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Costing The Clio V6

MarkK

New Member
For quite a while I've been wondering how the Clio V6 got approval for being produced in the first place as it seemed that the production costs must have been enormous. Just looking at the bodyshell, the costs of re-work to convert a standard front wheel drive front engined car to a rear wheel drive mid engined car are huge.

It's not as if that was done once to get a prototype right, or a small number of times to create a few race cars, but it was done 3000 times!

And then there are all the other components and sub-assemblies that are unique to the car.

When I started to look at my two cars, a Ph1 and a Ph2, the more I looked, the more amazed I became as it dawned on me that there is virtually nothing shared between them. The costs for re-design and tooling for the two phases of the road car must have been astronomical, and would only have been undertaken and implemented by organisations with a very short-term, cost-no-object, race car culture. And they had to shift production from Sweden to France!

And of course, as Duncan has recently mentioned, there is virtually nothing shared between the Trophy and either of the two road cars. There also seems to be precious little shared between the Vees and any of the standard production Clio range.

So in reality we have 3 almost entirely different cars, hand built by three different workforces in two different factories.

The recent article on the Clio V6 (Classic and Sports Car, Jan 2015) comments that (allegedly) Renault lost €70,000 for each £27,000 car made. So that means that each car cost €100,000 to build, in round numbers....all numbers in Euros from now on!

Also in round numbers, there were 3000 cars built, including the Trophy, the Ph1 and the Ph2 cars. That is €300,000,000 cost to build, with €90,000,000 revenue from sales and €210,000,000 LOSS for the entire Clio V6 venture.

This seems to be a massive amount of money for a car company to spend / lose over a 5 year period, until you put it into a Formula 1 perspective, and it was Renault deciding in 1998 to change what it was doing in F1 that gave birth to the Clio V6 concept.

Jean Francois Caubet, who manages Renault’s F1 engine programme, responded to a special Financial Times report on F1 costing recently. He revealed that Renault currently spend €120,000,000 a year on the engine programme, but recover €60,000,000 from sales of the engines, so 'only' incur a 'real' cost (loss) of €60,000,000 a year.

He went on to say that in the past, when they ran a full team, their total cost was around €280,000,000 a year, but they recovered €100,000,000 from TV rights and sponsorship, so incurred a cost of €180,000,000 a year.

When I first did the sums that suggested that Renault lost over 200 million euros on the Clio V6 programme, it just didn't make any sense that a car manufacturer would do that. But in the strange world of marketing and F1 spend, 5 years of the Clio V6 as a race car and 2 phases of road car costing little more than 1 year of running a full F1 team starts to make a bit of sense. I can begin to see the business case coming together in the late 1990s, but it seems inconceivable that such a car could ever be built again, even by a state owned company like Renault.

So next time you're driving your Vee, remember that it cost more than an Aston Martin Vantage to make. It was designed and developed by two organisations steeped in race car, including F1, experience, and each car was hand built in three different versions. It's not the top-of-the-pile hot hatch as described on 5th gear a few weeks ago, but something that has been so radically re-designed and developed that it stands apart from the normal categorisation of 'mere' production cars!

Mark
 
Interesting reading....don't forget to factor in that they raided the clio parts bin for numerous bits 'n' pieces.....headlights, dash, windscreen, side windows, most of interior ( except Id models ), door frames, window motors, wing mirrors, bonnet, body shell etc etc, so i am sure they shaved a little off their costs there, that said there is no denying the R&D costs, shipping them between factories, stripping down standard panels to put on Vee bespoke ones, redeveloping the motor, suspension etc etc etc.

So, next question, when are Renault ( or anyone for that matter ) going to make a documentary about it all ?.....
 
Hi Mark
An interesting post and yes the V6 is a very special car. It's a shame you never managed to see them being built at Dieppe. the final assembly was even more hand built than any series Aston Martin as the rolling chassis/body was parked in a bay then two guys would assemble the car by hand over a period of days.
As far as costs go though I would say don't believe everything you read as urban myths just get repeated over the years.
the car sold roughly in line with expectations - remember the previous RS project, the Spider, sold only in hundreds.

I don't believe the senior management at the time, when cost cutting was evident throughout the industry, would have approved the project if it was going to make a loss of 200million euro. There is Brand value in the publicity it brought but nothing like that.

