Product Development Obstacles In EV Manufacturing

Managing Greater Product Complexity

Compared to the traditional internal combustion engine (ICE) vehicle, an EV requires on average 80% fewer parts. Yet, there are key components which add to the complexity of its design, one being the battery. The battery poses several challenges, as it determines the vehicle’s driving range, charging capacity, safety, and cost—key factors that greatly influence consumers’ decision to purchase. Manufacturers must take these features into consideration as they look to optimize the EV design and attract new buyers.

Consumers are also wanting to accessorize their EVs with a wide range of smart, connected features such as self-driving technology, voice assistants, and adaptive cruise control with lane assist. To meet these demands and stand out from the competition, manufacturers must manage more sophisticated designs with the integration of advanced technologies such as the Internet of Things (IoT), sensors, and artificial intelligence (AI).

Achieving Regulatory Compliance

As the adoption of electric transportation becomes more widespread and new EV technologies emerge, global regulations are being established to ensure product reliability and address environmental impact.

Safety and Information Security
The International Organization for Standardization (ISO) and International Electrotechnical Commission (IEC) have published several standards, including ISO 6469, to enforce protection against electrical hazards and system failures. Guidelines for information security management (i.e., ISO/IEC 27000) have also been introduced to address the Internet of Things (IoT), charging infrastructure, and other underlying technologies that may pose cybersecurity or privacy risks.

Charging and Communication
ISO 15118 provides protocols for bidirectional communication between the EV and charging station so that drivers can simply plug in the vehicle and charge without having to worry about cards, apps, or PINs for authentication and billing. Additionally, the different modes for EV conductive charging systems are outlined in IEC 61851.

Quality Management
Although the ISO 9001 standard is not specific to electric transportation, companies across many industries use it as the basis for implementing a quality system to drive continuous improvement and increase customer satisfaction. 

Environmental Compliance
Environmental regulations such as Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) and Restriction of Hazardous Substances (RoHS) limit the use of certain hazardous materials for the manufacture of products. Other regulations such as the EU Battery Directive, EU End of Life Vehicle (ELV) Directive, and Waste Electrical and Electronic Equipment (WEEE) require manufacturers to ensure proper reuse, recycling, or disposal of certain parts and materials once they reach end of life. 

When it comes to environmental compliance, documentation and tracking of the components and raw materials that are used for production must occur throughout the entire lifecycle. Responsible sourcing and reporting of conflict minerals such as cobalt and lithium for battery production is also necessary to demonstrate due diligence. 

Navigating Supply Chain Challenges

To accelerate time to market (TTM), EV manufacturers are having to reevaluate how they interact with and manage their supply chain. 

The high demand for semiconductor chips and other critical electronic components across various sectors has forced manufacturers to contend with extended lead times and shortages. This is further compounded by the frequent supply chain disruptions that result from pandemics, natural disasters, and other unforeseen events. 

EV battery supply chains especially are negatively impacted due to the environmental and ethical concerns associated with sourcing key raw materials such as cobalt and lithium. Cobalt mining is concentrated in the Democratic Republic of Congo (DRC), which accounts for 65% of the global supply⁵. Various reports link the DRC’s mining industry to hazards such as forced labor and poor working conditions⁶. 

In light of these supply chain obstacles, EV manufacturers must adopt new sourcing strategies and supply chain communication methods to help mitigate risks. 

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