When Carl starts thinking hard, the whole building starts browning out.😂

Who knew a car door could be so complicated? These videos are amazing! I’m not really a car guy but these design principles could apply to any manufacturing. Thanks so much for sharing your expert knowledge Carl!

Already know it is going to be a fantastic review video when Carl is involved. Thanks Munro and Carl!

@laloajuria4678

Жыл бұрын

yea videos without sandy are so much better.

@AlanCoffey

Жыл бұрын

James is on the Riley side of the family 😮

@johncandelario294

Жыл бұрын

@@laloajuria4678 lol! I like the whole team. Each one has a different style.

Been watching Munroe since day 1. Carl is the best person to explain things on the show. He makes things very very easy to understand.

Carl you have excellent delivery = better understanding of the build process.

Just remember guys: this is THE car that is responsible for forever changing the public's perception of just what kind of car company Hyundai is. The designers were charged with that very difficult task, and in the process they created an iconic design. It's interesting to see how they accomplished that, but I think its important we remember that there is no price tag that can be placed on how important this vehicle is for Hyundai, and I doubt very seriously that they expect it to be profitable.

@xxwookey

Жыл бұрын

The Kona electric was also a big deal in that it was a remarkably efficient long-range vehicle (more efficient than this Ioniq5). So the Kona/E-niro made us take notice of Hyundia/Kia in the electric space and the Ioniq5/EV6 sealed the deal that they had moved well up the car company rankings.

@joec.5009

Жыл бұрын

true, but don't forget N vision 74 concept, gv80, gv70, g70 veloster n, g90, palisade and etc. all of their latest offerings are perception changing models. but the n vision 74 concept made hyundai dare i say 'desirable'. for me it's the greatest concept in this century.

@patreekotime4578

Жыл бұрын

@@joec.5009 Eh. I stopped paying attention to concept cars a long long time ago, once I realized that car companies almost never built anything even remotely close to the concepts, and rarely does the design language even vaguely make it into a real product. KZreadrs got me excited about the Honda e concept, and I fell for it, only to be disappointed with what they built. A real car you can see on a lot or on the street is so much more important than any concept. I dont get why anyone even pays attention to them anymore... especially these days when random fans are pumping out their own versions of digital concepts just as good or sometimes better looking than what the OEMs come up with. 🤷

@carholic-sz3qv

Жыл бұрын

Why wouldn't it be profitable!? Wtf!!! It's all about configurations! All of this same car aren't the same as showed in this video!

@carholic-sz3qv

Жыл бұрын

​@@patreekotime4578 lol!!!

One thing I can say is that Honda has loved plastic clips to assemble door components, and attach interior and even exterior garnish for several decades, and I’ve learned to be very annoyed by those little clips. There is also trouble with embrittlement and shrinkage over time. Right now, I’m working on an Insight with a wet seatbelt issue caused by deterioration of one or more clips attaching the A-pillar garnish and letting water in. The clips are single use and have to be cut with a utility knife to release the garnish. There are seven clips of one type and one special clip with an alignment barb which must be replaced when that garnish is removed. That is about $30 worth of special clips. That also accounts for about 20 minutes of labor charged to uninstall/reinstall. The discussion of clips and repair aggravation may mean little to a consumer who cycles through vehicles regularly on three year leases and never gets in a wreck. On the other hand, those off-lease vehicles enter the used market and someone has to maintain them. I don’t expect unabashed altruism from manufacturers to sacrifice earnings to make their products more repairable, but it is nice when they do. Vehicles which develop a reputation of expensive or difficult to maintain might hurt future sales.

BMW solved the door hinge problem in the 90’s by designing a “hanging” hinge. Door hangs on the body through paint, then can simply be lifted off for closure/trim install. Final install is with two 10mm fasteners on each hinge pivot

I subscribed to this channel months ago hoping to see ioniq 5 teardown analysis. You did not dissapoint

@MunroLive

Жыл бұрын

more to come!

