2 and PF3 by handling new C and D segment launches.

Ultimately, EMP2 is expected to cover half of Peugeot and Citroën vehicle sales worldwide.

EMP2 will enhance the competitiveness of new Peugeot and Citroën models thanks to:

An advanced "design to cost” approach, where each function is optimised.
The selection of equipment with the best quality and features for the money.
A best-in-class manufacturing process.
Mass purchasing.
High local content in China from the start.

EMP2 continues the drive to reduce the mass and CO2 emissions of future models

EMP2 focuses on slimming down future vehicles, with an exceptional average weight reduction of 70 kg for the platform’s technical aspects alone thanks to a virtuous product-process design featuring:

Widespread use of innovative, lighter weight materials, including very high strength steel, composite materials and aluminium.
Leading-edge forming and assembly processes (hot stamping, flexible rolling for variable thickness, hydroforming and laser welding).
Adaptable, downsized modules.

EMP2 also benefits from effective and efficient technological choices to reduce CO2 emissions. These include:

Engine optimisation (torque, power, friction)
Selective Catalytic Reduction (SCR) technology to reduce powertrain emissions for Euro 6-compliant diesels
Massive deployment of Stop & Start systems
Reduced friction (notably for brakes and with the use of ultra low rolling resistance tyres)
Enhanced aerodynamics

These efforts to achieve a significant reduction in weight and CO2 emissions will deliver an average 22% decline in fuel consumption for future EMP2 vehicles.

EMP2 offers:

Full coverage of worldwide body styles in the C and D segments.
A modular design that optimises invested resources.
Lighter weight vehicles and lower fuel consumption.
Innovative technological choices for constantly improved features.
Process choices informed by PSA Peugeot Citroën’s lean manufacturing expertise, for manufacturing flexibility and optimum quality of finish.

EMP2: a new platform to meet customer expectations

What isn’t visible has a major impact on what the customer does see.

Architecture and equipment choices for an even more attractive package of features

Whether to reduce vehicle weight (to deliver performance and driving pleasure) or to enhance features, PSA Peugeot Citroën has chosen exclusive architectures and innovative technologies for the customer’s benefit. These include:

Electric power steering compatible with the City-Park function, combined with an improved turning radius for unparalleled manoeuvrability.
An isolated engine cradle to reduce running noise.
Motorised callipers for a lighter, nimbler and quieter braking system.
The latest generation Electronic Stability Programme (ESP9) with three integrated sensors, compatible with future driving assistance systems (FARC and ACC-Stop).
New manual gearbox controls, for smoother shifting.
A quieter air conditioning system.
An enhanced deformable-beam rear suspension architecture for greater comfort when driving over bumps.
Quieter third-generation bearings.
Low tyre pressure sensors on all models for greater safety, longer tyre life and lower fuel consumption.
IXH heat exchangers for more effective and efficient air conditioning.
A new architecture for façade-mounted cooling, which clips on for easier repairs. This architecture also features off-centre cooling of turbocharger air to enhance the efficiency of turbo engines and promote optimal use of engine power in specific circumstances (power, maximum speed, towing).

New equipment and new processes also take the quality of Peugeot and Citroën vehicles to a higher level. Among them:

A new electrical system architecture (fuses, grounding, enhanced wiring and smart fuse box for managing battery issues).
Assembly kits for underbody components.
Use of toolless self-locking couplings for more reliable floor sealing.
New front and rear suspensions resulting in less tyre wear and brake noise.

Responses to future styling trends are already in EMP2’s DNA

EMP2 offers new vehicle proportions and greater styling potential, with:

A visual reduction in front overhang achieved by creating a more compact front module and advancing the centre of the wheel to allow for the use of large wheels—an attractive styling option that delivers a modern look and expresses performance.
Maximum wheel size above 700 mm and enhanced maximum track width (35 mm more than PF3)to highlight the wheels on all body styles (SUVs, sedans, etc.)
A wide range of wheelbase choices and a larger maximum wheelbase.
More compact use of space under the bonnet (up to 50 mm) and lower floor and ride height (up to 20 mm), to create low, efficient body styles without compromising spaciousness and visibility.

This move towards a more compact platform will offer appreciable flexibility for meeting future styling trends.

Impact on manufacturing facilities

Eight European production facilities involved

Process engineering for EMP2 is already completedat the Vigo and Sochaux assembly plants, which will produce the platform’s first two body styles.

Production has been launched in most of the upstream plants that manufacture pressed sections and mechanical components for suspension systems.

