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Global market review of automotive roof systems – forecasts to 2017 2010 edition
Global market review of automotive roof systems – forecasts to 2017
2010 edition
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© 2010 All content copyright Aroq Ltd. All rights reserved.
Global market review of automotive
roof systems – forecasts to 2017
2010 edition
April 2010
By Matthew Beecham
Published by
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Page iv Contents
© 2010 All content copyright Aroq Ltd. All rights reserved.
Contents
Single-user licence edition .......................................................................................................... ii
Copyright statement ............................................................................................................... ii Incredible ROI for your budget – single and multi-user licences ............................................. ii
just-auto.com membership ..................................................................................................... iii
Contents ...................................................................................................................................... iv
List of figures .............................................................................................................................. vi
List of tables .............................................................................................................................. vii
Preface ...................................................................................................................................... viii
Research methodology ........................................................................................................ viii
Report coverage .................................................................................................................. viii The author ............................................................................................................................ ix
Chapter 1 Introduction ................................................................................................................ 1
Chapter 2 The market .................................................................................................................. 3
Market trends ......................................................................................................................... 3
Market players ....................................................................................................................... 4
ArvinMeritor ................................................................................................................... 4
Q&A with ArvinMeritor ............................................................................................. 4 ASC Inc ......................................................................................................................... 6
Edscha .......................................................................................................................... 7 Heuliez .......................................................................................................................... 7 Inalfa Roof Systems....................................................................................................... 7
Q&A with Inalfa Roof Systems ................................................................................ 7
Karmann ........................................................................................................................ 9 Magna Car Top Systems ............................................................................................... 9
Q&A with Magna Car Top Systems ......................................................................... 9 Pininfarina ................................................................................................................... 13 Webasto ...................................................................................................................... 13
Market shares ...................................................................................................................... 14 Market forecasts .................................................................................................................. 16
Sunroof market ............................................................................................................ 16 Convertible roof market ............................................................................................... 22
Chapter 3 Technical review ....................................................................................................... 27
Defining the elements .......................................................................................................... 27 Recent innovations .............................................................................................................. 28
Q&A with Bayer MaterialScience ........................................................................... 29
Chapter 4 Manufacturers ........................................................................................................... 34
Page v Contents
© 2010 All content copyright Aroq Ltd. All rights reserved.
ArvinMeritor ......................................................................................................................... 34 ASC Inc ............................................................................................................................... 35 Heuliez................................................................................................................................. 35
Inalfa Roof Systems ............................................................................................................. 36 Edscha................................................................................................................................. 37 Magna Car Top Systems ..................................................................................................... 39 Webasto .............................................................................................................................. 40
Page vi List of figures
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List of figures
Figure 1: 2010 Audi A5 – roof supplied by Magna CTS ................................................................ 12
Figure 2: 2010 Chevrolet Corvette GS – roof supplied by Magna CTS ......................................... 12
Figure 3: 2010 Fiat 500C – roof supplied by Magna CTS ............................................................. 13
Figure 4: Manufacturer market shares for OE vehicle sunroofs for passenger cars and light trucks,
global (2009 % of volume) ..................................................................................... 14
Figure 5: Manufacturer market shares for OE vehicle sunroofs for passenger cars and light trucks,
Europe (2009 % of volume) ................................................................................... 15
Figure 6: Manufacturer market shares for OE vehicle sunroofs for passenger cars and light trucks,
North America (2009 % of volume) ........................................................................ 16
Figure 7: Webasto’s sales revenues by region, 2008 ................................................................... 41
Page vii List of tables
© 2010 All content copyright Aroq Ltd. All rights reserved.