Excellent presentation. Amazing the complexity involved.

@martinbeverley9536

Жыл бұрын

Yes. This video helps make Elon's "production is hell" comment more comprehendable.

Wow, the depth of knowledge is world class. Thank you Carl & Team Munro for a glimpse behind the curtain!

7:07 As an engineer, my primary take-home thought from Sandy & the other Munroe associates is to treat connectors like moving parts. Fewer is usually better, even if you don't realize it at first.

What a great video. To be honest rather astounding when all the steps, material choices, production steps and every else is taken into account.. Just for one door..

@deltajohnny

Жыл бұрын

Too much complication... if manufacturers reduced complexity we would have cheaper vehicles 👍👍

@bluetoad2668

Жыл бұрын

​​​@@deltajohnnythis could just be the reason for Tesla's high margins. Oh, and by the way - that doesn't mean you get cheaper vehicles - but it means cheaper vehicles are possible based on demand and supply

@drewthompson7457

Жыл бұрын

I was comparing this door to the one on my '61 Austin Mini. Is it really the consumers that demand so much more for a door these days? (government crash specs add a lot too)

@deltajohnny

Жыл бұрын

@@bluetoad2668 Let's hope that in a near future we can enjoy simple, comfortable, safe, easily repairable electric cars, without expensive solutions 👍

I love how he just keeps going when the lights go out! Lol😂 So proud of u guys!

As a future owner of an Ioniq 5 i am very interessted in the results. I think its a great car but i know there are also things that are not perfect. Thank you guys for the work you are doing. Great Job!

@bluetoad2668

Жыл бұрын

If you can then try to not get that Ioniq 5. I know two people who have had a lot of problems and Hyundai seems not to have very good parts and service setup - this could just be my corner of Europe I guess. These cars are being sold on at a discount. It's a shame because I like Hyundai in general. Just watch out for the 12v battery - get a spare one and figure out how to fit it to avoid being stranded.

@niuran7866

Жыл бұрын

@@bluetoad2668 If i could i didn't want to stop my order. The Ioniq 5 is a fantastic electric vehicle that offers a good range, sleek design, and advanced features for safe and enjoyable driving. Hyundai recently said this 12v battery problem was about the use of third party software and they will block those who have to many requests. We will see but i will try to avoid thirtd party software or check if there are problems with ioniq 5. I know also a few people that have ioniq 5 and nobody has the 12v battery problem, they didn't use thirtd party software with the ioniq5

@briank581

Жыл бұрын

@@niuran7866 Well said. Great to hear that!

Carl, you do very interesting videos (even with the lights off!). The biggest thing that just gets reinforced with every video is what Elon has stated many times…Production is HARD. I am starting to look at manufactured items closely to try to determine how they are actually made and assembled. If I were 40 years younger these curiosities would be followed up. I enjoy all Munro videos. I think Carl is your star simply because of how he explains things and also he has materials and processes to explain about that had never been considered by me which I guess makes the video not only interesting but educational. Excellent work, Carl

Great flow Carl. I Enjoyed your flawless presentation. Thanks Munro & Co.

I like Carl’s deep and simple explanations. However I keep waiting for a summing up. Like “this is wasteful”, “this is clever”, “this is what all auto manufacturers do except x which does it this other way to save money”, “if they used this fastener they would save this much and it would be more durable” etc.

Carl is the most interesting guy at Munro. Sorry Sandy. Love your presentations Mr. Crittenden!

@MunroLive

Жыл бұрын

Carl has almost just as many stories as Sandy!

Thx Carl! OMG a Million Dollar Door! It is really interesting looking at how components are made and assembled. Most of us have no idea! 🇨🇦

Munro needs to add solar panels to their roof and battery storage as backup power for their business.