Yes it would have cost more to build the ph 1 because TWR needed a profit margin so moving production to Dieppe would have saved money but unless you are Renault's finance director then it is impossible to put a final figure on the total projects costs.

Parts bought or made by a manufacturer cost a fraction of the price they would be supplied as a retail part and there were plenty of economies of scale with the standard Clio. Hence why for example it was cheaper to take a fully formed Clio bodyshell off the line and cut out the wings and modify the panels than produce a stamping for the new wings to be produced as an original one piece.

Would you be surprised if I told you that a manufacturer can make a profit on its cars even when the factory invoice the cars out to the sales distributors for only 50% of the final retail price? ;)

So actually, at least after the revenue of race cars etc, I wouldn't be surprised if they didn't lose much money at all. I suppose they can't have made a profit otherwise they would be making a mid engined version of the current car , but as a new Alpine is due to be launched next year it proves that the sums can be made to add up even on low volume cars.
 
Nice piece of work Mark :approve: Many manufacturers over the years have done loss leader vehicles purely to showcase their abilities and attract attention and the Vee seems to fit this remit as it certainly attracts attention in spades!
 
Graeme, I'm sure that the real costs will never be known, but I wouldn't be at all surprised to see them way above the retail price. I've done a fair bit of work with Jaguar and Ford over the years, looking at cost reductions in the production engineering side of the business, and it is staggering how the costs of the R&D, setup and tooling, production, overheads, sales and marketing, dealer network etc. etc. add in to the gross cost of production

For sure, individual components are built very cheaply at net cost, like £1500 for an aluminium bodyshell for an XK Jag, but when you start to add in the cost of development, production and all the overheads associated with that model, the gross cost of an £80k Jag comes out to just over £70k. Divide the gross costs back into the individual components, and the bodyshell is now heading up towards £10k to make.

So thinking about the Clio, if you took a top of the range 172 in the day, I guess that would have been around £20k to buy. Take out the dealer margin, and Renault's average 3% (gross) profit, and you have a car that cost over £18k to make. That's on a car that was mass produced using many components common to other models, so it has virtually no manual labour input, and huge economies of scale. The R&D cost would be massive for the Mk2 Clio as a whole, but it's spread over many hundreds of thousands of cars, so comes down a fair bit!

I can certainly believe that the V6 was a multiple of cost the 172 to build. Consider the large design and development costs, the production setup costs and the tooling costs for the 3 versions, and a lot of that coming from outside Renault, and it's only amortised over 3000 units.

The costs for building the engines and gearboxes would be very different to the cost of a mass produced V6 and 5 speed box, and components such as the wheels and brakes would be a premium price. All the smaller components that we now complain about the price of, such as the wheel arch liners and the boot 'bin', the engine covers and the underside shields, would be a large factor more expensive than the equivalent standard Clio items...where they have anything similar!

The cost of the base bodyshell would be very little, but the modifications, by hand, for each and every shell would be very high. Then add on the costs of the fibreglass outer body panels, and the labour costs to fit it all up, with a fair bit of messing about on each car I'll bet, and the costs would go through the roof.

Finally add in the cost of logistics, of marshaling the shell, engine, gearbox, suspension and interior, special bits, wheels etc., and getting them all to Sweden....after the facility had been set up, and the workforce trained up of course. Then pull that apart and change production to Dieppe, train up another workforce, create another set of tooling for the Ph2 cars.......on and on. I really can't see all that being done at an additional cost of £5k or £6k a car over the £18k cost of the fully automated build of the 172.

Mind you, I'm not sure it would be 5 times the cost of building the 172 either, but I really wouldn't be surprised if it was heading that way.

I'm sure there won't be a Renault executive in France who would divulge the real cost, if it was known. I'm also pretty sure that a fair bit of creativity must have been employed in putting forward the case for the V6 programme in the first place, with a very large ££££number attached to the 'soft' and intangible benefits arising from such a programme. For every Clio V6 made, we will sell an additional X standard Clios. There's another sum to do....how many more standard Clios would have to be sold to break even if the V6 Clios really did cost 100k euros to build!

Mark
 
How many million did Porsche get paid as consultants for engine and other development? Creative accountancy can 'lose' this, but just 1 million puts about 800 onto each Ph2 and knowing that Porsche won't design a pair of sunglasses for this I would think a factor of ten or possibly twenty at least would be needed to be added for this alone. Likewise tooling and production costs for the panels would be astronomical when amortised over 1300 units.
 