Sites directly concerned by the EMP2 platform in early 2013 include:

Sept-Fons foundry: brake discs.
Charleville foundry: cast iron front suspension pivots, Engine subframe aluminium front mounting casting and machining
Mulhouse metallurgical plant: hub and drive-shaft components forging.
Caen mechanical component plant: assembly and welding of subframe and front suspension wishbones, machining of pivots and brake discs, production of drive-shaft
Mulhouse mechanical component plant: assembly and welding of subframe and rear crossmembers, machining of brake discs, hubs and pivots, assembly of front Hub units.
St-Ouen plant: hot stamping.
Mulhouse and Rennes assembly plants: hot stamping.
Sochaux assembly plant: hot stamping, body-in-white, painting, assembly.

Best-in-class processes

Optimised body-in-white and assembly

Fully robotised body-in-white workshop setting the benchmark, for 55 vehicles per hour.
Supply chain flows improved by rationalising floor space and grouping loading operations together.
Optimised assembly time and ease.
Supply chain flows improved by small package deliveries.

The same versatile installations from one site to another

The virtually simultaneous launch at Sochaux and Vigo of two major body styles using the EMP2 platform has made it possible to take the variety of configurations offered by the platform into account from the beginning of the project and develop versatile processes for these variations that can be replicated at the different production sites.

Improved working conditions

Improving ergonomics and working conditions was a key concern throughout the project.

The most significant change concerns underbody work, which is one of the most strenuous parts of the assembly process.Above-the-head movements have been reduced by 80% by preparing parts in the mechanical area and docking them under the body during assembly.

Efficient Modular Platform - EMP2 summary

1. A modular architecture to meet the specific expectations of our main markets

From this single platform, PSA Peugeot Citroën will be able to develop a wide variety of body styles across several segments that are tailored to its different global markets. These include four and five door sedans, station wagons, MPVs, notchbacks, SUVs, cabriolets and coupés.

2. Broad powertrain selection on a single platform

Four-cylinder, hybrid, and four-wheel drive powertrains will also be available on this platform.

3. Substantial reductions in mass and CO2 emissions:

CO2 emissions cut by 13 g, mass reduced by 70 to 80kg, one less full tank a month

Through the use of lighter weight, innovative materials such as steel, composites and aluminium for suspension systems, as well as cutting-edge processes like hot stamping and laser welding, EMP 2 will make it possible to reducemass and CO2, while improving rigidity, safety and driving pleasure. Thanks to the potential of SCR technology to reduce NOx emission levels, EMP 2 is technically Euro 7 compliant.With these low-carbon modules, PSA Peugeot Citroën is strengthening its CO2leadership.

4. Innovative technological choices to support the upmarket strategy for future Peugeot and Citroën models

With solutions ranging from composite floors to ultra low rolling resistance tyres, EMP 2 will allow the Group to offer vehicleswith the most up-to-date equipment and features (new suspension systems, smooth steering and nimble handling, passenger compartment comfort, enhanced safety, etc.).

5. Greater stylistic freedom

EMP 2 offers greater flexibility to respond to new styling trends such as large wheels on all four corners, low body styles and low ride heights, regardless of the model (SUV, sedan etc.).

6. Global deployment

This new modular platform will develop a diversified product line-up and will cover 50% of the Group’s production volumes worldwide.

The assembly plants in Vigo (Spain) and Sochaux (France) will produce the first two body styles built on this platform as from early 2013.The platform will be deployed a year later in Wuhan, China.

7. Eight European sites will be involved in the creation of the platform

No fewer than eight of the Group’s European sites are involved in the deployment of the EMP 2 platform.

The different components for the creation of the platform are produced in several of the Group's plants:

Sept-Fons foundry: brake discs.
Charleville foundry: cast iron front suspension pivots, Engine subframe aluminium front mounting casting and machining
Mulhouse metallurgical plant: hub and drive-shaft components forging.

Caen mechanical component plant: assembly and welding of subframe and front suspension wishbones, machining of pivots and brake discs, production of drive-shaft
Mulhouse mechanical component plant: assembly and welding of subframe and rear crossmembers, machining of brake discs, hubs and pivots, assembly of front Hub units.
St-Ouen plant: hot stamping.
Mulhouse and Rennes assembly plants: hot stamping.
Sochaux assembly plant: hot stamping, body-in-white, painting, assembly.
Vigo assembly plant: hot stamping, body-in-white, painting, assembly.

8. Manufacturing flexibility: the same versatile installations at sites around the world

For example, at a mechanical component plant, rigid and rubber-mounted subframesare assembled on identical modules, one in Caen, the other in Mulhouse.

For body-to-white, different versions can be produced in the same streams without needing specific installations for either version.

9. Improved working conditions

Above the head movements will be reduced by 80% and there will be a substantial reduction in the number of “heavy” workstations (underbody operations kept to an absolute minimum).

10. Capital expenditure

€630 million has been invested to develop this platform

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