Wow the lights going off gave me a good chuckle! Keep that stuff in its GOLD! :)

Hi guys . This is back to basics . Love love love this this is what Munro live is all about 10/10 ❤ keep up this fantastic work

🙋‍♂️THANKS CARL,and MUNRO TEAM …FOR SHARING THIS… 😅VERY COMPLICATED AND EXPENSIVE 🤔💚💚💚

I had an Audi A2 for many years (very interesting car!). When I disassembeld the doors, I was very surprised about the relationship between the visible and touchable surface parts and the functional, technical assembly behind. While the former was very part-saving and simply designed, the inner workings of the door were extremely complicated, elaborate, and assembly-intensive (involving, among other things, more than twenty Phillips pan-head screws, per door). One would normally expect it the other way around, and Hyundai seems to have done it this way here.

Carl snaps his finger and there will be light ! AMEN !

Amazing detail on stuff us the buyer would never think about. Thank you Carl.

love the QC! yup! 110% out of the ballpark Carl ! GJ,GJ !! Team Munro!!🏁🏁💫

Love Carl.

A couple of observations regarding this review. The door hinges - the whole body is made somewhere else and is transported to a place where they kit it out with trims etc. The windows are not cut out in corners by Hyundai - they are shipped to them as you see them and assembled. I would also argue they are already made like that from the start - not cut out and any way that is the cost of the supplier, not Hyundai. The bottom trim with Philips screws: Granted - it could be folded and snapped into place, BUT - those are parts that commonly get scuffed or damaged by the owner. Now imagine a regular service shop and service guy having to replace that if the folding method was used - the result would be very bad. This way - anyone can replace that part with no special tools or knowledge. I am also 100% sure those screws are not handled by a person in the factory but rather by a machine ho screws all of them in one go. For me, this video proves that Hyundai actually makes puts more effort into manufacturing than others.

@StormyDog

Жыл бұрын

Obviously anything that's a "cost of the supplier" would be passed on to Hyundai with markup. Also making the body somewhere else and carting it to the Hyundai assembly plant sounds ridiculously inefficient.

@patreekotime4578

Жыл бұрын

If the windows are made with the cutout by the glass supplier, there is no additional cost in material, it is infinitely recyclable. Just like how Tesla drops the shaved sprues off of their castings back into the furnace. There may be an additional cost in tooling, but I doubt it as they are already cutting out a "window" shape.

@GOINFINITI

Жыл бұрын

@@StormyDog It would not. This is how it works - you send specs to suppliers and they come up with offers. After that you choose the best offer. Hyundai motor group owns heavy industry manufacturing also. THey even build tankers, planes etc. I also think there is no special carting cost involved - it all stays within the group and is probably connected directly to the assembly line. They have one of the best if not the best vertical integration manufacturing in the world.

@donaldosterhaut4385

Жыл бұрын

I once transported 5 medium duty cabs in white from Lima, Ohio to Garland, Texas. This was a distance of approximately 1,075 miles. I picked them up at the cab manufacturing plant and delivered them to the final assembly plant. And then we wonder why legacy manufacturers cannot compete with startups.

@Somethingaboutthat

Жыл бұрын

There are some really excellent videos on how integrated Hyundai’s manufacturing plants work. The ship building one blew my mind. They literally take the recycled aluminum off a ship straight into the smelter, no driving on land involved, it gets poured right in. That part from the smelter never leaves the plant until the entire ship leaves. They are masters at using the land and water to their advantage.

Several have mentioned it already but I feel the need to reintegrate. Carl your delivery is excellent on camera. We need to see more of you!

I actually thought this content would be boring as shit. Lol. *Well done!*

Great observations. It would be interesting to see a comparison of the Hyundai door panel with a much more efficient and cost effective panel that offers the same level of quality and feel. Especially where costs are involved. Also, Monro needs a Tesla Powerwall.

Carl has convinced me: I’m not buying an ev now……just a door. That’s all the technology I can handle.