List of tables
Table 1: Production of conventional-size sunroofs for light vehicle applications in Western Europe1,
Japan, North America, expected, best case and worst case scenario, 2007-20172
(‘000 units) ............................................................................................................. 17
Table 2: Market value of conventional-size sunroofs for light vehicle applications in Western
Europe, Japan, North America, expected, best case and worst case scenario, 2007-
2017 (EUR ‘000s) .................................................................................................. 18
Table 3: Production of large sunroofs for light vehicle applications in Western Europe, Japan,
North America, expected, best case and worst case scenario, 2007-2017 (‘000
units) ...................................................................................................................... 20
Table 4: Market value of large sunroofs for light vehicle applications in Western Europe, Japan,
North America, expected, best case and worst case scenario, 2007-2017 (EUR
‘000s) ..................................................................................................................... 21
Table 5: Production of retractable hardtop roof systems for light vehicle applications in Western
Europe, Japan, and North America, expected, best case and worst case scenario,
2007-2017 (‘000 units) ........................................................................................... 23
Table 6: Production of retractable soft-top roof systems for light vehicle applications in Western
Europe, Japan, and North America, expected, best case and worst case scenario,
2007-2017 (‘000 units) ........................................................................................... 24
Table 7: Production of retractable hardtop and soft-top roof systems for light vehicle applications in
Western Europe, Japan, and North America, expected, best case and worst case
scenario, 2007-2017 (‘000 units) ............................................................................ 25
Table 8: Magna Car Top Systems’ facilities worldwide, 2010 ....................................................... 39
Note: data in some tables may not sum due to rounding.
Page viii Preface
© 2010 All content copyright Aroq Ltd. All rights reserved.
Preface
Research methodology
This report is intended to provide an overview of the vehicle roof systems
industry, providing top level market volume and value forecasts through to
2017. Our forecasts are not extrapolative but dependent on the underlying
drivers of supply and demand. Our forecasts are largely based on interviews
with the author’s extensive international network of industry contacts. This
allows us to consider and explain the meaning and implications of industry
events, rather than offer simple descriptions based on incomplete data.
Our approach is divided into two distinct methodologies:
○ qualitative interviews – these are generally opinion-based, which aim
to build knowledge about future roof market trends and company
strategies; and
○ quantitative interviews – typically fact-based, focused on establishing
market values, shares, and volumes.
Our research typically concentrates on applications for light vehicles which
include all cars, light trucks and the various cross-over vehicle styles such as
sports utility vehicles and people carriers. These vehicles collectively account
for about 96% of the global vehicle build.
Report coverage
In this, the fifth edition of this report, just-auto reviews the key market drivers
for vehicle roof systems, and updates the market analysis. Following our
market overview in Chapter 1, just-auto’s product forecasts in Chapter 2
predict in some detail how the conventional sunroof, large roof, retractable
hardtop and soft-top roof system market will evolve in Western Europe, North
America and Japan from 2007 through to 2017. This chapter includes
exclusive Q&As with senior executives of ArvinMeritor, Bayer MaterialScience,
Inalfa Roof Systems and Magna Car Top Systems. Chapter 3 provides an
updated review of new product developments. Chapter 4 sets out profiles of
the major manufacturers, namely ArvinMeritor, ASC, Edscha, Heuliez, Inalfa
Roof Systems and Webasto.
Page ix Preface
© 2010 All content copyright Aroq Ltd. All rights reserved.
The author
Matthew Beecham has more than 18 years’ experience of researching, writing
and analysing market and technical trends in the global automotive
components industry. Since 2000, he has served as an associate editor for
just-auto. In addition to roof systems, he authors a range of global auto
components’ market research reviews, including batteries, braking systems,
coatings, clutches, cockpits, driver assistance systems, door modules, electric
motors, engine cooling systems, exhaust systems, front-end modules, fuel
injection, fuel tanks, glazing systems, ignitions, interiors, lighting, mirrors,
shock absorbers, spark plugs, rotating electrics, tyre pressure monitoring
systems, tyres, wheels and wipers. Matthew’s freelance assignments have
included working for AT Kearney, Belron, Bridgehead International, McKinsey,
Kuwait Institute for Scientific Research, Motorsport Industry Association, Motor
Industry Research Association and the Economist Intelligence Unit. He has
also written for magazines including Car Graphic (Japan), JAMA (Japan) and
Automotive Engineer (UK). He was awarded a PhD in automotive technology
transfer from Cranfield University.
