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OM in the News: Redesigning the Chevy Malibu

 While the US’s fuel economy requirements rose just 10 mpg in the past 30 years, they are now poised to rise 2 mpg on average each year over the next decade. And by 2025, new cars must average 54.5 mpg., twice today’s standard! Short of dramatic use of battery-power and hybrid vehicles, how can auto makers reach these lofty targets?  The answer, according to The Wall Street Journal (Aug.30,2011) is a whole bunch of seemingly small product redesign changes, the topic of Chapter 5.

Here is what GM has done to the 2013 Chevy Malibu, due in showrooms early next year, to create a car that will go 92 more miles on a tank of gas than the current model:

1. Round the front bumper, to reduce drag (.4 mpg).

2.  Angular rear tail lamp, to reduce airflow (.3 mpg).

3.  A compact, battery-operated, electric motor to provide more power during acceleration (5 mpg).

4.  No spare tire, but a portable air compressor to fix a flat, thus saving 128 lbs. of weight (.4 mpg).

5.  Aluminum, instead of steel in the hood and a rounded front corner (.4 mpg).

6. “Active shutters” behind the grille to allow air to cool the engine (.3 mpg).

7. Flattened underbody panels , to improve airflow under the car (.4 mpg).

The mpg race is indeed changing product design. The car’s redesign began 3 years ago and involved concentrating on details. “It takes looking at every single gram and kilogram and every part of the car”, says the Malibu’s engineering manager. The small changes Chevy is making add up to a 7.2 mpg improvement.

Discussion questions:

1. What are some other auto changes that can yield mileage improvements?

2. Ask students to each find a product and suggest ways to make it more efficient and ecologically friendly.

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