Great video, but covers only the moldings. I wonder if there will be a second video showing the door's window mechanism? I remember Sandy Munro comparing the Model S and the Model Y window mechanismm where the Model S has all the components like motor and cables bolted directly inside the frame of the door, something very complex to install. While Sandy was showing the Model Y using a preassembled window mechanism and speaker bolted to a plastic frame. And then during the car production, the operator needed only to insert the whole preassembled component. Even Sandy Munro shown that he patented this design long time ago when working at Ford. But this new design, saving a lot of assembly time was rejected by the management.!!!

There has to be a better way. Thanks for the content Carl.

Love the content, though I wonder how Carl can still hold it in after 3 takes, or Eric edit out all the giggles for Munro bloopers collection

Poly-warp-alene is funny :-)

DFM and DFA are the dark arts of the OEM.

Autofeeding screwdrivers are common in factories

🕵️‍♂️ Detroit CSI: Watching Detective Carl’s forensics gives me an appreciation for vehicle materials and assembly processes, both good and bad! Looks like Hyundai has got a little to learn here… 🧐

Munro team is the Master of "Lean Design ", hire them or your manufacturing cost become uncompetitive vs the leader in BEVs.

Blimey Carl. I'll never look at a car door the same way in future.

Not too sure why this showed up on my feed, but man this is such an awesome video

Great video, thanks for the thorough explanation!

Great job Carl. I really enjoyed it. Good knowledge transfer.

I for one, love the doors on my Ioniq 5. They feel very sturdy and weighty, and much nicer than Model 3/Y doors that feel like they are going to break when you close them.

@benjaminsmith2287

Жыл бұрын

And that's what matters most, IMO.

@ConstanceCox

Жыл бұрын

Hyundai...lololololololololol

@kryllin

Жыл бұрын

Gotta agree. My I5 feels incredibly solid

@1fadf23f

Жыл бұрын

@@ConstanceCox poop. HAHAHAHAHAHHAHAHAHHAHAHAH

@djwarren5081

Жыл бұрын

I imagine that Tesla would have made them less complex and therefore cheaper and more profitable.

Screens are also useful for keeping insects out while maintaining ventilation if you sleep overnite in a car at a campsite. The Hyndai screen only reduces light intensity, or increases privacy. But it doesn't lool like it would keep out insects. Occassionally, I sleep in the back of my Prius (plenty of room for two) when spending a night at a campsite. To keep out insects, the cold, or rain, I simply bought a length of window replacement screen material two and a half times a window height. Then drap it over the car door's window frame and hold it in place with magnet strips with the door shut. Use your imagination to trim the "glove" to fit your car. The advantages -- you can adjust the ventillation from within in the middle of the night if it gets cold or rains. When not in use, I just roll them up in a hiker's campingi mat or Yoga mat.

Bravo, Carl! Fascinating

Great video. How about doing a full Rolls Royce tear down. Let’s see the quality build of one of those ultra lux vehicle…

I like Carl's episodes.

Carls videos are the best.

Thanks Carl. Awesome stuff.

Excellent, Carl…

Carl is superb!

Great cost and process saving video wonderful job

The back window popped out of my friend’s Mercedes GL luxury SUV when he closed the door some years ago. He had another since then and has recently changed to a BMW X7 which seems better built [so far].

Great video, I think in videos like this you should always compare each process to a vehicle that does it differently. This not only helps show the alternative methods of assembly, but in most cases gives you many more chances to compare to tesla parts which as I am sure you know will at least double your view count per video.

@elmojito

Жыл бұрын

Good idea but seeing the many parts in that door it is quite evident to me that comparisons are very relevant for processes not necessarily about aesthetics. I am sure doing a very plain door with hard plastics would be the cheapest option but not the most visually appealing. For areas not seen by the end user, such as motors, cooling systems etc, definitely yes. I remember the comparison he made of the Rivian vs Lightning but somewhat lost in the equation is how much nicer it looked in the Rivian.