Page 1 Chapter 1 Introduction
© 2010 All content copyright Aroq Ltd. All rights reserved.
Chapter 1 Introduction
Since Mercedes-Benz offered the first car sunroof in 1932, the ways in which
automakers have sought to let the sun shine into the cabin have become
increasingly complex. In terms of future trends, Thomas Becher, chief engineer
of ArvinMeritor’s roof systems business based in Dietzenbach, Germany, told
just-auto: “Solid roof modules without additional integrated features seem to
have a cost disadvantage versus simple sheet-metal roof-skin structures. We
see a trend towards roof modules with integrated opening systems (multi-panel
etc) particularly because the modular technology supports the trend towards
top-loading assembly processes on the car manufacturer’s assembly line. This
provides potential for utilisation of various roof options on one body interface.”
Jos Sanders, director of advanced technology at Inalfa Roof Systems Group,
still sees a trend in growing size of sunroofs with bigger take-rates and across
more vehicle segments. He told us: “This, at the same time, drives a sense of
urgency for lowering the total weight of sunroofs. Customers and consumers
do appreciate that low-weight solutions require more advanced material
choices and technologies. However, there has to be a clear performance factor
to rectify additional costs. This is where technologies like solar-powered
sunroofs are struggling. The output performance and cost structure are not
balanced yet.”
Meanwhile, the expanding convertible segment is crossing all vehicle
segments. It is no longer a preserve of the luxury class. Roof makers say that
growing consumer acceptance as well as all-weather convertible top concepts
such as retractable hardtops will contribute to the market’s expansion. While
electrically operated convertible roof systems are industry standard for luxury
vehicles, roof makers are continuously working toward developing smaller,
lighter and cheaper systems. In terms of the pace of growth of the retractable
hardtop market in North America, Jan Just, executive vice president of Magna
Car Top Systems, told us: “Before the economic downturn we have been
seeing a slow but steady growth of the RHT market in North America. With the
recent discontinuation of vehicle lines/brands (Cadillac XLR, Pontiac G6) the
North American market appears to have declined. As the carmakers are
currently redefining themselves, future growth is expected. OEMs will keep
using convertible technologies to distinguish themselves and draw customers
Page 3 Chapter 2 The market
© 2010 All content copyright Aroq Ltd. All rights reserved.
Chapter 2 The market
Market trends
Panoramic sunroofs stretching the length and breadth of a vehicle are
becoming increasingly popular on both sides of the Atlantic. The trend is
toward roof systems, mainly of glass, with big openings that can be adjusted
even during driving. These designs give the best of both worlds: saving on cost
(compared to a convertible) and adding to the versatility of the car.
In fact, an increasing number of automakers are offering models featuring
large glass roofs. One reason is that large areas of glass give a sense of
openness and freedom. The selection on offer nowadays is varied, ranging
from the closed panoramic glass roof and so-called twin panels or multi-panels
through to the lamella sunroof.
The desire of many car designers to include increasingly large amounts of
glass in their cars presents glassmakers with new challenges because glass
cannot be shaped at will like steel or plastic. Other trends include producing a
smooth roof line using several glass panels, e.g. producing windscreens which
extend up into the glass roof.
Over the past few years, novel retractable hardtop (RHT) designs have
enabled automakers achieve that appearance of a coupé yet with four
comfortable seats.
It is clear that the expanding convertible segment is crossing all vehicle
segments. It is no longer a preserve of the luxury class. Roof makers say that
growing consumer acceptance as well as all-weather convertible top concepts
such as its retractable hardtops will contribute to the market’s expansion.
