Valvijet asked Cetim to carry out a reliable and objective cost estimate for the components of its technology, an essential prerequisite for discussions with its partners.
• To obtain a detailed and objective cost estimate for the system’s 80 parts.
• To validate the manufacturability of the components with a view to mass production.
• To engage in well-founded discussions with manufacturers on a sound economic basis.
Developed since 2018, the Valvijet high-energy turbulent jet ignition system aims to improve the efficiency of automotive internal combustion engines. By 2025, its reliability, proven over several hundred hours of testing, will make industrial production a viable prospect. “To convince manufacturers, demonstrating performance is not enough. Cost remains one of their main concerns, emphasises Vianney Rabhi, founder of Valvijet. It is therefore essential to carry out a very detailed cost analysis to initiate discussions.” He turned to Cetim to determine the production cost of the 80 parts, divided into four mechanical sub-assemblies, with a view to manufacturing in three distinct regions: Europe, Eastern Europe and Japan.
Cetim carried out a detailed industrial analysis of the parts, manufactured using a variety of processes: machining, sheet metal forming, casting, forging, plastic injection moulding, metal additive manufacturing and surface treatments. With a view to large-scale production, certain parts were redesigned and all cost items, from materials to packaging, were broken down to inform a ‘Design to Cost’ approach. Several technological scenarios were compared to optimise the design and manufacture of certain components and significantly reduce their unit cost. “Cetim has no financial stake in the matter. It holds nothing back, proceeding with complete objectivity and through open dialogue,” notes Vianney Rabhi. Today, this study is being shared with all of Valvijet’s partners, for whom Cetim’s credibility is a mark of reliability. The collaboration will continue across other aspects of the project.
• Detailed industrial analysis of the parts and their manufacturing processes.
• Identification of redesign options for certain components to enable mass production.
• Breakdown and costing of all cost items using a Design to Cost approach.
• Access to credible and objective industrial costing.
• Technical and economic optimisation of several components.
• Enhanced credibility of Valvijet among its industrial partners.
