Honda has set a goal to increase the ratio of EV and FCEV sales to 100% globally by 2040. As an important step toward achieving this goal, Honda is planning to launch a commercial-use mini-EV in the spring of 2024 in Japan. Mini-vehicles support people’s daily lives in Japan, and commercial-use mini-vehicles must fulfill particularly demanding requirements for both functionality and cost. What were the team's thoughts as they took on this new challenge? The development team members responsible for design, body design, the electric power unit, and purchasing shared their stories behind the development of the N-VAN based EV.
Assistant Chief Engineer
Automobile Development Center – Suzuka Factory, Automobile Development
Automobile Development Center, Automobile Operations,
Honda Motor Co., Ltd.
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Raika Kawatsu
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Assistant Chief Administrator
Model Cost Promotion Department
Automobile Development Center – Suzuka Factory, Automobile Development
Automobile Operations,
Honda Motor Co., Ltd.
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Yohei Senjo
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Assistant Chief Engineer
Energy Storage System Development Department
Energy Storage System Development Division
Energy System Design Development Unit
Honda Motor Co., Ltd.
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Ryohei Saiki
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Assistant Chief Designer
Product Design Studio
Design Center, Automobile Design Division
Honda R&D Co., Ltd.
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Takehisa Tanaka
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Taking on new challenges to create commercial-use mini-EVs. How did the team infuse the uniqueness of Honda.
The new commercial-use mini-EV is scheduled to go on sale in the spring of 2024. What were the primary focus points of the development team?
*1 The Ie-Mobi was a concept model exhibited at the 45th Tokyo Motor Show in 2017 to showcase Honda’s proposal for near-future vehicles. The key concept was that this vehicle could be connected to a house and used as a room with a size of approximately 3 tatami mats (5m2, 54 ft2), when it is not in use as a car.
One thing we focused on in developing the body design was not to make any change to the size of the cabin space. The exterior is also virtually the same as the base N-VAN. We believe that usability is the key factor for a commercial vehicle. Even with the change from an internal combustion engine to a battery and motor, our basic premise was to hold firm on the excellent usability of the N-VAN. By optimizing the packaging of the power unit mounts, we were able to maintain the size of the motor compartment, leading to a spacious cabin.
Optimizing the packaging of the power unit mounts was a big challenge for the development team. In the stage of working on the development concept, we examined whether the power unit would fit properly in the motor compartment by putting parts together like puzzle pieces. We began our development process after gaining a certain degree of confidence that they do fit; however, things did not go as smoothly as we planned in the actual development. It was a very detailed process that required millimeter-by-millimeter adjustments. As Mr. Kawatsu said, usability is the key for commercial-use vehicles. So, we actually went to a logistics company and observed how they work and conducted thorough research on how commercial vehicles would actually be used.
I wanted to know more about the usability of van type mini-vehicles in our daily lives. So, when delivery services rang the doorbell while I was home, I dashed out and watched their loading and unloading for a long time. I might have looked suspicious. We also talked to people from auto shops that customize the N-VAN and people who actually use N-VAN as a “shop on wheels.”
As a team, we also discussed quite a bit about the location of the charging port, didn't we?
Yes, most Honda vehicles have the fueling port on the left rear side, but this time we purposely placed the charging port at the front. For a commercial-use vehicle, it is more convenient to be able to load and unload cargo while charging. Another advantage is that it would make it easier to charge the vehicle even in a parking space with a narrow width.
There are many points that we were very particular about, but what I want to tell people the most is about the front grille. As a matter of fact, it is made of recycled materials from automotive bumpers. By using recycled materials for the front panel of the vehicle, which is the face of the vehicle, we wanted to communicate Honda's commitment to pursue the circular/resource-recycling society. That is one of the messages we wanted to convey.
As my focus areas are purchasing and business, I was very particular about how we can offer this model at affordable prices and still make it a viable business for Honda. Inevitably, BEVs will be more expensive than ICE models. Together with our factories and suppliers, we are trying to figure out how we can create a product that realizes an optimal balance between the cost and the value for our customers, and we are continuing to find out where else we can reduce the cost.
What were some of the challenges unique to the development of a commercial-use mini-EV?
At Honda, we hold many Waigaya*2 sessions with a large number of team members during the development process. I worked hard in the area of communications, conveying the vision for this model and how we will convince the rest of the company. We needed everyone involved to share the same thoughts about why we are electrifying the N-VAN at this timing, how this vehicle would contribute to society, and the concept of this model. To this end, we put effort into creating visual images. By creating solid images of our vision and presenting the future where people live more enjoyable lives, I felt that the direction of the wind changed, and a tailwind started blowing for us.”
*2 "Waigaya" refers to the unique culture of Honda to engage in open-minded and vigorous discussions about our dreams and how we work by sharing opinions regardless of the age or job title of the participants.
Before this model, I had worked on the N-BOX and N-WGN, which targeted general customers, so I struggled with the task of incorporating the image of “commercial use” into the drawings. However, thanks to the image drawings that Mr. Tanaka's team put together, it became easier to imagine how this model would be used in various situations, and we were able to create a body that would not deform no matter how roughly it was used.
Also, the use of recycled materials I mentioned earlier was more difficult than we had imagined. Because vehicle design and material development were carried out simultaneously, we had to change the design every time we changed the characteristics of the materials. To overcome this hurdle, we diligently conducted checks over and over again.