While electrically operated convertible-roof systems are industry standard for
luxury vehicles, roof makers are continuously working toward developing
smaller, lighter and cheaper systems.
Page 27 Chapter 3 Technical review
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Chapter 3 Technical review
Defining the elements
Inalfa Roof Systems supplies a range of vehicle roof systems for passenger
cars and trucks. The company defines its roof system products as follows:
○ Standard roofs – these are single-panel roof systems which have a
glass panel that is on average smaller than 0.5-m². These sunroofs are
assembled from inside the vehicle (known as bottom-loaded). Inalfa
says that there are two main types of standard sunroof:
o Tilt-vent-slide roof – here, the glass panel has a tilt position for
ventilation and a slide position where the glass panel slides inside
the vehicle between the roof surface and the headliner.
o Spoiler roof – a spoiler roof shares the same functionality as a tilt-
vent-slide roof. However, in the slide position the panel slides on
the outside of the vehicle in a tilted position.
○ Advanced roofs – Inalfa defines these as being technically more
complex than standard roofs and have a glass panel larger than 0.5-
m². These roofs can be assembled both as bottom-loaded and as top-
loaded systems. The company points out that a bottom-loaded system
is generally bolted to a roof reinforcement which forms part of the
vehicle, whereas a top-loaded system is glued from above onto the
vehicle. Inalfa says the main types of advanced roof systems are:
o Top slider roof – this roof type differs from the spoiler roof,
because the sliding movement is done in a near horizontal
position, whereas the spoiler slides in a tilted position. This feature
is mainly chosen for styling purposes, offering the least
interference with the original vehicle styling. To achieve this, an
additional fixing point at the rear end of the glass panel is required
which also makes the mechanism suitable for large glass panels.
o Multi-panel roof – the multi-panel roof is a combination of the
above systems but, as the name suggests, contains more than
one panel. All options are feasible, says Inalfa, whether it contains
one moving, two moving and/or additional fixed panels. The
moving panels can have tilting, tilt/sliding, spoiler or top-slider
movements. As a module, the system also carries a sunblind
system, completely independent electronics and has an electric
Page 34 Chapter 4 Manufacturers
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Chapter 4 Manufacturers
ArvinMeritor
ArvinMeritor is a worldwide supplier of sunroofs and roof system products for
use in passenger cars, light trucks and SUVs. Its roof system operation is
organised under the company’s Light Vehicle Systems (LVS) division. In May
2008, the company announced its plan to spin-off its LVS business to
ArvinMeritor shareholders, with its Commercial Vehicle Systems business
remaining with ArvinMeritor. Since then, the company has completed the sale
of its entire ownership interest in Gabriel de Venezuela and Meritor
Suspension Systems Company (finalised in October 2009) joint ventures; and
sold both its wheels business and Gabriel Ride Control Products North
America.
Consequently, ArvinMeritor has revised its reporting segments following these
recent divestitures. For continuing operations, the company will now report
results as defined within Commercial Truck, Industrial, Aftermarket & Trailer,
and Light Vehicle Systems. Of these four segments, Commercial Truck,
Industrial, and Aftermarket & Trailer are considered as being core businesses
for ArvinMeritor. Today, its Light Vehicle Systems business supplies mainly
roof and door systems for passenger cars to automakers. This business
includes the company’s remaining chassis operations.
More specifically, ArvinMeritor designs and produces a variety of roof modules,
including: a module with twin spoiler sunroof; a module with integrated roof
rack; a module with high level brake light; and a module with sunroof.
LVS is a supplier of complete roof modules comprised of a roof headliner
bound to an outer shell using its own patented process, which can also
incorporate LVS sunroof technology.
For the fourth quarter of 2009, ArvinMeritor posted sales revenues of
US$xxxm , down xx% over the com parable period in 2008. The decrease in
sales was mainly due to continued weakness in the global markets.