@TechViewOpinions

Жыл бұрын

The answer in monetary terms is Munro makes their money. I'm glad they shared what they were measuring. The serviceability is what stood out to me; or the lack thereof. I keep my vehicles long enough to where this is an issue.

@elmojito

Жыл бұрын

@@TechViewOpinions I also keep cars a very long time and agree with you. But I am of the opinion that making something cheaply may or may not translate to a long life but either lower selling prices or higher margins. Sometimes it may make servicing significantly mire expensive if you keep cars a long time. I have 2 cars that are over 22 year old already and unfortunately my newer 4 year old car probably will not last as long - they don't make them like they used to.

@carholic-sz3qv

Жыл бұрын

Wtf!!! Why does it have to be Tesla involved in this!?

@TechViewOpinions

Жыл бұрын

@carholic1336 it has become the standard and it's a fast moving one. Moving on the side of improvement. Tesla is NOT your grandfather's Olsmobile...

Amazing content. I learned a lot about something i kind of took for granted. In door design and cost . Not anymore.

Very cool Carl thnks

Nice, love Karl videos.

The bit about the pull up or powered blind reminds me of the elaborate system Audi used to have flush fitting powered door glass in order to get the low cd they were aiming for. It took a bit of teutonic thinking to sort it out and make it work.

Great educational video

Let's go! Love these breakdowns

@MunroLive

Жыл бұрын

Thanks for watching!

@SirDragonClaw

Жыл бұрын

@@MunroLive Awesome video, however I think in videos like this you should always compare each process to a vehicle that does it differently. This not only helps show the alternative methods of assembly, but in most cases gives you many more chances to compare to tesla parts which as I am sure you know will at least double your view count per video.

Love your reviews

@MunroLive

Жыл бұрын

Thank you so much!

I love Munr olives

Carl makes the job look easy. But working out every process used for the hole vehicle must be hard yakka.

this was a _master class_

I've tried to repair those inner door panels with those broken heat welded fasteners. Total pita. If ya can't find a wrecking yard panel, Stealerships gladly charge $1K-$2K for a replacement. JB Weld to the rescue.

Thank you

Astonishing video, this guy knows his sh*t

It makes sense that the top trims with the wrapped door panels takes more time to deliver than the other trims where you only get the substrate, without the vinyl wrap.

Thank you!

@MunroLive

Жыл бұрын

You're very welcome!

Thanks for interesting video 😊

@MunroLive

Жыл бұрын

Thanks for watching!

interesting program 🤓

Amazing.

Nice camera work. 😉

It used to be that you had to know all the nuts and bolts, now it’s adhesive and heat bonded plastic towers and the scary assembly time for phillips head screws…

Eow Hyundai is realy the best!

so like the blackout part lol.

Are you going to show other videos of the Ioniq 5.? So far Its been sealink with the Doors and seats. Maybe videos of the motor or the batteries.👍

I am already annoying my friends with all that Carl has taught me. :)

Carl is very good.

Awesome Carl, Great exposition on the various manufacturing methods involved .... and an idea of which to pick and when so to speak? Really shows the great extra cost of those much loved "soft to the touch" surfaces? Perhaps the TESLA Model 2 will avoid all of those discretionary excesses in favour of greater affordability and even more acceleration of the move to sustainable transport?

@gregkramer5588

Жыл бұрын

I imagine the model 2 will be a case study in simplicity. I also imagine it will also be the most boring generic appliance on the market.

@patreekotime4578

Жыл бұрын

We've seen cars with the cheapest possible interiors. 80s and 90s, especially Fords were just a sea of grey of injection molded hard plastic. Durable and easy to clean, but asthetically horrible. This is also a unique vehicle for Hyundai as it was charged with changing the public perceptions of Hyundai from cheap Korean junk, to a real competitive luxury auto manufacturer. It had to look good. Maybe Tesla can make cheap injection molded parts look good, but honestly, why bother? Durable is more important than pretty if you are making a down market vehicle.