The most difficult challenge in procurement for the BEV parts was the procurement of batteries. When a fuel tank is replaced with a battery, the cost goes up dramatically, so we are working not only within the area of procurement but also in cooperation with various areas including specifications, product quality, production and logistics to explore how we can suppress the cost. Then we work in collaboration with our suppliers to ensure stable procurement. Starting with this new commercial-use mini-EV model, Honda will expand the lineup of BEV models and increase overall sales volume, so that we can offer more affordable BEVs to our customers around the world. This is our current goal.
I am also in charge of the testing of the actual vehicle, and the most difficult part was ensuring safety performance in the event of a collision. We devised the design to release the impact so that high-voltage components would not be damaged when the power unit gets pushed with force in the event of a frontal collision.
Popularizing BEVs around the world! Pursuit of a sense of purpose, growth and dreams
When do you find your work rewarding?
It is such a predictable answer, but I feel most rewarded when I see customers using the vehicle I worked on. After a long struggle, the car goes out there to the market, and the moment I see customers enjoying it makes me really happy.
I feel rewarded when my work is appreciated by customers, of course, but also by my fellow associates within the company. That's why I always try to remember to be grateful to those around me, and I try to work in a way that achieves overall optimization for the project. Also, I usually work in Suzuka Factory, but this new commercial-use mini-EV model is being developed in Tochigi R&D Center, so working with young members in a completely new environment is very stimulating for me.
For a while after joining the company, I was working on models for markets outside Japan, so I didn't have many opportunities to see the cars I worked on being used by our customers. But since I started working on N Series models, I see them all the time in my everyday life and realized how happy it makes me. Also, as a project leader, there are many situations where I make requests to other team members, but the moment an output beyond my imagination comes out of the design team, I sometimes get goosebumps.
I have worked on some interesting models such as Clarity EV and Honda e, but this new commercial-use mini-EV is being developed as a model which will be used by a large number of customers. So, this project brought me closer to my dream. When I am on the development team for a mass-market model, I need to focus not only on making a good product but also on entire process until the car is put in the hands of our customers, including conveying how good this car is. That also leads to my personal growth as an engineer, so that is also a motivating factor.
When do you feel your growth?
The project cannot be completed only by the design team. There are so many people involved in new model development. Whether or not we can realize our ideal design depends on how well we can convey our own thoughts with passion and how much support we can gain. I feel the growth when I see an increase in the number of people who support my ideas and an expansion of the circle of fellow team members who are willing to collaborate.
It's also important to listen to what others have to say. One-way communication of what I want to do doesn’t work. I am always conscious about listening to what others place value on, and then have good discussions. Becoming more aware of that is where I can feel my growth.
I understand that very well.
When I was young, there was a period when I was somewhat self-righteous. However, as I was given more opportunities to work as part of a new model development team like this, and the number of people I need to work with increased, I realized that the way I used to do things does not work, so I changed my approach to work. Since the work of purchasing deals with money and thus has direct impact on the company's business results, it bears a heavy responsibility. Although I am just one of many associates, I am now capable of working on a project while making decisions based on what’s best for the company as a whole. I would say that is a growth for me.
Honda also has a term called the “Three Realities Principle*3.” I try to experience as many cars in person as possible, whether they are our own products or other companies’ products. Experiencing them alone will narrow my perspective, so recently I've started inviting my fellow associates, subordinates, and those who newly joined the company and are not very familiar with cars, yet. Because of my work, it is difficult to get rid of stereotypes built in my head, thinking, “A BEV should be this way.” But being more proactive in incorporating a third-party perspective and knowing values that are different from my own, I have been able to see cars more in depth.
*3 Honda’s approach to place importance on “going to the real spot, experiencing the real situation and making realistic decisions.”
Finally, tell us about your dreams you want to realize at Honda.
My answer is simple. I want to keep working on more cars and pleasing more customers. That is my dream.
I want young people to say, "Honda is awesome." I have a feeling that there were more passionate Honda fans in the past, and that's why I want to convey the attractiveness of Honda to younger generations of people and I want to be involved in the development of attractive products.
Once I began serving the project leader role, I've come to enjoy making drawings and realizing what someone else wants to do more than what I want to do. So, I would like to interact with more and more people and incorporate everything they want to do into my drawings. That is how I feel now.
I learned about global warming in elementary school, and that sparked my interest in electric vehicles. Since then, I have always wanted to make a BEV, so I joined Honda, and now I am advancing toward my dream. BEVs are not cars that sell like crazy, but I think one of the reasons for that is because various factors such as cost, design, infrastructure and timing were not well aligned. I believe that our development team has the energy to break through such a situation, and we developed this new commercial-use mini-EV with a confidence that it will be highly competitive against rival models. My dream is to continue to be a part of development teams like this and further popularize BEVs around the world.
Original article issued on September 15, 2023
The development theme of this new commercial-use mini-EV model was how to leverage our existing asset, the N-VAN, and expand the usability of the vehicle in the form of a BEV (100% electric vehicle).
The image we had in mind was that of a “basic container.” Our focus was to come up with a design that maximizes space and expands usability by featuring a cubical space. Instead of us defining how people should use this vehicle, we wanted the customers to put the finishing touches to their vehicle by customizing it more freely. In other words, we wanted to create a vehicle that would rely on the user to expand its characteristics or identity. We want to see this vehicle getting used flexibly for both commercial purposes, such as delivery services, as well as personal uses, such as for a variety of outdoor activities.