You're absolutely right Simon, and I'm sure that the external costs to the Clio V6 project would be mind boggling.

I guess that the biggest would have been TWR. They were prime contractors for 5 phases of work:

Design of the Ph1 car
Development / Testing of the Ph1 car
Setup of the manufacturing facility
Design of the Ph2 car
Development / Testing of the Ph2 car.

In one of the books is says that TWR had a team of '100 specialists, of whom 60 were engineers'. On a day rate, they would average around £2000 per day each, which for the team would be £200,000 a day, £1 million a week, £52 million a year. OK, they wouldn't normally charge a day rate for a 2 to 3 year contract, but considering how specialist the work was (who else could have done it?!), the experience, kit and prestige TWR brought to the project, I can well imagine that the team would have been, on paper at least, retained for the entire project at pretty strong rates. Tom Walkenshaw, being a very shrewd businessman would have made the most of this one-off opportunity for sure.

So design and development could easily have brought TWR anything between £50 million and £100 million, maybe more. Then there's the setup of the factory in Sweden, establishing the line kit, the tooling, employing the line staff, employing the managers and engineers, working with Renault on the many inventory management and production management processes and systems, and of course, the basic production design. The start up costs for this would have run into tens of millions, for sure.

And all this time, Renault would have a shadow team monitoring what TWR were doing, managing the project from Renault's perspective, developing and communicating their requirements and co-ordinating the activities of MOC Composites, Sadev, Magneti-Marelli, Solution-F, Porsche Engineering with TWR and the many divisions of Renault that would have been involved. This would have been a pretty large team as well, which at fully built up cost rates would add up to many tens of millions over the three years of design, development and setup.

And then there's the contract value for each of the suppliers above, each of which would have a considerable set-up, tooling and production cost for such limited production, and for sure would all have charge premium rates for such a high-profile / short timeframe project.

I really can see the design, development and production setup costs being well north of £100 million for the Clio V6 project, even heading up around £150 million or more, without taking into consideration the whole Trophy race program....I don't know if that was self funding, funded fully by Renault or just subsidised by Renault.

If the road cars were made at roughly break-even cost by the end, that must only have been because the design, development and setup costs had been fully written off by then.

But the whole Clio V6 project costing €300,000,000, as indicated in the article, now doesn't seem to be completely daft to me!

Mark
 
The more romantic, and pretty accurate 'tongue in cheek' history, is that a few guys had an idea, bodged one up in the workshop in their own time, showed the management (not the accountants) and the rest is history - just as it should be. Good on Renault for taking a punt.

The commercials are probably mind-boggling but only given the relatively small production numbers. I would be pretty sure Renault would have absorbed the costs either directly or indirectly - either way someone made a 'go' decision :bow: ... as with many fields where there is a vision and innovation commercials are not the primary driver.

Snippets of Information about the Vee

fr0610_prototype_14.jpg

fr0610_prototype_08.jpg

fr0610_prototype_09.jpg

fr0610_prototype_10.jpg
 
Interesting post.

As James says they're probably recovering all that loss with the costly replacement parts we're buying from them now.
 
As I said, creative accounting! How many divisions ended up taking costs against their budgets so that costs effectively disappeared. The cost of the specialised injection moulds for the panels would be horrendous though some would go both Ph1 and Ph2, these are not your normal GRP moulding cobbled up in a back street! :bow:
 
James":24mrb6fy said:
I bought some OEM brake discs so Renault are well and truly in the black now.

I hear that Renault france have now employed a certain Mrs C Blair on one of their management boards.
Your money has paid a minute or two of her salary!!


Seems odd that that there was a press release everywhere except in the UK :rofl:
 
Alpineandy":1jzl9flj said:
James":1jzl9flj said:
I bought some OEM brake discs so Renault are well and truly in the black now.

I hear that Renault france have now employed a certain Mrs C Blair on one of their management boards.
Your money has paid a minute or two of her salary!!


Seems odd that that there was a press release everywhere except in the UK :rofl:
That would damn nearly make me sell up :rofl:
 
Very little seems to be mentioned about Lotus' involvement in the birth of the V6.

How much is known about the design work that they did?

When I was working there (C 2000) they had the mid-engine prototype.

It really was 'cobbled together' but so cool, which is why I now own one!
 
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