@regaldridge4248

Жыл бұрын

@@gregkramer5588 Boring would be quite acceptable if it gets several more millions of zero emissions vehicles on the road? Affordable for the rest of us trumps finesse for the rich IMHO?

Interesting video. Do you these doors have any noise insulation and dampening? Some car doos like the Toyota Camry sound absolutely tinny.

upvoted!!!

Do they use the metal from the punch holes for other smaller stampings?

Carl is a door able.

I wonder if Hyundai is paying Munro to do this and provide them with a way to improve their parts design, manufacturing and assembly. If not, Hyundai engineers should watch this and take notes.

We’re the doors wax paper lined or wax lined? Hyundai seem to have a drain through door rather than sealed approach and it would be good to understand what weather protection is inside.

If you think about it. Even the Lucid air has less complexity on the door plastic assembly. Simplicity is elegance! If they had vinyl/soft-moulding. Lucid air would have a cheaper, better looking door than even the Ioniq 5.

In 50 years there will be no way to restore/repair/recover those plastic door panels, even if someone wanted to do so on a Hyundai. After seeing this video, I will never look at a car's interior in the same way again.

6:24 : are they not JIS screws instead ? They seem to have the dimple although I cannot be sure with the picture

Nice review.....but also I'm missing a few parts in this door review..... In my ioniq 5 the windows are electric regulated for opening and closing....inclusing switches. Also switches for locking/unl,ocking doors (on front door only). Also there will be a speaker in the door mounted,, connected to the audio system. Which makes the door even more complicated than shown in this video.... Fixing al those components could be a reason that some parts are welded together instead of being made from 1 component. And one little extra...The weight of any EV is not the most important part for the range and driving efficiency. It is important for any ICE car because accelerating will take extra energy....which turns into heat when braking. But within any EV this will be generating some more energy (back into battery) when braking/regenerating.. What is important for any EV to increase range..1: .electrical efficiency in all electric components and reducing drag wherever possible. Next to that...resistance from tyres on the road, internal resistance in all moving parts.

Hey Munro-Team, could you make a video where you explain how a Thermal-System works and maybe show different approaches to that? Because these systems are very complex and sometimes I get confused which part does which job

How do you know that the 12 screws are handled by a person, and not a robotic assembly step (with automated screw-handling?)

@williamgrunzweig571

Жыл бұрын

They are handled by a person at some point, based on your own logic. Machines don't load themselves do they? No they don't. A human has to load the screws into the machine, either in a prefabricated setup (like nail guns use) or a bin which auto loads...either way a human has to touch the screws somewhere in the process which adds to the cost of the part or process plus the machine to utilize the process that was just described. Having a design that doesn't utilize those screws is ideal, as he said other manufacturers have done. It saves money and time is all the presenter is saying...basically this car door is in need of a redesign for long term viability.

@xxwookey

Жыл бұрын

@@williamgrunzweig571 screw/nail guns are loaded in bulk, not individual screws - that's the point. This makes an enormous difference to this specific cost, which is why I wondered specifically about how/why he decided it was a manual operation. And yes robot installers do load themselves, or at least the loading can be automated - there are lots of variations on pruction maethods with complicated tradeoffs in capital cost, operational cost, and per-vehicle cost.

Amazing! Videos like this will show why manufacturing is interesting and needs to come back to America and the western countries. Outsourcing everything to China was a bad idea.

The only thing these lower body claddings around doors and wheel arches are good for is corrosion. STOP adding gladding. It’s costly, it’s ugly, it causes rust.

Thanks. And what is the other company which has a living bottom fitting without fasteners?

@patreekotime4578

Жыл бұрын

When they feel like they can name names they do. Sometimes they work with companies who dont want to be talked about publicly.

Sherlock Holmes in the non-fiction section of the library :) Nice!!